Thanksgiving Picking

Up in New York State to visit my family this Thanksgiving weekend, I reconnected with a guy near my sister’s house who has a lot full of antique iron in some fields off a back road. He’d advertised a Travelette late last year which I was interested in picking over but when the green truck landed in my lap, my plans changed. In February he said he also had a ’62 Travelall panel van in rough shape (he sent me a few pictures) so I figured I’d take a few hours and finally go check it out (the Travelette has since been purchased). I packed my standard recovery kit: tools, torch, PBblaster, impact gun, pry bars, and cold weather gear. I also bought a cordless angle grinder based on previous experiences, but left it in the box in case I didn’t need it.

If you didn’t know where to look for his yard you’d never find it, but what a collection he’s got. He’s heavy into Studebaker, Willys, and old Chevrolet, but there are all different makes sprinkled in. After carefully edging past an ancient Hudson, we cut some brush back and crawled through a hole in the fence to reach the truck.

It was beached next to a dually 50’s Chevrolet truck and a bathtub Nash that was sinking backwards into the dirt. The Travelall was well-used and picked over pretty good, so there wasn’t much to see there; I grabbed marker lights, the rear barn door handle (now I can soak this, disassemble it, and rekey it for the red truck) and the ’62 grille and headlight surrounds, which are in very good shape. The steering column was completely gone as was the manual box, so that was a bust.

I walked through the section I was in and came upon a ’68 pickup with a cap in very good shape. Both doors were inaccessible so I couldn’t get into the cab, and lifting the hood revealed column-shift manual steering, so I didn’t go for that. But the sheet metal on the front clip was in miraculously good shape. Both turn signal buckets were solid and the metal behind them was too, so I talked with the owner and made a deal on the entire nose. He agreed to let me cut it out as opposed to trying to remove all the fasteners (both of the fenders were garbage in the usual C-series way).

So I unfastened what I could, pulled the radiator and drained it for him, and cut both sides out as carefully as possible. I found that my normal-sized 20V batteries weren’t big enough to keep the grinder going for long, so I’ll have to get a pair of larger ones when these are worn out.

After about an hour I had the sheet metal free from the truck but had to cut the bottom mount bolt out to get it around a big homemade bumper. This took several trips back and forth to the garage, where he had my charger on a long extension cord. Then I had to jimmy the clip backwards to scoot it under the top lip of the same bumper. With that out, and a set of perfect taillight buckets, I hauled my finds back to the car and gave him my cash.

He then took me on a quick tour of the collection, where he’s got even more stuff across the street in another field, including a beautiful old cabover IH tractor, several C-series pickups, and a B-series Travelall that used to be a civil defense vehicle. There were rows and rows of Studebakers, a beautiful porthole Buick, Packards and Nashes and a Morris Minor minus its convertible top. The collection went on forever. These kinds of yards are all but extinct up here in salt country, so being able to spend at least five hours there on a snowy Friday was a lot of fun.

As for my new parts, the top of this nose is in rough shape, but I should be able to graft the bottom on to my existing sheet metal. The area around the turn signals on my truck is the worst rust besides the cowl vents I repaired last summer, so having some good metal to work with was worth the effort. I’ve got several taillight lenses, a perfect bucket, and several front lenses. And the ’62 grille and matching dual-light surrounds. All in all, not a bad haul.

Floorpan, Continued

I spent a couple of evenings this past week breaking down the green Travelall doors and collecting all of the parts to see how things look. The passenger door is in worse shape than the driver’s; there’s a fair bit of rust-through under the wing window on the bottom. Both doors are down to the metal, but on each one the lower hinge needs to be drilled out. That may make reusing them both tricky, but I think careful screw removal and re-tapping the hole is possible. Both windows, scissor assemblies, latch mechanisms, and most of the window channels are all in good shape. I’ve also got a second set of pre-’65 door latches for both sides from my friend Don in Ohio, which will come in handy as spares in case I need them.

The other thing Don sent me was a spare set of IH mirror assemblies. One of them is basically just the bracket, but the other held the mirror housing (minus the mirror) which actually worked in my favor, because I can see how the interior parts are assembled. Essentially there’s a long rod that goes through the center, threaded at each end, and held in place with two brackets welded to the rod. So even if I wanted to pull the rod out of my good housings I couldn’t.

To recap, the threads on one of my good mirrors was so rusted the bolts snapped off on each side, leaving me with no way to attach it to the bracket. Pretty much the only way I can make my good mirror work is to carefully pull one of the endcaps off, pull the threaded rod out, and replace it with a new one. The rod is pretty simple; it’s 1/4″ and takes a 1/4″ – 28 thread, which is easy to find a die for. It’s getting the cap off that worries me. It’s thin steel over an aluminum housing, so I have to be very careful taking things apart.

Saturday I stopped in at a neighborhood estate sale and picked up $20 worth of brand-name used tools that will come in handy for backups and spares, including four vice-grips and several wrenches.

Sunday I got back out to the truck and continued cutting and welding new metal in to the passenger’s footwell. I wound up taking more metal out, as I was having blow-through issues with bad metal and finding some pinholes as I was cleaning other sections. I think I’ve got all of the bad stuff out, and the stuff that’s still mildly pockmarked just got a thick coat of encapsulator. Underneath I ground out the rest of the welds and got it ready for paint. All of this took the majority of the day, as I was doing a lot of cutting and trimming, which sent me back and forth to the bench grinder.

The paint cured overnight and is now ready for seam sealer, which will be applied liberally around the edges before everything gets primed. On the outside edge of the footwell I ground everything flat and covered it in etch primer; it’s going to get several coats of chassis black and then a layer of undercoating to keep out the water.

Finally, I used some vinegar to flush out the inside of the gas tank and let that sit for a day and a half , shaking it around inside to get the crud out and neutralize any rust. Running a borescope down inside the tank, it looks shockingly clean apart from the remains of mud dauber nests. I flushed it with water and a solution of baking soda, then flushed it again and set it out to dry. The outside was covered with undercoating and some surface rust along the top and sides, so i hit that with a wire wheel and quickly got the whole thing down to bare metal. When the top and sides were clean I covered the trouble spots with Encapsulator and the bare spots with etch primer. I’m back and forth about pulling the fuel sender, but leaning towards leaving it in, as I know that it works and don’t want to mess with that.

So in the next couple of days when the temperature gets above 60˚ I’m going to apply sealer and paint to button up as much as I can.

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X-Ray Vision

I stumbled upon a re-listing of C1100 parts on Marketplace by a nice fellow named Don, who I’d bought a handful of things from earlier this year. One of the things in the upper corner of the picture that caught my eye was a set of West Coast mirror mounts, which immediately prompted me to get in touch. He sent me back a picture of them both, cautioning me that one was just the mount and the other was the mirror assembly minus the mirror. I told him that was what I was interested in.

This is almost as good as having an intact mirror; now I can see what the inside looks like and how my existing mirror is built without taking it apart. In the best case scenario I can pull the rod out of this one and put it in mine; in the worst case I can get a new threaded rod and fix the good one myself.

He’s also got a set of pre-’64 door latches, which are a lot more rare on the ground than the spares I’ve got, and something I can refurb on the bench and install at my leisure. We settled on a very fair price, and he’s going to throw the stuff in a box and ship it out to me next week.

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Steering and Commerce

I popped on Marketplace Wednesday morning to find that a fellow up in Frederick, who I’ve talked to before, has a Travelall steering column for sale. Crucially, it’s from a straight-axle manual steering truck, which means it should be a direct replacement for the one in the red bus. Which means I would have a direct replacement/test case for an electric steering setup. He’s got the manual box and some other odds and ends, so I’m going to make plans to go up and get it.

While I was on that site, I got a notification and found that my old college buddy Mike bought one of my shirts and was modeling it! I think it looks great. I should have several of my own arriving shortly—a longsleeve and a shortsleeve that I can use on the videos to model. I also ordered a sticker while I was there and was….less than impressed. The material is flimsy and the sticker is small. I’m going to pull these from the storefront and stick with my other vendors, I think.

Of Locks and Boxes

It’s been quiet for the past two weeks. Last weekend we were celebrating a birthday and dealing with a yard sale so all truck things were on hold. This weekend I was down in Southern Maryland busting a trio of brake drums free on the FiL’s 1966 Chrysler to make it mobile again.

Two weeks ago I jacked it up onto a set of Harbor Freight dollies and used my tow strap to pull it out of the garage and on to the driveway, the first time it’s seen daylight since 1980. The dollies were pretty useless on his ancient pitted asphalt so it was a necessity to get it rolling on its own wheels again. In the middle of that operation, my old floor jack decided 4,300 lbs of luxury convertible was just too much to lift, as we ran out to the local Harbor Freight for a replacement. I’ve been eyeballing a new floor jack for months but was holding off on buying one. As it turned out they were having a 40% off sale on the more expensive 3 ton model so I walked out with a beautiful new jack. And after chopping the front drum apart with a $15 angle grinder, we got the drum moving and the car rolling.

I wound up with something in my left eye from the brake drum and got terrible sleep Saturday evening (if I can’t get it out with an eye flush this evening I’m going to visit an ophthalmologist tomorrow) but woke up at 7 to meet a guy in Columbia who wanted to buy my two worst Scout fenders. I was happy to get $100 for them, which was half what I was asking, but I’m happy to have them out of the office and out of my way. And the four remaining fenders will work just fine if I need them to.

In the meantime it’s been raining pretty much nonstop this week, and I was in New York on Wednesday and Thursday. That being said, I had a little time after work on Thursday evening to mess with a new set of lock cylinders for the Travelall; they lock into the barrels just fine, but release when the key is turned to the 8 o’clock position. I don’t have them in the door so I can’t tell if the mechanical linkage to the door mechanism will keep them in place or not, but something tells me this isn’t correct. Which is strange, because they are an almost exact match to the original cylinders.

The Travelall heater box is ready to install.. Sunday I put the motor, heating element and wiring back in the box, drilled new holes for the back plate, and fastened that in place with new stainless screws. Then I used some of the adhesive-backed foam padding from the Scout heater box to fashion a new lip around the top edge to seal up that section. It may need some more work, or thicker foam depending on how the whole thing ages, but we’ll see.

Going-To-Town Rig

Well look at this luxurious new truck. Here’s a shot of the floor mats I ordered in the Scout from CocoMats; they are beautiful heavy-duty pieces that were cut perfectly. I couldn’t be happier with the fit and finish.  They make the inside of the truck look 47% less redneck, which is to say they are magical. Hazel approves as well. I cannot recommend this company highly enough; the whole buying experience was what you hope every purchase might be like in this day and age of Amazon.

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Preparations

We’re headed west into the heart of America next week in a truck only slightly younger than me, which means I have to pack just as many tools and medications for it as I do myself. I did a quick inventory today and made a list of stuff I’ll need:

  • A gallon of 50/50 coolant, and a gallon of distilled water
  • A gallon jug of 15/40 Rotella diesel oil, which is uniquely formulated to be nice to older flat-tappet engines like mine
  • Two spare fan belts (ordered via NAPA)
  • Power steering fluid
  • Brake fluid
  • Air filter
  • An Element fire extinguisher to supplement the bottle unit I have bolted to the seat base

In the ammo can, I’ve already got a bunch of other spare parts and tools—a fuel pump, coil, points and condenser, plug wire, bulbs, fuses, and electrical gear, plugs, assorted fasteners and zip ties. She’s running well right now, so the goal will be to get her cleaned up inside and top off the fluids to be ready to hit the road on Thursday.

I saw some trick floor mats on a build thread a few weeks ago and decided to pull the trigger on a set, figuring they would come in handy for heat abatement on this trip. They’re called CocoMats and they’re handmade and heavy-duty for cars like Porsches, but what I saw in the thread really impressed me. I ordered a set and they sent me a set of paper templates to lay in the truck and form to my specifications, which I did the night I got the package.

Looking for maximum coverage, I added material to the sides and brought them up to the edge of the vertical part of the firewall, and made a notch for the ramp under the gas pedal. The sample they sent is thick and beefy and the rubber on the bottom is covered in 1/8″ nubs that should keep it up off the metal where moisture collects. I sent the patterns back with a note and a sticker, and they’ve been super communicative with me the whole time. (The day after I placed the order I noticed they’d put an ad in my Hagerty magazine with a discount code, so I emailed them to ask if it was too late to apply that. They cheerfully sent an affirmative reply in less than an hour and refunded me the 10%. That’s some great customer service).

Unfortunately, they won’t be here in time for the trip, so we’ll just have to sweat it out like we normally do.

The other thing I did was take one of the spare horns from the green ’67 and swap it into the Scout in place of the Mercedes horn I put in a couple of years ago. I just didn’t like the half American/European sound of the two horns together and wanted to get the truck back to a true ‘Murican sound. Much better now. (fun fact: many cars use two horns tuned slightly differently, because the dissonance of two frequencies is easier to hear in high ambient noise situations).

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July 15 Update

Here’s a compilation of work I’ve done on the trucks before and after our vacation, starting from the heater box, moving through electrical, and finishing with some welding on the heater box.

I’ve gotten the wiring to the point where the dashboard is in the truck but I can’t hook everything up permanently for want of two rubber grommets for the smaller bulkhead connectors and several Packard 56 connectors I don’t already have, so I ordered a handful more this afternoon in the hopes that they’ll be here by the weekend.

The heater box came out more easily than I thought it would, and is in better shape than I was expecting, but still required repair. I cut two sections of metal out and welded new metal in, and bathed the interior in Rust Converter until I ran out (I’ll be picking more of that up this weekend). Once that’s completely treated it needs a skim coat of mud to cover the divots and bumps, and then I’ll paint it up and get it ready to re-assemble. I think I’ve found a local paint shop who can scan my existing paint color and mix me a pint to match. I’ve also got to figure out why the blower motor won’t work when I test it on 12v bench power and source some more coolant hose.

The other thing I ordered were a set of floor mats for the Scout, knowing that we’ll be driving through the August heat to Indiana. I figure having something else between us and the engine heat will be well appreciated. And, having something to cover the heat matting will also be welcome. I’m hopeful they’ll be here in time, but they’re handmade and the maker estimates 3-4 weeks before they ship, so it may be a futile exercise. We’ll see.

Slow Weekend

I did a little work on the fender this weekend to get it shaped up for body filler. I had to stop welding midway through  the third patch last weekend, so I plugged everything back in and finished that off today. It’s going to take a fair bit of filler to smooth everything out because I can’t get to the backside to hammer out any of the waves, but I’m not too worried about that. The whole thing is going to take some time and attention to finish off right, but I’m happy with the way things are going so far.

Updating the Travelall to-do list last week I realized I don’t have some of the information I need on the health of the engine, so I spent $20 on a compression tester for when the weather warms up. The last time I started her, she ran very rough, so I think there’s more work to do tuning her up. I’m going to pull the plugs, see how they look, and properly gap them all. Then I’ll do a compression test and put them back in.

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Weekly Roundup, 11.6

I had to run out on errands Sunday morning, and the weather was in the upper 60’s, so I grabbed Finn and we rolled out in the Scout for a fall adventure. Our first stop was down in Pasadena at the Eastwood store, where I needed to pick up some chassis black and a tube of seam sealer. As we wandered the store, my old friend Steven G. walked in, as he was shopping for supplies for his Scout. We caught up for a bit, and talked about getting a fall meetup together, and then I exited the store in a hurry before I was tempted to buy anything else. We stopped at the Home Depot for some other supplies and a precut 2×4′ sheet of plywood and headed home.

In the driveway, I pulled the original bumper off the mounts and hung it in place to see exactly how well it’ll fit. I think it needs a little more standoff than the original had, but with another 2″ or so it will work perfectly. I think I can make the original mounts work for the short term, and when I can get my hands on some larger longer box steel I’ll fabricate a permanent mount.

I opened up the rear doors and started brushing on the chassis black over encapsulator, and got a good portion of it done before the sun went down. The chassis paint is a lot thinner than the encapsulator, and tends to make more of a mess. While I was out there, Brian T. stopped by on his way back over the bridge, and we caught up for the first time in a couple of months.

After closing up the truck and garage, I brought the sheet of plywood in to the basement, turned on the football game, and set it up as a mounting rack for my spare wiring loom. The goal here is to rebuild the wiring loom so that I can pull the old one out and replace it with this. I’d originally contacted Super Scouts to price out a brand new loom, but after several weeks of waiting I was told their wiring specialist is two months behind. So I’ll take advantage of the inside time and learn how to disassemble, test, and rebuild the one I’ve got. One thing I am going to reach out to them about are some replacements for the bulkhead connectors I’ve got, to see if I can get any with intact mounting tabs.