Compression

Saturday morning broke with the first good sunshine we’ve had in a long time, so I decided that I would take advantage of as much of it as I could. After a mile-long walk with the dog and a cup of coffee with Jen, I put on my coveralls and headed out to the garage. The first thing I wanted to tackle was pulling and inspecting each spark plug I’d installed last year to ensure they were gapped correctly and to do a compression test. I pulled the coil wire, started with the #1 cylinder and worked my way backwards on the driver’s side, then finished on the passenger side.

All of the gaps looked right at spec, and the tips were all covered in gassy-smelling oil—which I expected, considering that I haven’t been able to get her running consistently for a long period of time. The most important information was good information: all of the cylinders had excellent compression, with the lowest of any of them at 125psi. This means the rings are in great shape and have hopefully reseated themselves after their long slumber.

When that was done I pulled the passenger fender out into the sun and hit it with sanding blocks for the second time, working the high spots down and smoothing out the second skim coat. It’s really shaping up on the outside, and I’m having great luck with the new filler.

One drawback was that the inner metal collar I’d welded on to the backside of the fuel port came off as I was sanding it down; when I welded the inside edges and then sanded off the excess metal apparently I was a little too zealous and weakened those welds. So this time I predrilled a bunch of pilot holes along the outer circumference and used those to tack the collar back in place from the back side—something I should have done in the first place. I’ll fill the inside edge with seam sealer to hide the welds, which are mostly hidden anyway. Then I skimmed filler on the low spots, which are (thankfully) decreasing in number.

Sunday morning I ran up the Scout for the first time in two weeks and let it warm up in the driveway. After attaching my ghetto exhaust extender (a 5′ length of HVAC pipe attached to the tailpipe, with 20′ of PVC reaching past the side of the garage) I turned both idle mixture screws all the way back into the carb and then backed them out 1/4 turn. Adding a little starting fluid to the carb, she fired right up and idled much smoother than she had two weeks ago, but then I saw the giant clouds of white smoke coming from the end of the exhaust and figured I’d better shut her down. So the rough idle issue is mostly sorted out, but I need a good windy day to run it up and clean the Berrymans out of the fuel system.

Next, I got to work tearing the front bench seat base down to the metal. I set up a GoPro and took a bunch of pictures, then started tearing the old vinyl off the frame. Removing the foam, burlap, and reed padding, I cut the old hog rings off and wire wheeled the outside elements, and then looked it over. There were three sections that needed to be welded back together, so I set up the MIG, dialed it in for thinner metal, and put them back together. Then I brushed encapsulator on the whole thing, which was a tedious job.

There are two sections on the back side that look like they could have been welded originally, but also maybe they weren’t. I texted Jeff to see what he thought and he told me his seat is from a ’68 and doesn’t look like mine. I’m mulling over whether I should weld in a set of supports there just to keep the whole thing sturdy.

While that was drying I pulled the fender out and continued sanding the high points down. It’s getting very close. There are only about five small areas that needed to be skimmed—hopefully for the last time—so I put some filler on to cure while the weather was still warm.

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Weekly Roundup, 1.28

Knowing it was going to be warm towards the end of the week, I made a beeline out to the local Eastwood store on Wednesday. They had the body filler I was looking for, a specialty brand that came highly recommended online, and  Amazon couldn’t promise to deliver it before then. I was able to throw in a new can of Encapsulator to meet the minimum for a coupon, so it worked out perfectly. This new filler is lighter and sands much easier, making bodywork much more pleasant. I was able to get the high spots knocked down quickly and then spent time finding the problem areas, marking them out with a Sharpie and readying them for the next skim. I actually covered more areas now that I know how easy it is to work with, and I’m looking forward to getting this piece cleaned up.

I got a call from my friend Jeff on Sunday morning, to ask me a question about my seats, which he’s starting today! He figures it should be a week or so to get them done, which means I need to get cracking on ordering foam and materials. That news made my day.

Meanwhile the Travelall/Travelette/C-series designs I’ve been working on have been getting some decent traction for the last two weeks; I’ve sold about 20 shirts and a bunch of mugs and other stuff. And I finished off the first custom design for a guy in Texas today, which has me thinking about how to take commissions when I get the Scout version working. I’m going to get a little merch produced to photograph and then I’ll use that for the next promotion cycle.

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Shades of Gray

I set up and sent off a care package to Jeff J. this morning, containing a couple of paint chips, two snips of vinyl from the original seat covers I bought from Ray this summer, and a down payment for two new seat covers. We talked a bit on the phone on Saturday and set up a plan; he’s got a bunch of other orders in line but he’s waiting on special-order vinyl so he thinks he can fit me in around those other jobs. The stuff I want is pretty basic and should be easy to lay hands on—it’s just lightly pebbled black and light gray. I went to Lowe’s and looked through their paint samples to find something close to the gray of the door panels and found a swatch one shade lighter and one three shades darker.

I’d like to go with the lighter to set off the black as much as possible, and for these I’m actually going to reverse the pattern so that the light color is on top and the seats are black.

The other thing that showed up was a set of new metal from SendCutSend, which will be used to add the filler hose opening on my spare passenger fender. In order to make the minimum order amount I doubled up on everything, so I have some pieces to practice on—especially the 1/2″ strip that needs to be bent into a perfect circle. I’m going to need to find a 4″ diameter pipe to use for forming somewhere. There’s actually a scrap metal dealer up in Pennsylvania who has box tube and other metals I need for the bumper mounts; I think I’ll add that to the list of purchases when I head up there.

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Weekly Roundup, 10.8

The beginning of the week was quiet, but I put almost two full days in over the weekend.

With the glass and other stuff out of the back of the Travelall, it’s much easier to start some of the preventative maintenance I’ve wanted to do to the rear frame and crossmembers. Saturday afternoon I lifted the rear bench seat out and pulled up the plywood floor. Then I put on some ear protection, fired up the compressor and the needle scaler, and got to work. Starting from the back I took as much scale off the unpainted metal as I could find, making my way to an area over the rear axle. Then I brushed on Rust Converter to everything I’d cleared and let it sit. I started around 4 and finished when the sun was setting, so there’s still a lot more to do—and I haven’t even touched the underside yet—but it’s already looking much better under there.

Reorganizing the garage a bit, I stumbled across an extra box of weatherstripping and realized it was doing me no good here. So I put it up on Marketplace and got a pretty immediate response from a guy in Washington, who was also interested in my old brake booster until I did the research and learned it would be something like $80 to ship it out to him in Washington. So the windshield gasket is on its way to him, and the brake booster remains in the Heavy Metal corner of the garage next to the old starters, spare Dana 20, and other stuff.

A brake has been instrumental to the plans I drew up for the doors on the seat base, because I wanted to bend a quarter-inch of metal along the edges on the three sides to add structural stability and make it look better. My Harbor Freight brake is woefully unprepared to bend 18 ga. metal at the measurement I need. On Sunday I met up with Bennett over at our friend Brian’s shop to get a couple of projects done. Bennett was there to clean up the carburetor on his Hudson project as well as tinker with Heavy D, which has been sitting there for several months waiting for a windshield replacement. I was there to use the heavy-duty finger brake Brian inherited with the pole barn shop on his property.

I started messing with the brake and putting a couple of scrap pieces through it to learn how it worked and where the sweet spot was. There was only one finger clamp on it, so the first long section of metal I bent didn’t stay still and bent unevenly. I took a break, had a donut, and Bennett suggested looking around the shop for the other fingers. I found them along the back wall and installed three of the fattest I could find, then put another long test sheet through. When those results looked much better, I marked out some new metal and started bending. We had to do some creative adjustment to the brake, because the bending plate was so close to the lever plate it wouldn’t release the metal when I’d bent the second side. This involved unscrewing the plate from the bottom to release my metal, but it worked. After I got two doors bent and test-fitted, I helped Bennett mess  around with Heavy D, got it started for the first time in forever, and installed a choke cable before we both headed for home.

Back at the house, I investigated how I could bend the short edge with the tools on hand. I’ve got a cheap wide vise I bought from Harbor Freight back in the day, and after some testing I realized I could bend the width I needed with that and a pair of vise-grips blocked into place, keeping the entire width of the metal on basically the same plane. After making the initial bend, I had to hammer the center sections flatter with a combination of deadblow hammer, wood blocks, and metal scraps. When I had it flat and straight, I welded the corners up, cleaned them up with the flap disc, and trimmed the length of each to allow for the width of the hinge knuckles.

When those were in place, I tacked the hinges in place and test fit the doors; all my cuts looked good. So I flipped the hinges, cut some tack holes in the doors, and welded those into place. If I had to do it over again, I’d have put the weld on the underside, but I think it looks pretty good either way.

So the doors are in place, and next I need to cut and install a pair of stops opposite the hinge side for the doors to sit on. I’m going to wait until the locks come in next week so that I can design around those. I was originally going to cap off that gap in the middle, but now I’m considering adding a plate underneath to make it a shallow tool well to utilize some dead space.

The other thing I spent a bunch of time looking for last week was a hinge of the proper size for mounting the seat to the box. The hinges on the seat base are beefy; the pin is 3/8″ in diameter and the knuckles are thick. I found a lot of hinges with the right pin size but nothing with a leaf the proper length—the interlocking sections of the hinge I’ve got are 1.5″ wide, and most industrial hinges I’ve found with that pin size are only 1″. While I was at Brian’s, I was looking at his scrap pile and found a beefy hinge with a 3/8″ pin and a 2″x2″ leaf—exactly what I had been looking for. I texted Brian about it and he told me to take it with me.

Monday I had off for Columbus Day, so I got back outside and kept rolling. First I cut two hinges down to the right size, trimmed the knuckle widths, and test fit them on the box. When I liked what I saw, I tacked them in and fit them to the seat. With that confirmation I burned them both into place and cleaned up the welds. The plates will get two bolts through the square tube for extra structural support, but I like where things are sitting (literally) now.

Then I got out the needle scaler and wire wheel and continued working on the chassis while I had the rear floor out. Before finishing up for the day, I brushed on some Rust Encapsulator. I’ll finish coat it with chassis black when it’s all ready, but there’s a lot more to go.

Meanwhile, I’ve tried removing old upholstery adhesive on the vertical surfaces with every chemical I can think of and a rubber eraser wheel with no success. Frustrated, I tried a small patch with the wire wheel and found that with a very light touch I could get most of the old crust off without going through the paint to metal—there are a few places where the paint is very light—but it mostly came off with little damage. I was always going to respray the inside anyway, so I’m not worried about patchy areas. It’s nice to have that stuff cleaned up, for sure. I’m going to see if Hobo Freight sells a plastic bristle wheel for an angle grinder and see if that’s more gentle on the paint.

Boxed, Part 3

This weekly update is regrettably several days past my usual Friday schedule, but given the amount of stuff I’ve been posting this year, I figure that’s OK.

With winter fast approaching and a week and a half worth of wet weather behind us, I knew I was going to have to do something about dry storage for the Travelall. Erecting a new garage is out of the question, and putting the awning up isn’t going to fly, so I went with the cheapest option: an inexpensive Suburban-sized car cover from Amazon. At first I was afraid it wasn’t going to be big enough to cover my truck’s ample backside, but once I adjusted the front, the rear fit snugly over the taillights with little to spare. It’s tight enough that I don’t even think I’d need to tie it down, although having two built-in straps is a nice feature.

On Sunday I had the afternoon to keep working on the seat cage, so I finished cleaning up the joins and smoothing everything out. Then I put it in the truck, taped a rectangle of cardboard to the top, and scribed out the trans tunnel. With some adjustments and a second template, I laid it on some 18 ga. steel and cut out the front section. After I trimmed it to where I liked things, I tacked it in place and did one last check before tacking the perimeter in place every inch.

When I’d ground down the welds, I cut out two rectangles for the ends and tacked those in. I did another test fit, ground some things down, and tacked each side into place.

Then I adjusted the welder settings, sealed up the top and sides, and ground everything down to smooth with the flap disc. At this point I’m trying to figure out how I’m going to arrange the two doors; currently I like the idea of countersinking them inside the cages that they’re flush with the top. I’ve got a hinge here from Grainger ready to go, but the locksets they sent me are way too small (curse you, Internet!). So I’ll spend some more time considering that solution.

The other thing that came in the mail were two 3D printed plastic visor clips, something the truck didn’t come with and that I haven’t seen anywhere else. I took a chance based on a comment from the Round-Body Travelalls group on Facebook, and I was not disappointed when they showed up. With two stainless screws from my bench stock, the clip went right into the existing holes on the driver’s side and the visor snapped into place. They need to be sanded and cleaned up, but I’m happy.

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Boxed, Part 2

Here’s where the box stands as of last night. I put weight on the cage to set it in place, then tacked some scrap metal to the open end of each bottom bar. With both bars at the proper angle, I measured and cut two legs to meet up with the ends and tacked them to the top bar. After checking that fit, I brought the whole assembly inside and welded it all up, as well as added two sections along the bottom side of the short edge. I closed up the holes on the bottom ends and smoothed the welds out on all of the outer edges with a flap disc.

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Boxed

5K7A1544

After Day 2 of Hurricane Ophelia or whatever they’re now calling this blustery rainstorm that was supposed to have leveled the East Coast, I have a report on the repairs to the Travelall. In short, everything I did to the cowl looks pretty good. I saw one drop of water from the driver’s side vent opening that I haven’t been able to figure out yet, but the rest of the seams all look like they held well. Both of the floors are damp but I suspect that’s due to leaky door seals more than water coming through the cowl. There’s water along the sills in back as well which bears this theory out a little more. Along with the weatherstripping, Today I ordered a car cover so she can overwinter without getting wet, as well as postpone a hasty respray of the roof until the weather warms up and allows paint to dry and cure properly.

Sunday afternoon it was too rainy to be working outside but too warm to not be working. So I jumped the gun on my seat locker project and got started. In the garage, I tuned the radio to the Ravens game, then cut metal down and assembled the top of the cage first, knowing that the curves on the bottom would be difficult to assemble without it.

The rectangle went together smoothly, and I used the tailgate of the Scout as a level worktable to get everything squared up. I measured the height of the step again, cut four legs and tacked them into place. I’m not getting fancy with 45˚ butt-joint welds here because everything will get covered in sheet metal when this is complete.

Then I put spacers under the legs and looked at how the bottom of the cage would come together. The floor slopes down gently from the center, and the transmission tunnel sits in the center of that area. It’s a lot shorter than I envisioned, so my original design is being modified as I go. I don’t actually have enough vertical height for a length of tube spanning the front floor, so I have to cut legs that will tie into the upper bar.

I cut two short lengths of tube for the front side of the cage and tacked them into place just short of where the tunnel starts. With those in place I can gauge the angles I’ll need to cut the legs up to the top tube. I’m going to leave the bottom of the cage off in back, and weld in some tabs that can mount directly to the step wall.

By 7PM I was losing light, and couldn’t work in the truck anymore, so I cut two short lengths and tacked them in across the top of the cage where they’ll be the supports for a set of piano hinges.

The next step will be dragging the welding gear out to the driveway, putting weight on the cage, and tacking scrap metal to the open end of each bottom bar. From there I can get a proper idea of the angle for the legs, cut them down, and weld them in. Then two tubes go at the bottom of the thin sides to complete the boxes. I’ll cap off the open ends of the tubes and grind everything down smooth, and then start bending sheet metal.

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Weekly Roundup, 9.15

After calling around last week and leaving messages at several local glass installers, I finally got two on the phone. The first guy balked when I told him what year the truck was but said they’d be able to handle it if I drove it to their shop. He then quoted me a price of $500 to have someone come out and do it in the driveway. The second shop was much easier to work with, and after I sent a couple of pictures to the office manager, she got back to me and said they’d be able to do both the windshield and the rear quarter glass for less than the first quote. So I made an appointment and ordered some rubber from IHPA. I have a brand new gasket waiting, and I can’t wait for Tuesday.

I cleaned up the truck in preparation for having the glass put in, and looked over the front seat again. For some reason I’ve been thinking the bar frame mounts directly onto the seat bases, completely forgetting there are two track mounts that go between. After slapping myself in the forehead, I fished the set of tracks I bought from Ray out of my parts bin and looked them over, and everything became much clearer. I did some rust repair and cleanup on both, and ground off a bent and warped bolt on the driver’s side track. After sorting out the hardware issue, I welded a new bolt on to the track and cleaned it up. I taped off the tracks and hit them with etch primer before they got two coats of IH red. I’ll let them sit and cure for a couple of days, then install new hardware and a spring on each side. I sprayed the bar frame with semigloss black and let that sit to cure as well. When it’s all ready, I have new hardware and a spring on each side to mount it to the frame, and then I have to source a cable to reach across under the seat to release both of the slide catches.

And on the subject of seat bases, I got a bunch of metal delivered on Thursday for the rear seat locker. I can’t wait to dig into that project.

We went out over lunchtime on Friday to pick up the Scout, and I can’t believe how quiet she is again. The mechanic replaced the valve, manifold and gasket, and now she sounds like I remember. One other thing he fixed was the front wheel bearing. When he put it on the lift he watched the tire droop and investigated; apparently when he pulled it apart the inner bearing was just destroyed. So he replaced the parts and repacked everything and it should be good to go. This is disturbing, as I just had this fixed before I went to Nats two years ago, so clearly the work wasn’t done properly. Lesson learned. In either case, I drove home with a huge smile on my face.

While waiting for the mechanic to call, I scuffed, primed and painted the new battery tray and got it ready for installation. Saturday evening I pulled the remains of the old one off and cleaned up the inner fender as well as I could before brushing on Rust Converter, followed by a coat of black Rust Encapsulator. When that was dry I dropped the tray in place and bolted it down. Now I’ve got to find a 9.5″ threaded rod in the proper width to use for the inside hold down point, and I can cut out and fabricate my own hold down bar to cap it off.

Weekly Roundup, 7.28.23

It’s been a quiet week on the project front; the heat outside has made things hard to accomplish after work.

That being said, I had a little free time last Friday and figured I’d try assembling the front bench to see if I could figure out how it worked. With a little trial and error, I was able to understand how the base and the rear go together, and measure for some hardware. The big question mark is how the seat attaches to the base itself. I remember Ray mentioning something about bolts coming up through the base into the seat but I can’t for the life of me understand how or what on the bottom of the seat they mate with. But knowing how the base is aligned makes a huge difference in the angle of the seatback.

The next step for this part will be grinding rust off the larger parts of the bare frame I’ve got and preparing it for foam, and then disassembling the seat. Having it in the truck, I realize the gray matches the steering wheel and dashboard, and I like how the black wraps around the top, down the sides, and scallops around the edges of the base. I’m leaning further towards having Jeff basically just match this pattern if possible. I did take a little time to wire-wheel the surface rust off the floors and shoot it with IH Red Rust-Stop, just to say I did something.

Last Monday I found a local metal supplier close to my town and attempted to navigate their website to figure out how much a sheet of plate steel would cost; eventually I gave up and called them. Surprised at how low the cost was for a 4×8’ sheet of steel, I ordered one and got off the phone. Later that day I realized I had no easy way of getting a 4×8’ sheet of steel home with the truck at the garage and no place big enough to easily store it, so I called back and canceled the order. Looking elsewhere, I found Onlinemetals.com and used their site to order three smaller (and more storage-friendly) sheets of 18 and 20 gauge steel. The sheet of 20 showed up Wednesday and it’s as beefy as I figured it would be; the 18 is still somewhere in transit. I went back and ordered a sheet of 16 gauge just to be safe, which will hopefully be here next week.

I heard back from IHPA on Tuesday, who couldn’t find the Travelall brake part I needed, but they pointed me to the Scout Connection. I called over there and within two minutes Dave had the part in hand and was taking my credit card information. From what he described it sounds like the right element, and I’m hoping it’ll be correct when it gets here later this week—I’d LOVE to get the brakes finally sorted and working, and then move on to the clutch.

Thursday I went to get the Scout from the shop it was sitting at for two weeks; they dicked around and never looked at it until I called and bugged them. In the meantime I struck up a conversation with a fellow Scout owner from Annapolis who recommended his mechanic, and I’ve got an appointment with him in the middle of August to drive it down and have him take a look. For now, it’s good to have my girl sitting under cover in the garage again.

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Weekly Roundup, 7.21.23

I had to make some space in the garage on Sunday after we got back, and took the opportunity to break out the wire wheel and clean off both seat bases.

After a coat of Rust Encapsulator I brushed on some black chassis coating and let them cure.

Monday we dropped the Scout off at a mechanic for them to replace the manifold and gasket.

Out in the garage I looked over the two seat bases and test fit them in the truck. The rear base will need some bracing but it’s definitely usable. Then, looking for someplace to store parts, I hauled the rear bench out and put it in the truck. It’s really not in bad shape at all, and it looks right at home in there.

The new door cards, behind all of the grease and rust, were originally the same gray as the ones in the truck. I test fit the drivers side to test a hunch, and I was right: there are two holes present to mount an armrest behind the door handle which line up with the door cards. So I’ll have to keep an eye out for those in the future.

I started cataloging parts and identifying what they are. Two of the door assemblies are clearly from a later truck, and they’re both for the right side, so I’ll see if I can resell them at some point. The rear door hinges are in good shape, and I started soaking them in PBblaster to remove various bolts from the assemblies. The glass went up into the attic. I’ve got to pick up a third bin for spare parts and keep working on storage solutions. One thing for sure is that the two PT cruiser seats left over from the Scout are going to the dump instead of taking up space.

Thursday after work I went right outside and decided it was time to lose the platform and old seats. I don’t have a ton of free space in the garage, and what better location to put it all than in the truck. Plus, I wanted to see what the floor looked like underneath.

First the seats came out; they were held in by eight bolts each, and the four rear inboard bolts on both seats were inaccessible underneath, so I had to use the grinder to cut them off. With those gone it took a little while to free up the platform and pull that out; underneath I found decades of dirt, one mouse nest, and some garbage.

After donning a mask and cleaning all that out I disassembled the rear platform base and the extender on the back step.

The floors are all in fantastic shape. The worst part is on the driver’s rear step by the door: water was probably getting in through the door seal and pooling between the wood and the metal. I should be able to cut that part out and weld new metal in. Under the driver’s seat there’s mainly surface rust which can be ground out pretty easily, and a few other small areas that can be cleaned up.

And when those seats are gone, I’ve got to figure out how to get a 4×8′ sheet of 18 gauge steel home from the supplier in Elkridge next week. I purchased it over the phone Thursday afternoon for pickup, and hopefully I’ll have the Scout back by the end of the week. With that and a $30 pneumatic metal nibbler I should be able to start welding things back together on the truck.