Rod's 84 BabyBajaF100

hobbyturnedobsession · Thu Sep 05, 2019 7:05 pm

Way to go bud. Uh oh you're in trouble with a travel trailer. It's a rabbit hole!

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S00TLYFE · Post by **S00TLYFE** » Thu Sep 05, 2019 8:13 pm

FInally got caught up with your thread Rod, looks like you’ve gotten a lot of great work done man. Got a buddy moving down under to continue his career, down Melbourne way, he should be there a couple weeks from now.

AussieRod · Post by **AussieRod** » Fri Sep 06, 2019 4:31 am

S00TLYFE wrote:FInally got caught up with your thread Rod, looks like you’ve gotten a lot of great work done man. Got a buddy moving down under to continue his career, down Melbourne way, he should be there a couple weeks from now.

Cool! I'll PM you my number, get him to call and say g'day and we can catch up and sink a few coldies.

AussieRod · Post by **AussieRod** » Fri Sep 06, 2019 4:33 am

S00TLYFE wrote:FInally got caught up with your thread Rod, looks like you’ve gotten a lot of great work done man. Got a buddy moving down under to continue his career, down Melbourne way, he should be there a couple weeks from now.

Thanks. It would have been done 6 months ago, but too much work and too many distractions. The weather is getting better slowly, though, so more will get done more quickly now.

AussieRod · Post by **AussieRod** » Fri Sep 06, 2019 4:36 am

hobbyturnedobsession wrote:Way to go bud. Uh oh you're in trouble with a travel trailer. It's a rabbit hole!

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Ha ha! Yeah, it could be a problem, but I have a plan on what I want and how to set it up. Same width / footprint as the truck, same height as the roof to make it streamlined when towing and only what I NEED.

No frills, no fluff, just utilarian and useful.

hobbyturnedobsession · Fri Sep 06, 2019 7:28 am

Carly and I started with a 10' Lance camper. Loved it until we had twins and a dog. It was like trying to walk through a house party to go to the bathroom. We ended up trading it in for a trailer. It's alot of fun.

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AussieRod · Post by **AussieRod** » Mon Sep 09, 2019 2:22 am

Sept 9:
Just thought I'd run this. I found the correct fuel sender on JBG for US$59 and asked for a shipping quote. The sender kit only was US$59, the complete pump was US$80. I only needed the correct sender, as I was going to swap the pump from the 87-91 version. However, the shipping quote came back at US$68! WTF?

I politely refused, as paying more than the purchase price for postage is not economical for me. I generally work on 60 - 75% as an absolute max., depending on whether I can get it locally or not, or if the thing is available at all, or how badly I need it. Local pricing on a sender assembly exceeds AU$200+. So, I did some trolling on eBay and came up with a better deal. Autopartsgeek (us based) had a complete sender/pump ass'y for US$69.95, plus US$23.60 for shipping??? WTF? I don't get it. This is 1/3 JBG's shipping cost. I also had to pay US$14.07 IMPORT duties (because I live in ARSE-tralia, and we get buttfucked on postage from the US to here) and which includes local GST. It still worked out substantially cheaper on price than JBG (a first, actually) or buying locally. The senders were selling for the same price as a complete assembly, so I decided on the full monty. That gives me a second spare fuel pump for the spare parts box. It pays to shop online, me thinks.
Postage is my biggest extra cost rebuilding my truck, probably accounting for 30% of it's current build cost.

Gotta go out and get some work done on the Disco.

Later.

AussieRod · Post by **AussieRod** » Wed Sep 11, 2019 7:32 am

Sept 12:
Well, I have a line on a '78 Dana 60 FF, just waiting for the seller to confirm the ratio. The price is good but it's a 4 hour drive away. The other item I've found is a shortbed canopy for my truck. Haven't seen one of these for sale in about 8 years, so I put a bid in and will wait. The best part is, both the diff and canopy are less than 15 minutes from each other, so I can get a two-fer.
I also found a rear fuel filler tube from a 88 F250 at a local wrecker. It cost a bit more than I wanted to pay, but it's the screw cap type and it was there, so I handed over the cash. It needs a slight panel beating, but I'll do that tomorrow at work and clean it up ready to install with the tank. I will also pick up a roll of EFI hose to re-plumb the fuel system once the sender unit arrives. I have an addition to the towbar, and a couple of things to weld, then I'll get it sandblasted at work and painted so I can install it prior to the fuel tank going in. I have some propane plumbing to do as well during the install, so I can run the truck from tanks in my future get-away trailer.
I'll post up more on the weekend, hopefully with some pics.
Cheers.

zachwabbit · Post by **zachwabbit** » Wed Sep 11, 2019 11:05 am

Right on! I wish I had your patience, I’ve changed vehicles more times than I can keep track of in the past 7 years haha

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AussieRod · Post by **AussieRod** » Thu Sep 12, 2019 2:37 am

zachwabbit wrote:Right on! I wish I had your patience, I’ve changed vehicles more times than I can keep track of in the past 7 years haha

Patience has been forced upon me, Mate. It's always been either no money, but plenty of time, or no time, but money for parts. My fly-in-fly -out last year was good, as it gave me both, but I spent most of the money paying off my mortgage robbery. Now, it's just finding time to work on it, with all the family problems and cars to fix, and other shit to distract me, I rarely have any time for myself. But, it's getting done slowly. Steve (Chasetruck) once said it's like eating an elephant...... one bite at a time.

ChaseTruck754 · Post by **ChaseTruck754** » Thu Sep 12, 2019 9:13 am

You're doing much better at eating the elephant than I am Rod! I tried to eat an elephant, hippo, giraffe and whale all at once for some stupid arse reason & now none are done and all are sitting and/or being sold. I wish I would have had the focus of an "old" man when I had the time, freedom and money for projects of my bachelor days!

AussieRod · Post by **AussieRod** » Sun Sep 15, 2019 5:29 am

ChaseTruck754 wrote:You're doing much better at eating the elephant than I am Rod! I tried to eat an elephant, hippo, giraffe and whale all at once for some stupid arse reason & now none are done and all are sitting and/or being sold. I wish I would have had the focus of an "old" man when I had the time, freedom and money for projects of my bachelor days!

HAHAHAHAHAHAHA!

Well, should I state the obvious and say it was self-inflicted, huh? Sometimes the biggest mistake many of us make is that our plans are always more ambitious than reality. Throw in a mortgage, marriage and kids and say goodbye to all your plans. After the 2 GFB trips to Baja, there was nothing I wanted more than a truck just like some of the fantastic Broncos on the trip, but reality took hold and I checked myself up. The cost for me to do that here is at LEAST 5 TIMES what it would cost if I lived in CA. Our south pacific pesos don't have the same purchasing power there, so I have to satisfy myself with dreams. A set of J40 Deavers would cost me nearly AU$3,000 once they hit my doorstep.

Ditto any other "heavy" item(s) I would need, such as fibreglass, wheels and tyres, etc. Postage, taxes and duties end up making something cost 3 times it's purchase value.

I've wheeled, dealed, skrimped and saved to get this far, and now the light at the end of the tunnel is no longer a locomotive bearing down on me, I have to stay focused on getting it back on the road FIRST, then start modifying it to suit my needs(wants). However, having said that, I do keep changing my mind now and then, which slows progress down a tad. Having said that too, I did get some stuff done this last week(end):
I dragged out all the reat fuel tank hardware and stacked it in the bed, ready for the re-fit:

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While I was cleaning up and straightening my new rear filler neck, I took the liberty of hole-sawing out the gas nozzle restrictor, so it is easier to fill/top up from jerry cans:

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I also ordered the correct value fuel gauge to fit into the dash for the side tank, so I can keep the level monitored:

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All the info I have says it should be a 75 - 10 ohm value, so I'll cut a dash plate for it and drill a couple of switch holes for the transfer pump and make up a harness to conect it to the side tank and the dash wiring. The new sender/pump assembly should be here this week, along with the new vapour vent for the top of the tank. The original vent in this rear tank was broken when I got it, so I swiped the good one from the side tank (because I didn't have plans to use it thinking it would hit the T-case). Now I have the side tank back in, I re-swiped the vent to re-use. However, the plan to fit another propane tank under the rear turned out to be too expensive to be worth the trouble, and I wanted the gasoline range just in case propane was unavailable.
The next thing I changed was the exhaust.

I know, it was all nice and sounded great, but I didn't want to waste a lot of time trying to re-engineer some kind of hanger for the muffler that would allow for heat expansion and keep the tailpipe tip from rattling on the fender edge, so I went for a rear exit and over-the-axle tailpipe. First, I cut the muffler section about 4" from the 3 bolt flange at the Y pipe and added a bullet resonator, to extend the muffler close enough to use the original Ford muffler hanger:

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I had to shorten the drop 1" and turn the clamp tab toward the front to be able to properly hang the muffler:

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AussieRod · Post by **AussieRod** » Sun Sep 15, 2019 5:42 am

Cont:
I used a hose clip to secure the muffler outlet to the hanger, and it worked out just nice:

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The camera bateries died right about then, so no pics of the tailpipe build, but you get the idea (I had to get a presciption filled, so I picked up new batteries while I was out):

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I even re-used the old rear hanger, so it's all factory (except for the pipe size). I pulled back the curtain hiding the truck from the street, brought the Triton around and jump-started the old girl to see how loud it was. Honestly, I was expecting LOUD, because no resonator in the tailpipe, but boy, was I in for a surprise! It is MUCH quieter than before, probably due to fitting the resonator BEFORE the muffler, rather than after it. It provides some expansion space for the sound waves before they hit the muffler baffles in the Flowmaster, and takes off some of the "bark". I couldn't run the engine too long, as the power steering pump is AWOL, so I had to pack it up. The power steering is next. That's a post for later in the week.
Cheers.

AussieRod · Post by **AussieRod** » Tue Sep 17, 2019 5:57 am

Sept. 17:
Just a quickie tonight. Forgive the blurry pics, it was getting dark real quick so I barely had time to snap away. Made a transfer mount for the propane feed from my future trailer:

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The new tank vent arrived today, too.
Picked up some fittings and a piece of appropriate hose to repair the power steering hi-pressure hose:

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I'll take the steel line into work tomorrow, cut it and silver solder on the repair tail for the new hose connector.
Only managed to get a metre and a half of EFI hose, plus some joiner pieces so I don't waste all that good hose during the tank install:

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My Superlift 2.5" lift block kit came today as well, it's in the background:

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Sender/pump should be here next week. Going to Phillip Island to pick up the SWB canopy I won on eBay tonight on Saturday, and hopefully my (new to me) Dana 60 FF axle in 4.11:1 at the same time. My +2" springs and shocks should be arriving in about 2 weeks (wanted the cheapest postage, so they will see the world on the way to downunder).
Unbeknownst to me, I'd had a Saginaw P/S pump for the late model Clevo set-up in the bowels of my garage. It currently is waiting for me to give it a clean out and re-assembly. I got rid of the Zford style outlet fitting and salvaged one from an old FSJ Sag pump I had out in the junk pile. I have the correct adaptor to JIC -6 for it, so I can make up the hose once I repair the steel pipe. This particular version of P/S pump for a Clevo wasn't fitted to any factory vehicles here, but it is a conversion available (still), using the Ford plastic pump mount and a clever use of spacers and a flat bar adaptor.

AussieRod · Post by **AussieRod** » Tue Sep 17, 2019 6:02 am

Found pics of the Sag pump set-up on eBay:

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They only want a cool AU$495.00, plus $35.00 to post it.......

https://www.ebay.com.au/itm/POWER-STEER ... ctupt=true

AussieRod · Post by **AussieRod** » Wed Sep 18, 2019 5:50 am

Sept 18:
Cleaned up the rear fuel tank real nice and installed it tonight. Made sure I fitted the new vent valve and pipe BEFORE I lifted the tank in this time. Due to the exhaust tip getting in the way, had to put the filler hose through some gymnastics to get it up over the frame rail with the right side lifted in over the exhaust. Lucky for me, the tailpipe clears just over an inch and a quarter, so no mods needed. Also silver soldered the repair fitting to the power steering pipe at work today. I'll clean and re-assemble the pump hopefully before the weekend so I can make up the hose and fit it all Sunday.
I'm heading to Phillip Island early Saturday morning to pick up the Dana 60 FF and the tub canopy. The canopy came off a '79 SWB, so if all the info I have is correct, it SHOULD fit on mine. If not, I'll clean it up and re-sell it. The diff will be put aside for now until I have room and time to go through it (not making any plans until it's in my garage). Now I need to find a D50 TTB and pivots, plus a NP435 and bellhousing for the V8. Next week will be a big eBay sale so I can get rid of unwanted stuff and recoup some cash.
More tomorrow.

ChaseTruck754 · Post by **ChaseTruck754** » Wed Sep 18, 2019 7:19 am

Rod - for the canopy, the beds are the same dimensions. The back of the cab/rear window has a slightly larger angle on the 73-79 trucks if memory serves, but the canopy should still work.

AussieRod · Post by **AussieRod** » Wed Sep 18, 2019 2:31 pm

ChaseTruck754 wrote:Rod - for the canopy, the beds are the same dimensions. The back of the cab/rear window has a slightly larger angle on the 73-79 trucks if memory serves, but the canopy should still work.

Thanks for that, Steve. I was reasonably certain they were the same size, only the outer panels were different. The seller wrecks F trucks and Broncos and assured me it should fit. Pics:

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The front glass will be with it, as it was still in the back of the truck it came off. Like I said, I'll clean it up and fit it....... if it doesn't fit, I'll re-sell it.

More later.

AussieRod · Post by **AussieRod** » Thu Sep 19, 2019 4:35 am

Sept 19:
Pulled the fuel pump from the rail and made up an extension to join the front hose to the fuel filter. I WAS going to re-fit the filter back in it's old position above the diff, but decided to keep it where it is now.
Pump removed:

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I managed, with great patience to get the new fuel line in behind the side tank and clip it up like before. There isn't much room in there for my big c*nt scratchers, so I had to take the time and be methodical. All the lines are re-fitted in clips like before and secure:

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The 87 - 91 sender is still in the tank and will stay there until I'm ready to swap it over:

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Rear filler tube fitted, just needs 3 self tappers to secure it:

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I only have to go buy one of those solid state pumps for the fuel transfer, mount and connect it and the fuel system is almost done. Next week I'll start the wiring and get everything electrically working, finish the power steering and carpet install and go drive it again. Another bite outta that bloody elephant.

Cheers.

AussieRod · Post by **AussieRod** » Sat Sep 21, 2019 4:43 am

Sept 21:
Well, after 8 1/2 hours of driving, the canopy and D60 FF are home. A quickie look and I'm thinking the top of the canopy at the front will hit the top of the cab. It's getting a pressure clean tomorrow and a dry off with the air hose, then I'll have a go at sliding it on to see if it was worth the trouble. At worse, I'll fit a new rear window locking handle, clean it all up and fix the rear cab sliding window that came with it and put it back on eBay. Being this side of Melb might give it a better chance of selling.
I'm tired, more tomorrow.