Rod's 84 BabyBajaF100

[AussieRod]

Saturday October 20:
Been a bit busy since getting home. I missed my connecting flight, but managed to get the next flight 1 hour later (cost me $150 for a late fee, c*nts). Thursday was a rest day, I am always buggered the following day and need a day out. Friday was going to Melb and getting visas for the China trip and glasses organised before we go. Today, I went back to Melb to visit my parents and go to the local gun show. I picked up 2 more packets of cheap ($22.50 a pack) PPU .308 150 gn SP, some Sellier and Bellot 150 gn 30 cal projectiles, Hornady .303 174 gn FMJ pills and some Nato 7.62 ammo. My new door strikers have arrived, I'll fit them tomorrow and adjust the doors. I'll also grab some new door seal, too, and fit that in place of the old tatty originals. The JBG seals are too big, I can't close the doors. I need to finish off the accellerator and TV cable and fit the propane mixer so I can go drive it next week. If the cash holds out after the weekend, I'll get the 'screen fitted Tuesday. The exhaust will get some paint and the resonator tomorrow, too. More later.
Cheers.

[AussieRod]

Tuesday October 23:
Needed to spend some quality time with the Handbrake (earning brownie points), so didn't do anything yesterday. Now that I have some free time again, I got the F100 out of the garage and set it up to do the resonator. After removing the tail pipe (with welding gloves because it was bloody hot), I trimmed off the section after the chassis upturn and bolted it back on to set and tack the resi on:

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I then trimmed off the elbow to tack that onto the resi once I'd tacked it to the tailpipe:

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After tacking it all together (and doing to obligitory start to hear it) I removed the assembly and welded it fully. I'd also marked the cut off when it was tacked up to cut it once welded:

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Now it has lost that metallic raspy note and is more mellow and deep, but still sounds nice when idling "on the cam" and at revs. Once that was all done, I removed the exhaust and after a good clean and wire brush of the welds, etc. I hung it up and gave it a good coat of flat black hi-temp paint while it was still hot. Once dry, on it went with some Ultra Copper sealant.

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cont.

[AussieRod]

Tuesday 23 October, cont.

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After finishing off the exhaust (for now), I couldn't resist the temptation to fit Mike's old Bronco wheels and tyres to see how they look on the F100:
Instant 3" lift (sorry about the shadows, it's late arvo):

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One of the rears (LHS) is a different offset to the other 3, so it sits out 3/4":

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The right side JUST hangs out, fine for everyday use, but not for RWC inspection:

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Plenty of roon unter her bum now:

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Side on, the clearance underneath is fantastic, nothing to hook up or drag if I go crawling:

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Really happy with the underside, although after the inspection, and rego (if I go that way) I will make up a mid-flap to protect the rear end, shocks, etc. like some of the GFB guys have done.
cont 2.

[AussieRod]

Tuesday 23 October cont 2:
Also fitted the new door strikers. The passenger (LH) door is perfect, but the driver side (RH) the top is in too far and will need a slight hinge adjustment to correct it once the new seals go in (tomorrow). I will also get some art craft brushes, as I need to go around the body and chassis and do some touch-ups to make it all look a little closer to new(ish):

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Once she was under the carport, I snapped this. The front wheels have a little negative camber, almost perfect to keep the tops of the tyres level with the fender edges:

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Once the new tyres go on the Alcoas, they will fit nicely under all the fender edges and look really good. Likely I will book the 'screen for Thursday and do the TV cable set-up tomorrow so it is ready to drive Friday. Can't wait
More tomorrow.
Cheers for now.

[AussieRod]

Wednesday 24 October:
Got a call an hour ago, it seems I'm NOT going back to QLD until further notice. Apparently, the mine will not be going back to work, so only a skeleton crew will be present. Hopefully the mine will sort out it's debt problem(s) and I can go back. So, next Wed, instead of flying back to work, I'll be back in the workshop until I go to China. Good, because I have more time on the truck and time to prepare for the trip, BAD, because I lose a shitload of money. Anyway, I'm off to pick up some chook food and stop off to get the door seal pinchweld. Then, I'll continue the throttle tab I'm fabbing for the carb/TV cable.
More later.

[AussieRod]

Wednesday 24 October arvo update:
After a couple of trips to my supplier (forgot the pinchweld sample), I picked up 8 metres of door seal/pinchweld and started replacing the door seals. I had to basically undo the dash top to get the bottom screws out of the A pillar panels, trying hard not to break anything, but as the trims have a standout at the bottoms that hooks under the crash pad, I had to carefully work the new seal around them into place. I didn't bother re-installing those screws, as the trims sit tight enough, and the new seals work perfectly (almost). The LH door closes perfect, no movement and is easy to open and close without using force:

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The upper rear corner was the problem area on the LH door, but the old seal was hard and mis-shapen from age, so replacing it was necessary:

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The RH door seal went in easy too, so it wasn't as big a battle as I'd anticipated:

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Top of the LH door seal where it is damaged:

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RH side was much worse and over a longer area (due to more use):

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After re-installing all the screws in the dash top, I noticed the centre radio panel has a huge crack across the top section of it. Now, I didn't break this installing it before, and it didn't break during this part of the work, so I'll have to say it has given up somewhere in between. Never mind, I'm trolling ebay for the clock replacement so it's the same as Mike's Bronco. The piece for the carb is done and I was fabbing the accell cable bracket to suit when the camera batteries said "F you". I can't find ANY decent batteries these days, they never last like they did several years ago. Maybe this is something to do with the prepper craze? Anyway, I'll find some new batteries for tomorrow and after I fab the cable bracket, I'll snap some pics as I assemble and adjust the cable(s).
I also noticed there is a gap in the door to seal on the front of the upper door frame on the RH door. As the rear of the door is too far into the frame, it seems the door has been closed heavily on something at some stage and has bent the front of the upper frame out. As I can't bend the rear part of the frame, I might stick a padded block into the rear part and use some force to reset the front of the frame to match the door opening. Then I can adjust the door at the hinges to make it align better to the cab opening. I'll work on this once the accelerator and TV cable are sorted.
Enough for tonight, more tomorrow.
Cheers.

[AussieRod]

Ok, it's Friday.
Yesterday, I finished the throttle lever tab and fitted it up. Due to a slight dog-leg in the throttle lever, I couldn't fit it behind as I planned withour running out of thread on the stud, so with some minor adjustment, it fits:

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I redrilled and cut down the original accellerator cable bracket and it works perfectly, all the alignments are good, just need to fine adjust the TV cable to match:

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Today, I'll get some allen head bolts for the passenger seat, mount it and the centre seat belts and clean up the floor and cab. Might even throw in the centre console and see what it all looks like. While I'm getting bolts, I'll try and find a co-ax extention, if not, I'll mount the UHF in the underdash centre and go from there.
More later.

[AussieRod]

Friday 26 October:
What did I do today? Oh, yeah, I fitted the tracks to the passenger seat, made a new lock connector and re-fitted the seat to the frame. I then dug out the centre console box and bolted that back on. I also fitted the plugs back into the floor. I'll need to fab some tabs that bolt the frame to the centre belt holes and also extend the seat belt mounts up so I can re-fit the buckles for the outer belts. Now it's starting to look like it should inside:

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I then tackled the driver's door, by using my knee on the inside and pulling the upper frame in. I did the rear first, then the front, then adjusted the bottom hinge to pull the door in about an 1/8". It seems to fit the door opening much better, but I can't re-position the striker any more or the door will sit in too far at the back and look stupid:

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I mounted the little Icom UHF on the front of the console box. That seemed to be the most logical place, as I am starting to run out of room. Anyway, it's mounted in place, ready to do the wiring and co-ax, the floor cover and it's patch. That will have 2 holes for the shift cable and wiring for the inhibitor switch(es) on the shifter and radio (to the battery direct). I also bought a little 2.1dB gain ariel for the roof, so I don't wipe out my longer 4.5dB whip in a shopping centre underground carpark (done that before):

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While I was warming it up to back it back under the carport, it was getting dark and with the dropcloth over the front, I noticed the alternator light was partly on. That might explain the low voltage (12V) on the volt meter, instead of the 14+ it should be. That and the battery seems to lose charge a lot, I suspect a dead diode in the alternator. I'll duck down to the local supplier monday and sus out a 80A or 120A replacement, get the part # and troll ebay for a replacement. The windscreen place is open tomorrow morning, so I'll call and book the window for Monday, as we will go to Melbourne Tuesday to pick up passports, glasses, etc. I'll print out the unregistered vehicle permit while I'm out and wednesday, after a thorough check, I'm going for a drive.
More tomorrow.

[AussieRod]

Saturday 27 October:
Cont. from yesterday.
Radio mount shot:

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Rather than extend the co-ax, I will re-route the co-ax back from the dash, use some convoluted cover and run it behind the seat(s) on the mounting tube and I won't need an extension. I'm in the process of doing the wiring for the inhibitor switches and UHF now, so I'd better get back to it.
Later.

[AussieRod]

Saturday 27 October cont.
Well, got all the wiring done. The radio was a disappointment, though. No wonder I got it for free, it's programmed to a private network from the ex company next to my work. It's going in the rubbish bin and I'll find a replacement that DOES work. It will cost me more to re-program it here than a replacement costs, so no use wasting my time with it.
Installed the trans tunnel cover and made a patch plate for the manual gearstick hole:

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Brought the wiring through and tied it all up nice and neat:

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Now the inside looks better, just need to cover the floor and order a carpet set:

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Found the little LED flood and wired it up as my reverse light, works perfectly:

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Gonna install the bumper/towbar tomorrow morning and finish off all/any brackets it needs, then clean it up ready for paint or powdercoat. After that, I'll attack the front bumper and finish that off.
More later, maybe.

[AussieRod]

Sunday/Monday 28/29 October:
Condensing 2 days into one. Got the bumpers out yesterday, stripped off all the lights, etc. and started cleaning them up, finishing the welding they needed and welding on tabs, brackets and such. Did the rear first, cleaned up the welds on each end:

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Welded on a small mount for the Anderson plug holder:

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Pile of things removed. Multi-pin trailer plug (fits trailer or the caravan), Anderson plog holder, reverse LED:

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I bolted it back on the truck to do the final wiring terminations and make sure everything still is as it was when I dis-assembled it.
Cont.

[AussieRod]

My internet connection is completely f**ked, it took 5 trys to get this loaded up! This problem has been going on for a few months now, and the pricks won't contact me like they said the would, nor have they been around to fix the problem.

Front bar getting tabbed:

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Back on the truck:

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I'm going back out after dinner to finish the trailer plug off, check the wiring for the licence plate LED and start planning the HDPE for the front bumper, simmilar to alpinejd3's bumper. I need to fab a few brackets and tabs for the install. These I'll make at work later this week. Ordered the windscreen for fitting tomorrow, so if that goes well, I'll get the unregistered permit tomorrow arvo and go for a short drive. I might steal the power steering cooler from the old Jeep and start working out the location for that, then go looking for a sheet of aluminium for a skid plate.
More later.

[AussieRod]

Tuesday 30 October:
WOOHOO!!! It finally has a windscreen!!

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Then this paper wasp buzzed me while I was trying to take another pic, so I smashed it with a piece of 3"x 2" I had nearby:

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Flattened him and his paper nest he was building. That'll learn him.
I'm going in to organise my permit, then after I go print it, I'll have a leasurely drive up and down the road to get the feel for it and do a system's check.
More later.

[AussieRod]

Tuesday 30 October:
For the first time in 6 1/2 years, I drove my truck.
However, the transmission wouldn't co-operate. It would NOT shift out of 1st, unless I revved the piss out of it, and it would shift 1-3. I didn't go far, just in case, so on the way back, I could smell something strange, like burning plastic. I stopped, hopped underneath to see the ziptie on the cooler bypass had broken off and the loop was sitting on the right connector pipe. Lucky for me, I had used good quality hi-temp hose, so I idled home and using my welding gloves, managed to re-tie the loop back up to the filler tube and put a couple extras on there to keep it there. Next, I checked fluid level, slightly over-full but ok, then checked the TV cable. It was tight, so I lossened the ferrule and got slack, then after checking with the test piece, decided on a pos before tightening it up. It took a couple of Kays for the trans to finally co-operate, but it shifts good and firm, and kicks down with a boot full. It's running a bit warm, I guess the electric fans are either not capable, or blocking airflow thru the rad, so I will go back to the clutch fan and see how that goes. Otherwise, it's firm and tight and gets up and boogies when I drill the loud pedal. It sounds shit hot, too, but probably still too loud for general use. The noise is outside, the cab is quiet inside with the windows up, so I'll leave it for now
Officially, IT LIVES!!!!

[ChaseTruck754]

Congrats!

[yikes]

Holy smokes! It's alive! Congratulations Rod. Long time coming.

[AussieRod]

Thanks, guys, it's been a journey. Yeah, it's been TOO long, but that was my lazy arse not working on it when I could. As I drive it and slowly work out the bugs, I'll be able to relax and enjoy it more. Now, it's nerve racking, as I drive and try to think of anything I forgot to fit or tighten up, what might/will go wrong, etc. It feels every bump, too, so I'd better check the tyre pressures and see if that helps. I hate those Coopers, they're like solid rubber and harsh on the road.
I'm in Melb today, so I'll fit the wiper arms tonight, with new inserts, bolt in the driver's seat belt buckle, etc and make it safe to drive to work tomorrow.

I drove it last night, in the cooler evening, with the GPS to check the speedo and see if it ran any cooler. It runs the same as daytime, so I might need to run a different thermostat (again) and fit the factory clutch fan and shroud to help keep it under control. The speedo is absolutely DEAD ON (fluked that, didn't I?) and it cruises along in O/D @ 1700 rpm at 100 km/h. I'm thinking I will have to go to 4:11 gears, to keep the revs at 1800 - 1900 in O/D to allow the engine to work efficiently with the big tyres. The old 8.8 is still there, it has 4:10's in it, it just needs an axle and wheel cylinders to work. Perhaps a weekend swap to try it out. Anyway, more later.
Cheers.

[AussieRod]

Wednesday 31 October:
Cleaned and painted the wiper arms, they'll go on tomorrow after work with new rubber inserts. I dragged out the tub mounted propane tank and started prepping that for a test fit and run the system to empty it out for re-certification. No sense wasting good propane. I'm currently working out the math to decide tyre size vs gear ratio to see if I can get a nice compromise. Right now, the O/D gives me 1600 rpm @ 65 mph with the 3.70 rear gear, 4.11 will give me about 1800, and 4.56 a shade over 2000 rpm at 65 mph. This is with the 33" tyre. It will cost me a shitload to go 4.56 in the TTB, but I can get a factory 4.11 (from the 6cyl version, like mine), so that looks the way to go. I can always use 31" tyres if I need more gear. Anyway, I have to shower and go to bed, so I can get up for work in the morning.
Cheers.

[Pickuptrucker]

Nice work!

[AussieRod]

Nice work!

Thanks