2023 In Review

It’s January and currently about 44˚, so there isn’t much getting done outside on the trucks in an unheated garage. In the interest of keeping my motivation level up, I suppose I should recap the events of 2023, as they were pretty eventful for the Dugan IH Barn (or whatever I’m calling this assemblage of vehicles).


March 2023


December 2023

So from the top, in rough order:

Wow, writing it all out like that really helps put things into perspective.

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Welding and Sanding

Here’s a quick breakdown of the repairs to my spare fender. I started with an order to SendCutSend for a set of new laser-cut steel donuts for the outside and inside edges, as well as three 1/2″ strips to bend for a flange to connect both. I welded the outer flange in first because it had a slight curve, then built an inside section and tacked that in place. When I saw that it would collect rain the way I’d built it, I used a second donut and strip to mount flush to the outside edge and tacked it all in place. Next was welding a small patch in at the bottom, where water and mud pool and rust the metal out from the inside.

While that was cooling I sanded the top layer of blue paint off the fender to reveal some past damage and Bondo, which was not unexpected. I skimmed some Bondo over the two welds and sanded everything down, but the fuel mount area is going to need a lot more attention. I’m looking around for alternatives to off-the-shelf Bondo and have found that Evercoat products seem to get good reviews, so I think I’ll buy a gallon of that in the springtime to continue bodywork projects.

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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Amboolamps

Baltimore has its own peculiar accent, and I have spent the last thirty years perfecting my impression of its odd mixture of southern, West Virginian, DelMarVan and redneck patois which makes oil sound like oll and sink sound like zink and leads to interesting sentences like Dose crabs smell turrble, lake dere spereled. Amboolamps is a favorite of the Lockardugan household and we use it whenever we can, along with po-leese and farfarter.

In any case, this Travelall ambulance showed up on Marketplace last week to be parted out, and I contacted the seller to see if any of the sheet metal was worth saving; he told me it was all junk. If it had been closer it would have been worth a road trip up just to look over (and possibly to save the rear set of doors for spares) but Massachusetts is too far away to entertain that idea and I think he wants to sell the whole thing together.

The interesting thing here is that additional section they installed between the two doors to lengthen the truck—from the looks of things that metal was some of the first to start breaking down. This would have been an amazing truck to save about ten or fifteen years ago. Dat’sa shayme, hon. 

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All Quiet on the International Front

It’s been very cold in Maryland the last couple of weeks, and with the short amount of daylight we’re getting there isn’t a whole lot of time to get anything done on the trucks while it’s warm. The Travelall has been under a snug car cover for the last couple of weeks and the Scout is snoring in the shed, both hooked up to battery tenders. I don’t see much happening on the trucks themselves until after New Years, because we’ve got to source a second daily driver with the loss of the Honda at Thanksgiving.

I have been in touch with Jeff J. about seat covers, however, and we’re formulating a plan for him to sew me new ones based on the pictures I sent up. I’ve got a source for foam identified, and when we get past Christmas I can place an order for supplies to work on them inside. I also checked in with Brendan B. about the power steering gear he offered me, and we’ve got that set aside for after the holidays when I can get up there to pick it up.

The other thing I think I’ll work on is the spare drinker’s side fender, which I got with a large hole cut out where the fuel filler used to be. Other than that, it’s in great shape, so I’m going to pull the trigger on some new metal from Sendcutsend, clean up the area, and spend some time welding a new fuel filler assembly in place.

Weekly Roundup, 11.21

Bennett got the Hudson registered last week and sent us some video of a test-drive out on the road, and it motivated me to finish the process on the Travelall. Saturday morning I figured I’d run down to the Motor Vehicle Administration and get the title and plates sorted out. What I didn’t know was that they’ve gone to appointment-only, so I left without getting anything done. Knowing that Vermont closed the title loophole and hearing from friends that it’s now next to impossible to get a title for anything without one, I wanted to get the truck as legal as possible before any further clampdown occurs.

This morning I returned with an appointment time and all of my paperwork in hand, and was first in line at the title window. After looking over my Vermont registration, then taking it back behind the window and conferring with three other people, the lady helping me sent a copy of it upstairs to check the serial against a list of stolen and problem VINs. It came back approved within about five minutes, which surprised the hell out of her. From there it was smooth sailing; she gave me a set of 50-year antique plates and then registered my vintage plates to those, I paid the title fee, and walked out with the registration and a new set of plates. Most importantly, my Maryland title should show up in the mail next week. And with that, the value of the truck just skyrocketed.

Meanwhile, with the weather getting colder and the amount of daylight coming to an all-time low, it’s hard to be outside making things happen. By the time I get out to the driveway I’ve only got about six hours of good warm time to work; at 4PM the sun is low behind the house and the driveway is already cooling off.

Sunday’s plan was to lay out the wiring board I set up in the basement and start tracing out wires from the cut-down fuse panel I inherited. I cleaned off a contact on one of the headlight bulb connectors and tried to find connectivity between that and one of the eight black wires behind the dash, but couldn’t trace it. Neither wire in the connector worked, but it was cold and I wasn’t thinking clear enough. I should have traced the wires from that connector to the actual headlight to see where its endpoint was.

After that I pulled the dash gauge panel out and unscrewed the speedometer cable, which was remarkably easy to do. All of the Scouts I’ve ever tried this on have fought me like a dog with a bone, and usually drawn blood. With the panel out of the way I could see all of the wiring behind the dash better, and now I can make some kind of plan to test that stuff out.

While I was thinking about my next move on wiring, I pulled the passenger rear wheel off and hit all of the frame and exposed metal on that side with the needle scaler to remove any surface rust, then brushed on encapsulator to seal it. Pretty much everything under the rear half has been done with the exception of the inside of the main frame rails. For that, I want to get the girl up on a lift and spend an afternoon underneath cleaning everything out, because it’s very hard to reach when it’s on the ground.

I had to stop at about 2 to go out and run errands, so I warmed up the Scout and loaded Hazel in the back to copilot. We had a lot to accomplish, so it wasn’t until about 4 tht we got back home, and by then it was getting cold and I had a pie to bake. So I cleaned up my tools, measured the two bumpers for modified mounts, and put the cover back on the truck.

A post popped up on Instagram earlier this week featuring a blue Travelall in pretty rough shape, offered by Barnes IH up in Pennsylvania. He said it was probably a parts truck and showed a few pictures, and I was lucky enough to see it only a few hours after it went up. I talked to them the following morning about some of the stuff I was interested in—mainly the factory A/C unit, which looks incredible and would be the perfect centerpiece to an A/C upgrade in the future. I also asked about the heater box and the chrome side spears along the body. He told me he had someone down south interested in buying the whole thing and he’d get back to me.

It turned out later that guy bought the whole truck, but they have an entire C-series power steering setup (and inner fender!) available for a reasonable price, so I’m going to jump on that in the next couple of weeks. He said he’s also got a chrome spear set squirreled away that he’s got to check on; this isn’t necessary (my truck didn’t come with it) but A little more bling wouldn’t be a bad thing.

In the meantime, I’m on the hunt for an original C-series A/C unit. Look at how beautiful that thing is. I’m pretty sure I could modify a Vintage Air system to work with a unit like that; the trick is to find one in good shape.

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Rewiring Pregame

I’m slowly mapping out the process for rewiring the Travelall, and every time I look at the wiring diagram I become exhausted and feel like I need to go lie down. A lot of this is basically just understanding the scope of the project and gathering the tools needed to get it done, a lot of which I already have. This video goes into some of the basics and begins with a welcome reminder that this isn’t really that hard, as long as one takes their time and remains organized. He links to a super-handy spreadsheet with some parts links, which are appreciated. He also recommends a labelmaker printing on heat-shrink tubing, but the one he specifies is pricy, so I’ll have to figure something else out there.

So far I’ve got large poster-sized printouts of the early 1960 diagram and the 1968 D-series diagram, and I have to identify the spare harness I’ve got on the bench. If it’s 1963-compatible, I’m in good shape. If it’s not I have to figure out how different it is and rebuild it. From there, the next steps are:

  • Compare and identify the major plug connectors—are the pinouts the same?
  • Trace the main wires back to the fuse panel and label everything
  • Pull the connectors apart and clean all the connections
  • Test each of the wires from beginning to end and replace anything that’s gone bad.
  • Replace any bulb fittings or other special elements

I know Super Scouts has a barrel full of old wiring looms, so I’d bet they have connectors available to buy; I’m going to contact them to see if they’ll sell me the ones I need to complete this.

Update: I looked over the two printouts I’ve got here to identify the spare wiring harness in the basement, and as I suspected it’s a later model assembly, which means it’s not plug-and-play with the one in the truck. From what the D-series diagram shows, the fuse block is completely different and the connectors are all barrel-style while the earlier C-series connectors are square. So, Plan B: I’m going to get a length of wire, solder on a male spade, and set up a continuity test with a multimeter. If I can figure out which wires go where, I’ll use some fancy solder connectors to hook the spare fuse block I’ve got with the wires in the dash. Some of the wires are pretty easy to sleuth out but it’s going to take time to sort out the others.

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Weekly Roundup 11.13

I don’t have a ton of major updates this week; most of what happened was maintenance-based. The main task was to drop the hardtop onto the Scout to prepare for a 180-mile drive to Southern Maryland, and with a few small hiccups this process went smoothly. With the top out of the way I moved a bunch of stuff up into the garage attic—the cracked rear Travelall glass, extra sheet metal, etc.

The other thing I did was to roughly assemble the front bench seat and drop it into the Travelall to get it out of the way. I’ve got most of the hardware required and it went together pretty quickly. This is the first time I’ve seen both seats in the truck and it’s kind of inspiring, even though they both look ghetto.

One other interesting Travelall development—I was sitting on the bench seat and tested the brakes to see if they were holding pressure, and with a few pumps they built resistance. Later I was out back and walking towards the truck when I looked up and noticed the rear brake light was on. This is the first time any of the lighting on the truck has come to life anywhere; I thought it had all been cut out when the fuse panel was removed. I released the trailer brake (it’s been on since I put the truck on a battery tender) and the light went out, so clearly someone bodged that in and bypassed the fused wiring. How and why this bulb decided to come on is a mystery, but at least I know there’s some signal making its way out to the back.