Travelall – Page 11

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.

Posted on October 9, 2023 | by bill | Leave a Comment | Posted in Friends, Seats, Travelall, Welding

Market Research

A Travelall popped up in Pennsylvania on Marketplace yesterday, and I of course clicked to take a closer look. It’s a 1962 4×4 with a transplanted 392 in the engine bay, and originally came from Colorado. There’s only one shot of the inside and none of the engine bay. It’s got a liberal coating of what the kids call “patina”, which is to say, the Colorado sun blasted off all of the paint on the horizontal surfaces. There are a couple of underside shots which look very similar in condition to the red bus in my driveway, and there’s rot in the front fenders in the same places. The seller wants $17,500.

As a 2WD, my truck isn’t quite as desirable, but if I can get the red bus up and running for half of that cost, I figure I’ll be far ahead of the market.

Posted on October 3, 2023 | by bill | Leave a Comment | Posted in Inspiration, Travelall

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.

Posted on October 2, 2023 | by bill | Leave a Comment | Posted in Seats, Travelall, Welding

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.

Posted on September 28, 2023 | by bill | Leave a Comment | Posted in Seats, Travelall, Welding

Boxed

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.

Posted on September 25, 2023 | by bill | Leave a Comment | Posted in Seats, Travelall, Welding

Weekly Roundup, 9.22

Currently, we have Tropical Storm Ophelia blowing through Maryland, bringing rain and high winds all the way up the Chesapeake Bay. I’ve been keenly aware of the weather ever since I took the canopy down over the truck, wondering how the cowl repairs will hold up in the rain. Before the surgery, an hour of rain would soak the floorboards, all the water dumping directly down through the rusty holes. From what I can tell now, after 12 straight hours the repairs have all held up really well. There’s no water penetration from above; all I can see are small rivulets forming from dried-out weatherstripping around the doors.

The question is, which door seals do I need? There are three offered by most Light Line dealers: an interior door edge seal, a door seal set, and a pillar door seal set. I have the pillar door seal set, which looks like it goes along the inside of the door and is glued in with sealant (which I don’t have). They’re getting familiar with me at IHPA, so I’ll have to call over there and get the details.

In back, the new window is sealed tight, but the rear window on the driver’s side is leaking from a 1″ split in the gasket up top. So I’ve added another rear window gasket to the purchase list. I think I’m going to have the installer from last week come back out and give our luck another shot replacing that side.

Someone on the Round-Body Travelalls FB group posted a very interesting picture of a Travelall with a brand-new bumper, and mentioned that the bumper for a 1957-60 Ford F-150 will fit a Travelall and look very similar to boot. My bumper looks like it was dragged behind the truck and then re-attached with bubble gum, so I think maybe this will be an option—I don’t foresee tripping over a C-series bumper in good shape anytime soon.

I called Super Scout Specialists to inquire about what a new dash wiring harness would cost, and the guy who assembles them is supposed to call me back. I’m going to ask him what it would cost to add circuits for A/C, power steering (I may go electric), trailer lights, charging ports, and a couple of spares, as well as swapping the fuse panel to spade fuses. That will be the next big project—pulling the dash apart and sorting out the electrical system (god help me).

On the Scout side, everything is running quietly as it should. I noticed that my temperature gauge is now dead, so I threw a temp sender in our biweekly Amazon cart for replacement. If that’s not the issue, I have something like six spare gauges in my parts stash that can easily be swapped in.

Posted on September 23, 2023 | by bill | Leave a Comment | Posted in Future Plans, Purchasing, Travelall

Glassy

Tuesday I had an auto glass guy stop by the house to install my windshield and second-hand unobtanium rear quarter glass. When he got out of the truck and I saw his beard was as gray as mine, I began to worry a little less. He started with the windshield, for which I’d already stretched and mounted the gasket, and while I was inside on a call got it installed in about 20 minutes. Apparently it would have been faster but the outer edges of the curved sections looked wider than the frame, but after giving it a think, he figured it out and got it in place.

Then he turned to the rear glass. After cutting out the old gasket and removing the cracked piece, we surveyed the pinch welds and found them to be in very good shape, with just a little surface rust in the rear lower corner and along the middle of the bottom edge.

I sanded them and hit them with some rust stop while he started carefully stretching the gasket on to the old glass. I put hands on the edges and between the two of us we got it mounted without snapping the curved sections. After letting it sit for about ten minutes, we carried it over to the truck and set it in place. He was surprised that it had to be roped in from the outside, but once he got his head around that he had me sit inside and hold it in place while he worked his way around the perimeter. All in all, we got it in place in about twenty minutes, and I breathed a huge sigh of relief.

He was a really cool guy and I tipped him well for his skill; he thanked me for the most interesting install job he’s had in a long time. After he left, I took the canopy down and made the place look 34% less redneck. It’s great to have the glass out of the back of the truck and my storage crate for the side glass out of the way in the garage.

Posted on September 20, 2023 | by bill | 2 Comments | Posted in Travelall

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.

Posted on September 16, 2023 | by bill | 1 Comment | Posted in Progress, Repairs, Seats, Travelall

Future Projects

September is here, and Finn is back in school, and the mornings aren’t quite as warm as they were a few weeks ago. I’m looking at the fall as a time to wrap up some of my current projects and the winter for tackling some new ones where I don’t need to be outside. To recap, here’s where we currently stand on the Travelall:

The cowl area is complete; now the windshield needs to go back in and I have to put the hood back on in order to close the truck up for the winter. I’d like to install new weatherstripping around the doors as well, but I’m going to work with what I’ve got.

I took some time to troubleshoot the starting issue—she was starting normally for a long while and decided to stop the week I worked on the cowl. On Sunday I ran through all of the basics—tested for spark, filled the carb bowl, and made sure the choke was working correctly—and finally got her to light off but not stay running. I knew the fuel lines were all clean; they’re brand new all the way back to the tank. So I replaced the fuel filter I’d placed between the pump and the carb, which was full of black sediment, and lit her off again. She caught and suddenly ran more smoothly; fuel was spurting happily into the filter where I hadn’t seen anything before. I’d hooked a couple of 4″ PVC pipes to the tailpipe pointed out behind the garage so I let her run for five or ten minutes to get warm and see how the engine responded. I topped off the radiator and waited until the top rad hose felt hot; I don’t have a working temp gauge in the truck so I don’t know if the thermostat opened. I’ll put a laser sensor on it next time I run it and see where the filler neck reads. I didn’t have time to test the clutch or brakes, though—and I already see one leak at the junction above the rear axle.

With winter approaching, I’ve got three projects in mind, two of which I should be able to tackle indoors and out of the elements:

The top is still a patchwork of primed spots; I’d like to get one full coat of primer on the whole thing and, ideally, spray the whole top out with IH red. With the weather getting colder this may be tricky, but if I’ve still got the canopy over it I won’t have to worry about dew or leaves falling into new paint.
I’ve got two full bench seats waiting for new material. This will start with burlap over the springs, several layers of strong foam, and new upholstery. I’ve got an IH friend who specializes in period-correct patterns and materials, and he’s teed up to produce some vinyl coverings for me. My brother-in-law has hog ring pliers and all the rings I need to complete this project, which is fantastic.
Thinking ahead to lockable storage in the truck, I surveyed the rear bed to see if I could sink a steel lockbox into the floor in the center or on either side of the rear axle. Unfortunately, because the frame was an offshoot of a pickup truck design, it wasn’t engineered for space efficiency. The frame and axle take up a huge amount of space toward the front of the truck, and the beefy hitch mount running up the middle prevents me from dropping a deep well at the back. It’s not out of the question; there’s space above the hitch bar where I could drop a 30″w x 15″l x 5″d metal box in the middle of the floor, and I may well do this. It’s just not very deep—unless I build it with a hump in the middle. More planning will be required.There’s a guy on YouTube who has the same model Travelall who replaced the factory tube cage holding the rear bench with a lockbox, taking advantage of ~2376 cubic inches of space. I’ve already started sketching out some plans for a similar box made out of 1″ square tube and a bunch of the 16 gauge sheet I’ve got sitting in the garage. My plan is similar to his in that I’m planning on two top-mounted doors accessible from either side, using piano hinges and flush-mounted truckbox handles. The axle hump takes up a fair bit of the space inside, but having someplace to lock tools and parts is key. I’ll probably buy another 40MM ammo can and use that for additional storage in the rear section.

Posted on September 5, 2023 | by bill | Leave a Comment | Posted in Future Plans, Travelall

Steps Forward and Backward

So I watched all the videos and I made the plans, and Saturday afternoon I asked Jen to help me set the windshield in place so that I could start installing it. What I found was that we couldn’t get it oriented on the bottom lip of the windshield frame correctly, nor could we get the top centered without the bottom sliding out of the lip and everything going to hell. I tried several times, even pulling the guide rope out of the channel (they tell you to stuff a 1/4″ rope in the main channel and use that to set the whole thing in place once it’s properly seated) but we couldn’t get it to work. So I requested quotes from about six different glass companies in the area to see if anyone has a specialist who can come out and put it in for me.

I did finish spraying out the cowl, for the most part, and took a wire wheel to the grate inset. When I had that down to bare metal I hit it with etch primer and then a coat of red. I’m going to buy some plastic screen and zip tie it to the underside like I did with the Scout grille to keep crud out of the cowl. Then I had Finn help me put the hood back in place and screwed that back down to make things look a little cleaner. It needs to come off again and get a thorough wash, sand, and rust treatment on the underside, but for now it makes the truck look a little more presentable.

Then I hooked two lengths of 4″ PVC pipe I had behind the garage up to the exhaust to send that out and away from the house, and tried to start the engine. No amount of cranking would do the trick—I put a bunch of gas in the carb and opened up the choke, but couldn’t get it to catch. I’ve got to do some serious troubleshooting tomorrow to see if I can figure out what the problem is.

After much stopping and starting, I’ve got six Quick ‘N Easy roof racks prepped and ready to install. To recap, three were in great shape, and three had various bolts frozen in place from long-term corrosion. I finally got the right size bolts for my tap and drill and finished setting those up this afternoon only to find out that aluminum and stainless steel don’t play well together. So I have to go back out and find steel bolts in the correct size and I can call this project done.

Posted on September 3, 2023 | by bill | Leave a Comment | Posted in Travelall