The 'Rust Bucket' re-build

#26 by 123hotchef , Sat Sep 20, 2014 8:52 pm

go for decent stainless ones mate u wont regret it!

#27 by Antonio , Sat Sep 20, 2014 9:00 pm

Quote: 123hotchef wrote in post #66
go for decent stainless ones mate u wont regret it!

I will @123hotchef when i put the new bash plates i fabricate back on mate, will armour under the wishbones too i think

#28 by Antonio , Mon Sep 22, 2014 9:03 am

Yesterday late afternoon decided to jetwash under the truck with the bashplates off before i started working on it this mornin (in 20mins)
Well i had a small leak from the sump.....after a good blast...had to put a bucket under it last night to catch the oil
So i'l have to fix that now before anything else........see how wide spread it is and take it from there, ......i'l post later.

#29 by Antonio , Wed Sep 24, 2014 11:07 pm

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So...started to take the hub off today...the cap screws off,.....everything seemed ok at first glance
took the circlip out and took all the 8mm alen key bolts off (when re-placing bolts torque to 50-60Nm)....and finaly the hub off

#30 by Antonio , Wed Sep 24, 2014 11:28 pm

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well i was told a grub screw had snapped in the hub.....but as you can see in the first pic. the key has worn away!
the key on the main hub is ok and undamaged....
Made some burgers with chopped onions and small diced bacon in them while i was outside
the key was 10mmx 4mm, cleaned it up....bit of tin to protect from the weld....and just went for it...
It did come out better than it looks in the picture..... put it all back together, no problem locked in ok.....will order some manual hubs next month and keep them with me on truck, soon as these fail il swap them over, its an easy job, you dont really have to take wheel off to get hub off, so can do anywhere.

#31 by Antonio , Wed Sep 24, 2014 11:33 pm

will start on sump tommorow morning.....if the weather is ok...
see if i can weld it for now, till i get a new one.
@krutly is right.....think my answer to all is weld it

#32 by krutly , Thu Sep 25, 2014 8:39 am

I had no idea that free wheeling hubs were that straight forward to fit till Chris did his "how to"
I'm tempted with them myself now

#33 by 123hotchef , Thu Sep 25, 2014 8:52 am

Do it kurt make sure you get the red ones form k and s they are the heavy duty ones. Simples to do even I could do it.

#34 by krutly , Thu Sep 25, 2014 8:55 am

so I guess it's a good way of saving your CV joints then is it ? or have I got that wrong ?

#35 by McK , Thu Sep 25, 2014 9:12 am

Quote: krutly wrote in post #97
so I guess it's a good way of saving your CV joints then is it ? or have I got that wrong ?

You are correct, unlock the hubs and the half shafts don't turn. Ideal for saving wear during road use on trucks with acute half shaft angles due to suspension lifts.

PS 32 degrees here and is only 09:15

#36 by Antonio , Thu Sep 25, 2014 9:56 am

had to patch up a hole in the pasenger foot-well, in the cornner so never started on the sump.....will start today....
so....steering relay rod and torsion bar to come off first.....
Diff mounts and prop bolts off to try lower enough to get sump out....will do a separate thread in a min. for feedback and tips.

#37 by Antonio , Fri Sep 26, 2014 10:54 am

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First thing made sure the truck is supported safely,drained all the oil and took off the torsion bar at the front, the easiest part of the job....
Before i took the steering down i had a better look at the sump, cleaned it a bit.....it's the back end of the pan as always ....it's a lot worse than i thought, if i try prise it off it will bend and fall to bits...
So a new sump is to be ordered....but have to wait becouse need to get the Pajero sorted too this weekend at KORC.
Have minimised the leak with a stubby screw,put oil in just to move the truck out of the yard for nowand bring it round to the front of the house. Need to do some work to the Voyager too.......will i ever see that light at the end of the tunnel

#38 by Antonio , Sun Oct 12, 2014 8:40 pm

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Well after a bit of a break here we are again....
New sump, original mitsy part....and just a pic to show what it looks like inside
Got a gasket for it even if not listed for this sump, and will be also using Hylomar blue gasket seal...
Followed what was advised by @LezT....
Took bolts off engine mounts(on chassis two on each side)then the four bolts that hold the intercooler in place and lifted engine to bulkhead, took power steering cooling pipe off just underneth radiator (needs changing also rotten and leaking) and pan just slides out, put it back temp with two bolts cos it got dark...will put new one on when i can in next days.

#39 by Antonio , Sun Oct 12, 2014 8:52 pm

Hi @LezT , @123hotchef ....
dont want to go off topic but had to change bearings, rear cylinders and shoes in the back of the focus first (Need it for work 60miles a day)
then started on truck, i used the support to lift the engine as advised by Lez...beter than having trolly jack in the way...
took the pan out....as posted just need put new pan in...
if its not raining il do it in the morning, i'm on nights for the next two weeks...
Thanks for the tips Lez, spot on mate

#40 by 123hotchef , Sun Oct 12, 2014 8:54 pm

good idea that Lez the man

#41 by Antonio , Sun Oct 12, 2014 8:59 pm

Il take some pics of the bottom end of engine with sump off so all can see the oil pick up and why you just can't yank the sump out....
I'f i had'nt done the car i would have finished it today...

#42 by 123hotchef , Sun Oct 12, 2014 9:20 pm

intregued thats all mate might need to know one day

#43 by Antonio , Sun Oct 12, 2014 9:53 pm

ok so just to recap all the work that has been done on the truck till now.....
Torsion bar lift
New Exhaust
new fuel lines
Fuel tank
chassis repaired
Diff lock axle, vacume pump etc. and silicone hoses
new shocks
new leaf springs, u bolts
rear brake lines/hoses
LezT shackles and bushes
Temp lowered shock mounts
Set off 15" off set steelies (Used)
Set of 16" off set steelies and mud tyres (Used)
New 6" front chrome spotlights
New rear work lights
New Sump
New suspension torsion bar polly bushes

#44 by Antonio , Mon Oct 13, 2014 9:01 am

Hi @woody13 @LezT ,....Thanks for the support...got a bit to go yet
Power steering cooling pipe (under rad)
New front top/bottom ball joints
Top ball joint spacers
All new front wishbone polly bushes top/bottom
Refurbish front calippers (have new seal kit)
Front brake lines/hoses
Change brake servo
Would need another fuel tank, this one was fixed (welded)
Pro comp shocks all round
Snorkel
.....and everything else that i find on the way
MODS:
4" bodylift with all extended parts needed
Rock sliders
Twin batteries
15"x 10.5" s with 32mm off set
Maxxis creepy crawlers or bighorn 33"x 12.5x 15"
New back tub 14" shorter
McK style front bumper
13000lb winch
Fabricated skid plates

#45 by Antonio , Mon Oct 13, 2014 9:03 am

Quote: Antonio wrote in post #135
Hi @woody13 @LezT ,....Thanks for the support...got a bit to go yet
Power steering cooling pipe (under rad)
New front top/bottom ball joints
Top ball joint spacers
All new front wishbone polly bushes top/bottom
Refurbish front calippers (have new seal kit)
Front brake lines/hoses
Change brake servo
Would need another fuel tank, this one was fixed (welded)
Pro comp shocks all round
Snorkel
.....and everything else that i find on the way
MODS:
4" bodylift with all extended parts needed
Rock sliders
Twin batteries
15"x 10.5" s with 32mm off set
Maxxis creepy crawlers or bighorn 33"x 12.5x 15"
New back tub 14" shorter
McK style front bumper
13000lb winch
Fabricated skid plates

Hi @krutly still got a long way to go mate

#46 by Antonio , Mon Oct 13, 2014 9:18 am

Quote: 123hotchef wrote in post #139
we are all always half way through

Thats it mate.....
Need to start controlling my budget a bit more.....comments on spending where made last night

Shes ok but i have spent over 3k on motor projects since the start of the year
The rust bucket
Voyager
Focus
And now the Paj.......

#47 by Antonio , Sat Oct 18, 2014 9:28 pm

Quote: Antonio wrote in post #109

Well after a bit of a break here we are again....
New sump, original mitsy part....and just a pic to show what it looks like inside
Got a gasket for it even if not listed for this sump, and will be also using Hylomar blue gasket seal...
Followed what was advised by @LezT....
Took bolts off engine mounts(on chassis two on each side)then the four bolts that hold the intercooler in place and lifted engine to bulkhead, took power steering cooling pipe off just underneth radiator (needs changing also rotten and leaking) and pan just slides out, put it back temp with two bolts cos it got dark...will put new one on when i can in next days.

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so here are the pics with the sump off and you can see the pick up that sits low in the sump, this is why when you take off the sump don't force it....and you can see all the inside of the engine from here. I had to work with lamp as it was dark so pics may not be too clear.
And the new sump is now on, will fill with oil in the morning and check for leaks.
Need to sort the power steering cooling pipe (waiting for delivery) then bash plates back on.....and Kirton next weekend

#48 by Antonio , Mon Oct 20, 2014 12:41 pm

Checked under the truck this morning and no oil on the floor!!! First time since i'v owned it, just awaiting power steering pipe then bash plates on......
And been so busy i just realised MOT ran out on 8th Sept, have only used it 6-7 times in last year due to all the work on it!! so book it in for Friday.

#49 by Antonio , Wed Oct 22, 2014 10:08 am

Well give the post/delivery another 30 min. Then I'm gonna go out get some 3/4 pipe and make a temp steering pipe.....
To do list before MOT Friday:
Steering pipe
Front bar back on
Bash plates + drill tap new holes
Rear number plate + lights
Rear fog light.

#50 by Antonio , Fri Oct 24, 2014 12:15 pm

Quote: Antonio wrote in post #154
Well give the post/delivery another 30 min. Then I'm gonna go out get some 3/4 pipe and make a temp steering pipe.....
To do list before MOT Friday:
Steering pipe
Front bar back on
Bash plates + drill tap new holes
Rear number plate + lights
Rear fog light.

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only got bash plates to put back on and another list is done

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