Rod's 84 BabyBajaF100

AussieRod · Post by **AussieRod** » Wed Jul 04, 2012 4:59 am

Mas. 9" bits in washtub, getting cleaned. Its done 478,000 km, and all the bearings are showing wear, but all still run smoothly and the gearset is still shiny and has no visible pitting or wear:

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Diff housing ready for pressure cleaning, U bolts, spring plates, etc going to wire buffing at work:

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brakes in line for clean up next:

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ESHALLBETTER · Post by **ESHALLBETTER** » Wed Jul 04, 2012 6:51 am

Can you convert the 9" to disc? I know they have some goofy rules you are stuck living with. It's not a hard swap, and worth while in my opinion, if for no other reason than you will never have to deal with drum brake again!

AussieRod · Post by **AussieRod** » Wed Jul 04, 2012 1:48 pm

ESHALLBETTER wrote:Can you convert the 9" to disc? I know they have some goofy rules you are stuck living with. It's not a hard swap, and worth while in my opinion, if for no other reason than you will never have to deal with drum brake again!

I hear ya

Nothing I'd like better. After the roadworthy inspection, I will look at a disc conversion when I re-gear the truck. Unless it is a factory set-up, I will need engineer's approval. There isn't any way around that here, unfortunately.

AussieRod · Post by **AussieRod** » Thu Jul 05, 2012 4:36 am

Thursday update:
Apart from finishing floating floor tonight, nothing to report. However, I finally got some axle and bearing pics today:

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The seals were stuffed and leaking, so new bearings were a must. I drill the collars and split them with a cold chisel and hammer, grind the inner races almost through and do the same:

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New bearings:

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AussieRod · Post by **AussieRod** » Thu Jul 05, 2012 4:50 am

Figure some of you might be intrested in what I do during the day, edited for more detail;
Water transfer pipe for front spray bar and remote control monitor on CAT 773B ex dump truck (to be fitted with custom built water tank):

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Pipe and mounting for Akron remote controlled monitor, same truck:

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water tank under construction for 773B:

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773F with water tank fitted for pivot pin/bushing fit-up and tacking. The tank will be removed to weld the pivot bushing in and pipework underneath (my job):

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I'm doing the water pump feed, transfer pipework, spray bars and pump mounts, fitting up and routing hydraulic hoses and fittings and all the ancillary work on these. Lots of fiddly little bits and pieces.
I HATE pipe work

economig · Post by **economig** » Thu Jul 05, 2012 5:34 am

Very cool Rod!

AussieRod · Post by **AussieRod** » Fri Jul 06, 2012 3:29 am

D'oh! Now I remember why I wanted to mount the tank at the rear...... with the front tank gone, I can use a Bronco long-travel mount, or fab up my own mount for my 10" Fox coil-overs sans coil seats. Otherwise, I need to perform some clearance surgury on the tank to clear the LH side of the mount and damper. The bed floor will require some cutting and a new clearance hump built into the floor to clear. I can get a NEW tank to my door for $250, but I can pick one up in USA for $90 and and a new pump and it can be shipped with all the stuff I have to collect and freight back. I will sneak into work early tomorrow (Saturday), clean the axle housing and press on the axle bearings, the head home to do more floor work. Sunday I will be working on the 9" and making a list of all the stuff I want to collect/purchase in USA when I come over for the BajaHID Adventure. More pics for the monster tomorrow.

hobbyturnedobsession · Fri Jul 06, 2012 5:57 pm

Alright Rod! I need to get moving again youre making me look bad ha. Ill miss you this year for the trip tho.

AussieRod · Post by **AussieRod** » Sun Jul 08, 2012 3:17 am

Dont feel bad, Randy, not everyone has the time and/or space to do something on this grand a scale.

AussieRod · Post by **AussieRod** » Sun Jul 08, 2012 3:28 am

Scored well today, drove 300km each way and picked up a good rear 19 gal tank, with LP pump/sender still installed, the HP pump, all the lines and 2 way valve/filter, upper and lower straps AND, the complete rear harness! Picked all that up for the princly sum of $70.

Tomorrow, I will post pics, and pull the pump so I can take the tank out for a thorough clean out, then a re-paint ready to fit. Only need the X member to fit it now, but I will prop it up in its correct position and start fitting fuel pipes, and make a start on the wiring harness. The 2 way valve wont be fitted, I will install a factory style canister inline filter in its place and make a joiner for the return hose. Hope to have the 9" assembled by the weekend and have it rolling some time shortly after that

Pics tomorrow.

Nick · Post by **Nick** » Sun Jul 08, 2012 10:09 am

You are moving along nicely, Mate! I'm envious of you guys that posses the skills to take a truck down to the bare bones, then build it up better than it ever was.

AussieRod · Post by **AussieRod** » Sun Jul 08, 2012 2:28 pm

Nick wrote:You are moving along nicely, Mate! I'm envious of you guys that posses the skills to take a truck down to the bare bones, then build it up better than it ever was.

Thanks, Nick

Your Bronco is coming up really nice too. I want the same 9" you have under the F100, but thats for later

Everyone keeps asking me, "Will it ever run again? Can you put it back together again?"

I just wink and tell them wait a little, they wont know it when its finished. Those who saw it prior to the teardown cant believe their eyes when they see the frame now as it stands. I just hope the end result wont be let down by me

AussieRod · Post by **AussieRod** » Mon Jul 09, 2012 4:36 am

Promised pics of fuel tank, etc:

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The bottom pump is my spare I already had:

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Tank sender/pump:

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Tank inlet with vent pipe support:

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AussieRod · Post by **AussieRod** » Mon Jul 09, 2012 4:51 am

So, I broke my pump ring tool trying to remove the locking ring.... thats down the back yard somewhere. A hammer and drift got it moving without damaging anything, pulled the sender/pump and found this:

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Just as well I ALWAYS check the sender and or pump whenever I buy a tank, as I get about 1 good one out of 5. Can anyone tell me if the 90 - 96 HP pump/sender will fit in its place? I'd much prefer a single in-tank pump over running 2 seperate pumps (just means I have to carry 2 pumps instead of 1 spare). After emptying 2 gallons of stale, stinking gas out of the tank ready for cleaning, I decided to attack the harness, stripping off the miles of insulation tape:

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Said tape:

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The tank and fuel system came out of a 4WD Ambulance, that the seller was restoring to a pick-up, much the same as I was doing, except his frame prep consisted of a piss-poor wire brush and pressure clean, followed by a heavy coat of shitty black paint that was flaking off everywhere. I also noticed it was a LWB frame, and that the body builder had added 8 more inches to the wheelbase on top of the std LWB. The join was pretty neat, better than most I have seen. I will have to play with the different fuel line lengths to fit my chassis and the new harness, I will strip out the EFI portion and graft it into my harness along with a few extra wires. The original curved plug will be re-used for the body wiring, and a new Deutsch plug will take care of the EFI harness connection.
I also found out why one axle seal was leaking so badly, whoever fitted the last axle bearing damaged the seal surface removing or installing it. I will try and true it up on the lathe tomorrow, to see if I can reclaim it, if not, I will have to find another axle on Ebay. I might even do a little preheat and TIG it up and repolish it to see if it will repair it. It wont need much, and I dont think that will affect the axle strength too much either. A new rear end is planned for next year, so it only has to last until then

Thats all, folks, until next time, adios muchachos!

philofab · Post by **philofab** » Mon Jul 09, 2012 6:59 am

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The newer pump is too big to fit through the hole. You are better off buying a Walbro 255lph hi psi pump, it will replace your low pressure pump.

http://www.autoperformanceengineering.c ... specs.html

AussieRod · Post by **AussieRod** » Mon Jul 09, 2012 7:30 am

Sorry, Philo, but now I am confused. Correct me if I'm wrong, but 80 - 85 fuel tanks (front or rear) have a 2" sender hole, and 86 - 96 EFI tanks have a 3 5/8" sender hole. How can the 3 5/8" 90 - 96 pump/sender ass'y NOT fit the same hole as the 3 5/8" 86 - 89 tank? Or is this something to do with the position of the pump inside the tank? I have been researching this for days, and I cant see what would stop me from using the later hi-pressure pump in the earlier (lo-pressure pump style) tank with the same size sender hole.

I am not doubting your knowledge or expertese here, but I cant see for the life of me why this cant be done. Educate me.

philofab · Post by **philofab** » Mon Jul 09, 2012 7:35 am

Your photo looked like the smaller style to me.

I still wouldn't bother with changing the hanger and fuel pump to the newer style, I'd just get a replacement pump that offers higher pressure and LPH. The earlier style pumps are small enough that you could stuff two in there and have a built in backup.

AussieRod · Post by **AussieRod** » Mon Jul 09, 2012 7:40 am

philofab wrote:Your photo looked like the smaller style to me.

I still wouldn't bother with changing the hanger and fuel pump to the newer style, I'd just get a replacement pump that offers higher pressure and LPH. The earlier style pumps are small enough that you could stuff two in there and have a built in backup.

Its definately a 3 5/8" hole in the tank, I measured it tonight after I pulled the sender and pump out. I was just going to either buy a whole new 90 - 96 pump/sender unit, or do as you suggested, fit a 190 or 255 in place of the lo-pressure punp in there now. I dont have to do it tomorrow, so I will think it over for a few days. Thanks for your input, either way, Philo, its always appreciated.

philofab · Post by **philofab** » Mon Jul 09, 2012 8:07 am

AussieRod wrote:
philofab wrote:Your photo looked like the smaller style to me.

I still wouldn't bother with changing the hanger and fuel pump to the newer style, I'd just get a replacement pump that offers higher pressure and LPH. The earlier style pumps are small enough that you could stuff two in there and have a built in backup.
Its definately a 3 5/8" hole in the tank, I measured it tonight after I pulled the sender and pump out. I was just going to either buy a whole new 90 - 96 pump/sender unit, or do as you suggested, fit a 190 or 255 in place of the lo-pressure punp in there now. I dont have to do it tomorrow, so I will think it over for a few days. Thanks for your input, either way, Philo, its always appreciated.

I don't know if you planning on using your stock gauge but the senders use different ohm scales.

AussieRod · Post by **AussieRod** » Mon Jul 09, 2012 2:07 pm

Ah! Perhaps thats what the main difference is, not so much the pump. Hmmmm, need to reconsider that. Thanks for that insight.