'74 Build: Dirtbike250x's Project: "Rotten Orange" (1 Viewer)

[dirtbike250x]

In order to keep this build in line with the actual happenings of the project, there will be jumping between body work and engine work as me and my dad have been taking on both projects as a team.

The areas behind the rocker panels have also been capped, although not the prettiest, I believe the less open area under the truck will greatly reduce the future rust.

With that concluded was the end of underside of the body fabrication and it was time for paint. The following post will be about coating of the underside.

And for engine posts:

First we wanted to explore the top of the head to get a brief idea of the condition of the engine.

Not to bad, little dirty... but nothing in pieces!

Off came the headers to re-coat them as they began to surface rust and attempt to get a seal without over using the goop that was used before....

 

[dirtbike250x]

To coat the underside of the truck we had a few ideas. However, after coating the frame in POR15 with two coats along with the axles and not even using an entire court, we had a whole can to use and might as well use it on the body. Good protection and shouldn't chip off seemed like a fair idea to coat the underside. Along with a rubberized seam sealer the underside would be sealed tight from moisture getting into those bad areas for rust to form.

With about an hour and half of prep time attempting to clean as much as the old stuff on the truck between oils and previous coating materials. The underside was ready to be sealed.

With some help painting the underside two coats were completed in another hour or so...

And the final product...

Hopefully with the glossy black, it allows easier clean up, and the protection POR claims turns out to be true as this work to prevent corrosion has been exhausting.

It was very satisfying to finally see some final product results rather than constant prep work. Long term projects like this are new to me, a side of me wants this truck to be done tomorrow while I also enjoy the ability to create to my own 40 build. While I type this and watch the FJ40 Hankook tire commercial it boosts the motivation to continue to make these final product projects complete to reach the ultimate satisfaction of the first start of the engine to the first drive with my dad and me.

 

[dirtbike250x]

Once the painting part of the under body was complete, we used a rubberized seam sealer to get another level of protection from corrosion.

Next was the installation of brake lines. We used the SS kit from Cruiser Corps and some extended soft lines down to the axles. The lines seemed to need some massaging to fit correctly but eventually the frame was plumbed.

(Maybe a little to long?)

Anyway...Jump back to engine. As it was previously shown we did a little clean up on the engine which resulted in a little painting after that...But first we must pull the transmission off.

Fortunately we did, as some of the hardware holding it in place was not the safest set up.

Since the transmission was off might as well take a look a the clutch condition...onto the next post

 

[dirtbike250x]

How about a few more painted picture of the engine. Really starting to like seeing some finished looking components.

The out came the clutch and pressure plate, and eventually the flywheel as we ran into a bit of problem with the pressure plate hardware....

One of these does not seem suitable to be securing a pressure plate...

 

[dirtbike250x]

From the previous post looking at the bolts that were used previously. It seems one of the previous bolts broke off in the fly wheel. The hole was then drilled, and that screw was used to tap into the new hole.

The first step to getting a proper bolt in that hole again was fly wheel removal...

It also was found that the rear main seal did not seem to be pressed in all the way? After cleaning the surface a far bit and a couple taps it seemed to seat in much better, maybe even stop the leak? Let's hope so.

Anyway it took some finesse, but after re-drilling the hole we were able to get a tap in and a new bolt found a new hole.

Looking at the clutch and pressure plate condition, they certainly were not "toast" but the age and life it once had is obviously unknown. It is easiest to replace outside of the truck rather than trying to do from under the truck so we figured a new clutch kit was the best bet (plus I have never replaced a automotive clutch before )

Out came the pilot bearing and all clutch components were now gone.

And through the magic of a build thread we will speed up time and...


A new clutch

The full kit from Exedy included everything we needed the pilot bearing, pressure plate, friction material (clutch disk) and throw out bearing. Of course the product looked great but for actual evaluation of it will have to come at another point, you know like when the truck is drive-able

Install was a breeze and our new threaded hole took nice torque during install...

 

[dirtbike250x]

So I have been away from the updates for quite some time, but I have recently made a video talking about what I have learned from the process so far. Thanks for watching.