Rod's 84 BabyBajaF100

[AussieRod]

Wire joints, etc:

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Got it all neatly P-clipped up and ready to connect. The bulb holders are pretty much stuffed and/or corroded, so I will have to get raped again and buy/ship some new ones over. IF the back lets me, I will crawl under during the week and start connecting the chassis harness to the body wiring and then look at fitting the engine/trans for the rest.

Oh, this is the old rear wiring as it came off the truck:

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More soon, cheers

[AussieRod]

Oct 2: Time for an update, I guess.

I've had a big change of heart with the truck. I've decided to go back to my KISS principle and NOT go EFI. Although the harness is basically done and has been test fitted and powered up, I am going back to carb. I've also had a change of engine. My misgivings about whether the 5.0L will be powerful enough aren't an issue, it's just that every engine I have at my disposal requires a lot of money for freshening up (broken rings, etc.) and I'm just too stupid/stubborn to just get it done. So, I'm going 351C. Mick has kindly donated the engine from his old rusted out police interceptor thats been sitting around for 5 years and we've collectively bought a sump kit for it. I spent yesterday firing it up for a run test to see if it is still good and it has passed with flying colours. He stored it well, as I instructed him to, and time has been good to it. It's currently on the stand, awaiting clean up and paint.
This is it after I pulled it from the rusted hulk up the back yard and brought it down to the garage:

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The sump (oil pan):

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Oil pump (Melling) and pick-up, drive shaft, etc.:

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I also scored a free pair of engine mounts through a friend who was going to throw them away. The drive plate is ordered and should arrive next week sometime, and my mate will donate the 2 bbl Holley 500 I'll use ( for dual fuel use with a propane hat). I already have the power steering pump and bracket for this engine, so all I have to do is figure out what few parts I still need and git 'er done. I'll update with pics as it comes together and hopefully it should be in and running before we head off to Japan in November.
Stay tuned.

[Quailhunter]

Rod, Its your truck, do what makes you fell good.

[AussieRod]

Rod, Its your truck, do what makes you fell good.

True. If I could have what I REALLY want, it would be a 427 crate motor in front of a PATS AOD, but the bank balance won't allow it. So, this is the next best thing. Next year I will build a killer Clevo and go from there.

[AussieRod]

Nov 27: Time for an update.

Due to preparing for our trip to Japan, I didn't get as much done as I wanted to, but I got the engine stripped down to where I wanted it, pressure cleaned and painted it and got it looking nice. I fitted the oil pan and pick-up, along with the good Melling oil pump that came with the kit. The timing chain was stuffed, so I ordered a new one, but that turned into an almost disaster, as it was for a Clev with the old style windsor SVO crank without the shoulder at the front journal. After a fruitless week trying to contact the company I bought it off, I decided to fix it myself. After a lot of measuring, the machinist at work took off the extra material that spaced the lower gear forward and also I got him to do a clearance curt on the upper cam gear to clear the shim (which was too tight). It all finally went together perfectly and I buttoned it all up with a new seal, water pump and painted all the accessory brackets. I still have to get a PS pulley for the crank, but that,s the least of my worries right now. It also took some doing to get the old pilot bearing out of the back of the crank without damaging anything, but I managed that ok. The flex plate wouldn't quite fit the convertor (lucky I checked it first) so I drilled the holes from 11 mm to 12 1/2 mm and it fitted great. The flange nuts will hide the oversize holes. After double checking everything, I bolted the 2 together and zero problems.
Ready to fit:

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I had already fitted the master cyl. brake pipes, e-brake cable and did some prep work the last few days:

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Tonight, I carefully pulled out the radiator support and propped up the hood. It took a little wiggling, but it went in just fine:

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I'll leave the radiator support out for a few days while I get some bits and pieces done in there, then it will go back on and I'll finish buttoning up everything for a start. Trans cooler, lines, fuel system and some minor wiring and it should bellow into life. I have to grab some proper exhaust manifolds and a Y pipe to fab up an exhaust, but I have some lined up ready to get it done. Then the T case will go in, the front and rear driveshafts will get done and with some minor things to do, I MIGHT be able to drive it by my birthday. Who knows. \
More soon(er).

[AussieRod]

Dec 6 update:
Been mainly going through all the bits and pieces left to find all the missing pieces of the puzzle. Got all the dual fuel parts out and cleaned up the mixer and carb adapter, hoses, convertor and other shit. Tonight, I spent crawling underneath to re-hash the fuel system back to carb set-up by removing the return line, hi-pressure pump and tidying up the area. I'ii fit a plug to the return fitting on the tank and just keep the low-press pump in the tank to supply fuel up to the Holley. Since the local parts store wants me to pay $60 for a rear trans mount, I fished out the new Autofab one I bought last time over and will clean and paint that to fit tomorrow. Then I will start the wiring phase to get ready for a test and start. Trans lines, fittings and cooler are on their way from Ebay, I need to fit the bumper to make the P/S cooler mounts and trans filter mounts, tabs for the cover and skid plates and a rough fit-up prior to sandblast and hammertone.
Pics of the fuel system work:

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Parts pile for cleaning/fit-up:

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Refitted the front rad support to make cooler mounts, cooling fan mounts, etc.:

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Oh, I made a flat bet for the Triton, too. It's been on about 2 years now, and I love it. Compact with hide away tie down points, etc.:

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More updates to follow.

[AussieRod]

Dec 8 update:
Worked on the truck again after work, cleaned and painted the Autofab rear trans mount and installed it:

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Made some washers at work and bolted the engine mounts to the chassis mounts. Now the engine/trans unit is secure, I can clean up, prep and install the transfer case as soon as I get some wiring under there completed:

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Put all the screws into the fender liners and got them out of the way:

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Temporary install of front bumper to finalise PS cooler mounts, skid plate, trans filter mount and cover plate for the top:

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Going to install the PS cooler above the lower tube behind the skid plate, with ports neatly cut out covered in mesh and a cover plate to keep the air flowing thru the cooler instead of around it under there:

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And finally started the engine bay wiring, got the LH side mostly in, just need to make some mounts for the HID ballasts (FINALLY get to use the BAJAHID prize I won):

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The washer bottle will get a thorough cleaning and epoxy the top back on, then I'll work on the other side while it dries. The engine harness needs some rebuilding to suit the V8 and I have to make the lighting harness for the bumper and the Propane dual fuel harness. The carb arrives this weekend, and hopefully the trans cooler and fittings early next week, then I can work on a first start up.
More soon.

[AussieRod]

Dec 15 update:
Haven't done a lot on the truck, but I've basically completed the wiring for the truck, the lights, wipers, etc. all work. I just need to lay out, cut & shut and re-solder the engine harness, wrap it and secure it, clean and fit the carb and adaptor, start on the propane system and tie up a shitload of loose ends. Tonight, I've been on a finding mission, trying to locate all the remaining parts so I can continue on while I wait for a heap of items from Ebay and USA, etc.
T/case ready for final clean and fit:

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Heap of parts laid out ready to be processed:

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Carb and adaptors:

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Propane conversion stuff:

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9 inch centre and parts:

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Brakes stuff for front and rear:

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Trying to focus on getting in at least 2 - 3 hours a night when time/schedule allows. I will have to make a jumper hose for the trans cooler, as I am waiting for fittings and hose from o/s. By next week it will be a go-er (I hope).
Cheers. More soon.

[VintageIronFab]

Looks like things are going well Rob!

[AussieRod]

Looks like things are going well Rob!

Yeah, finally starting to see the light clearly at the end of the tunnel. I'm gunna hit it hard this weekend and try to get a lot of loose ends tied up. Any progress is good

[SteveG]

Clean work, Rod. Looking good.

[AussieRod]

Thanks Steve.

Dec 18 update:
Didn't get half as much as I planned done, but progress was made none the less. Saturday was a waste, domestic stuff got in the way (falling asleep for a couple of hours didn't help, either) Today, after a slow start, I got the t/case cleaned up a bit and installed it:

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I started to assemble the 9 inch, but came across a stumbling block with threw a spanner into the works. I decided to do a tooth count just before dropping the pumpkin into the cleaned housing, only to discover it was 37/10 or 3.70:1 LS, not the 3.50 LS the tag said it was. After searching fruitlessly on Ebay, I've decided to install the 3.70 and worry about it AFTER rego, rather than worry about it now. I just need to A/ don't use 4WD or B/ use odd size tyres to even out the wheel ratio front to rear. Then, when I went to install the seal, it turns out to be for the small pinion support, not the large one. I'll pick up the correct seal tomorrow and some nylok nuts for the U bolts while I'm there. The backing plates will be bead blasted tomorrow along with a couple other things, all going well the housing SHOULD be assembled and painted tomorrow night, Tuesday, I'll fit it to the truck and clean/re-fit all the brakes etc. I wont be driving it on my birthday after all, but it WILL be driveable by the end of January and THAT is a promise (to myself).
9 inch coming together:

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More updates to follow. Cheers.

[AussieRod]

Dec 20, another update;

Well, I found out the seal for the 9 inch was actually for an 8.8, so i won't throw it away. The new seal is ordered and I should pick it up Wed arvo, and it can go in whenever. The 9 inch went together well, and its had 2 coats of black gloss enamel:
Drying on the engine hoist:

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After painting the second coat, I put the back half up on stands and wheeled out the old 8.8 that's been holding it up for the last 4 years.
Ready for the new rear end:

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The old 4.10 8.8. I'll give this a refurbish later on in case it's needed:

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Tyre stack:

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Oh, when I pushed the truck out back under the carport after installing the engine, I forgot to lower the hood and dragged the front edge on the light bracket. Another repair I need to do. I wasn't happy, I can tell you, but it was my own fault, so I'll just fix it and move on:

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The offending angle iron:

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Tomorrow, the 9 inch will go under the truck and be bolted in. I have new nylok nuts and hardened washers for the U bolts, and the spring plates are already painted. Then, the brake parts will be cleaned, new cylinders will go on and the brakes buttoned up. The new drums I put on the 8.8 will finish the deal. That's enough for tonight, another day tomorrow and more progress. Cheers.

[ChaseTruck754]

Bummer on the hood. it's the worst feeling when it's a silly thing & your own fault. All you can do is bite your lip & move forward.

Good to see this thing is getting close.

[AussieRod]

Thanks, Steve. I'm busting my hump at work, and it is taking it out of me, but I'm commited to finding time every day to at least something done.

[ChaseTruck754]

I see that & 1 bite at a time is how you eat an elephant like this project. I need to make myself do the same! I saw you say the "2-3 hours a day" thing in the earlier post & pretty much kicked myself for not forcing myself to do the same. The couch gets a firm, suction cup type hold on my arse after my wife & kids go to bed and I sit there numbing my brain to the glowing box vs. being productive like I should. I've said to myself time & time again I need to break that spell & get my butt back out in the garage. After a long day of work and then family time my garage hours are about 10-midnight and I'm being lazy and also a wuss right now & saying it's cold.

[AussieRod]

I know exactly where you are coming from. After work, I'm usually completely buggered and need some down time, and unfortunately get stuck in a chair asleep. We have just come out of almost 10 months of rain and shitty weather, so motivation has been low. I SHOULD have had this finished a LONG time ago, but I was lazy. Now, I NEED this truck going, so it's MAKE the time now we have daylight saving. Money is my other enemy, too. I don't have a lot of spare cash now my 2nd job vapourised, so I have to scrimp and save t be able to buy the bits I need (postage from stateside doesn't help my cause. either). Even ONE hour a day will make progress. Speaking of which, I'd better go do something on it before I fall asleep again.
Cheers.

[ChaseTruck754]

Sounds completely familiar. My stuff should have been done long ago too. New kids and life gives one a different "schedule" though... My side cash is all but caput and motivation is low with the truck now outside in the cold. 3 sleeping people in the house make is so the noise level has to stay completely low. So yeah, I'm still in the lazy faze trying to leech of some of your motivation!

[AussieRod]

Jan 4 update (for the new year):

Progress has been made, although it doesn't look it. The 3 days for Xmas and Boxing day here were BRUTALLY hot (compared to the recent weather), so not a lot got done. I spent most of the time making sure the animals (2 goats and 30+ chickens survived the heat). Many of the little things I've done aren't apparent at first glance, but they do add up:

Shit loads of wiring (fuel pump and lock-off, lights, starter, fans, etc):

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Carb and propane mixer mocked up:

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Yoke and seal installed, fuel tank vent finished and exhaust hangers refitted:

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The original Munroe rear shocks are still ok, so they got cleaned and a coat of 27 y.o. yellow to refresh them:

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There is lots more, the engine connector harness, lots of little bibs and bobs that seem endless, but like Steve Chasetruck says, one bite at a time eats the elephant. Now I am back at work, I use my breaks and after work to fab small mounts, tabs and brackets as required to finish off more and more of the leftover things to do. Closer and closer. More updates soon.
Cheers and Happy New Year!

[ChaseTruck754]

All the little stuff like this kills me Rod. You work for hours and the visual reward of seeing what got done is nill. So frustrating and can keep slackers like me from moving forward. Yet without doing it the project never gets done. Keep chomping away & inching forward & you'll be driving it soon!