Here’s a recap of the last three weeks of truck projects. I’m getting closer to catching up on these; I still have another day of EV video to cut and edit. Luckily I was able to finish this one up on the plane home from Florida.
→ This is a syndicated post from my Scout weblog. More info here.
I got Darth Haul running well enough to take her down the street for a pizza and beer run. I’m having a little issue pulling gas from the tank, and after a little roadside troubleshooting I believe there’s something in the tank clogging the pickup. I’m planning on driving her 12 miles out and back to Brian’s place on Saturday, so I’m going to take the boat tank and a length of fuel line with me for backup.
Here’s a video featuring Darth Haul’s first drive around the neighborhood from start to finish. I swapped the EFI out for the original carburetor just so that I could get the damn thing on the road. It’s running poorly right now, so I pulled the carb apart, cleared it out with brake cleaner, and re-assembled everything. Next up, I have to tune the engine properly and then I’ll swap carbs back out to properly set up the EFI.
Here’s a video from this weekend: I was able to spend a little bit of the day working on the truck on Saturday, with Finn sitting in the back seat working on a project of her own. The gist here was that I got the fuel injection system working after swapping the old carb on, running the engine to temperature, and swapping the new carb back.
Four years ago, I knew just enough about engines and brakes and car stuff to do basic maintenance without getting myself into trouble. I was comfortable with the basics of a tune-up; I could swap spark plugs and wires and change oil and brake pads and do basic bodywork—mainly skimming Bondo over dents. I’d had enough experience in the repo lot, with my own cars, and with home renovations to know the ins and outs of most the tools and materials. But as the years went by, the guys willing to work on old iron started retiring, and it got harder and harder to source a reliable mechanic.
When I bought Darth Haul I knew I was going to have to take a lot of the work on myself, and that was the point. I’d already taken the welding class so I knew I was in good shape to try more serious bodywork, but the engine stuff—the deeper stuff beyond cleaning out a carburetor—that was the scary part. Over the course of the last two and a half years, between working on Darth, Bob’s Chrysler, and several of my friends’ trucks, I’ve learned a ton about how engines work, how to diagnose more complicated issues, and most importantly, how to not let the fear of breaking something stop me from trying.
A couple of weeks ago, I took the plunge and installed a fuel injection system on Darth. We’re not talking about something as serious as tearing the top of the engine off and getting down to the camshaft, but it was a lot more involved than swapping the plugs. My experience pulling off grotty old carburetors and cleaning them came in handy for bolting down a shiny new unit. Ordeals with clogged, leaking and absent fuel lines was vital for routing a fuel system not designed the way the EFI manufacturer was expecting. After getting everything installed, I was stymied by a weird electrical glitch—but I fixed that by installing a relay, something I’d recently learned how to do when I put an auxiliary fuse panel in. Then I couldn’t get it to start—and used my previous experience working through Bob’s ignition system to diagnose a burnt out condenser in the distributor, a result of me welding on the truck without disconnecting the battery.
Yesterday I swapped a new condenser into the distributor, switched the cameras on, and turned the key: the truck fired right up. She ran like dogshit, because the timing settings are way off, but she started. I’d been having a kind of shitty week up until that point, and that victory, plus a couple of wins at work was enough to turn my mood around.
It feels really good to work towards something and see the light at the end of the tunnel; if I can get the timing sorted out tomorrow and get the truck running smoothly, then I can try to break the clutch free from the flywheel and see if she’ll move.
Here’s the latest YouTube video from the last two and a half weeks. It’s a bit overdue because of the weather, but it covers a bunch of different projects.
Over on the Scout weblog, I went into detail on the reupholstery and installation of a rear seat in the Travelall.
After doing some online research and gathering all of the materials, it was actually quite easy to do, but it’s still clear I would need practice to get it perfect every time. I’ve got the base to the front bench pretty much wrapped up on a table in the basement, and tomorrow I’m going to haul the backrest down from the garage attic to get that started.
Here’s the video update from the last two weeks of work on the red bus.
→ This is a syndicated post from my Scout weblog. More info here.
It was a pretty quiet weekend here, but I’m still trying to get warm-weather things done before the cold weather hits. I did some work on the door cards I got up in Massachussetts to get them ready for paint. They were covered in about three inches of grease and dirt, so I played a hunch and used Easy-Off oven cleaner to clean them off. When I had all the crud removed I could see where the rust lived. Originally I was going to sandblast them but I figured that would take forever, so I just used the wire wheel to remove all of the bad stuff. Meanwhile I covered the back sides with Rust Converter to keep them clean.
Friday afternoon I went to the local Sherwin Williams Automotive and had them match and mix a quart of base color from the beat-up original door panel on the truck. I had them match from the area behind the door escutcheon, which hadn’t been dulled by UV rays over 60 years. After some back and forth I used some of their paint matching chips to get as close as possible in the sunlight out in front of the store. The best price I could get was on a quart of base coat in satin, which is going to need a final clearcoat at some point in the future. But the difference being roughly $200, I was happy to go with the more inexpensive option.
On Sunday morning, I cleaned everything off with acetone and got my table ready to shoot everything. All four panels needed two light coats for good coverage—the base was a lot thinner than the other paint I’ve been shooting.
Then I shot the heater box and heater cover. Everything flashed very quickly and within two hours was more than dry to the touch.
I hung all four-door cards on the truck to keep them out of the way and make sure they didn’t get scratched up in the garage.
Meanwhile, I was working on new mounts for the west coast mirrors. What I decided was to mount these using existing holes in the doors. There were, over time, about four different mirror installations on the truck, one of them being perfect for the mirrors I have. I bought four regular steel bolts and pushed them through the back sides of the doors to weld in place. Then I ground the backsides down as much as possible to give clearance for the weatherstripping and doors.
The passenger side still needed to be worked on: all the old holes had to be ground out and welded over like I did on the driver’s side. Then I cleaned those up, feathered some filler over them, and sanded it smooth. As of Sunday evening, both mirrors are hung on each door with a quick coat of basic rattle can red over everything.
The Sherwin Williams guy told me about some inexpensive clear coat I could get on Amazon much cheaper than in his store, so I’ve got that in my cart for next weekend. It’s a satin finish so it won’t be as dull as the original cards, but if it protects everything I’m not going to complain. And when the heater box is finished, I can reinstall that and get more of the stuff under the dash completed, which is one of the fall projects on my list.
→ This is a syndicated post from my Scout weblog. More info here.
This is just a test of the system; I don’t have the dash officially installed (still waiting on rubber firewall grommets) but I got a package of replacement connectors for the last two firewall plugs and swapped out the old brittle ones. Because I couldn’t help myself, I hooked things up and tried it out. The turn signals trigger the dash lights, so there’s clearly something not connected correctly, but the truck starts off a new ignition barrel, and none of the fuses blew!