81 BJ42 - I have to bring it home and pass inspection

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Moving on... I am sending the bumper to powder tomorrow so while giving it a last look I decided to mount everything and see where the lights and winch end up.

I'd rather have the lights inboard a bit more but there just ain't no room.

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I like the bumper. Nice balanced look. I must admit the top triangular plates that join to the frame looked a little massive at first, but with the lights there... it works! I'll be in Cowtown in the end of march if you decide you don't like it....;)

Kurt is one of the best suppliers I have found for LC parts. Always answers the phone, super helpfull to get me the right part even if he doesnt stock it and the prices are fair.

I'm glad you posted earlier about the 2" sander... makes life so much easier!
 
Kevin, I think you mentioned this earlier, but are you planning to sell a bumper kit? Just the cut plate (not bent or assembled)?
 
Love that bumper!

Have you tried out those aux lights yet? I had a set of clear lense ones like that on my Surf, and they were useless. Yours look to be in much better condition than mine were, the chrome on the reflectors was flaking off, but you could honestly not tell from in the truck if they were on or not. Curious if it was just the ones I had or not.
 
mass production, limited run ...
i know a couple guys that would pay for a bumper that clean.
congrats on a work of art.
light placement, i like where they are. a balanced look.
 
2x on a bumper run. It looks really nice and exactly what I am looking for. Hell, I'd take the roof rack too.

Great build and can not wait to see this and the 45 in person.

Cheers
 
Awl_TEQ said:
Moving on... I am sending the bumper to powder tomorrow so while giving it a last look I decided to mount everything and see where the lights and winch end up.

I'd rather have the lights inboard a bit more but there just ain't no room.
Click to expand...

I have to stop looking at your threads Kevin. Now I hate my bumper.:whoops:
 
Like the placement of the winch...:beer:


Built up a truck for a kid from Kali many moons ago, he was halfways down to south america and was having over heating issues...

Winch blocking rad, I did not install the winch:popcorn:

Rob
 
This post has held my interest since inception. Well done, you are an inspiration to us all.

The bloke with the winch finally got me to post. What A LOAD OF BOLLOCKS, it would have to be a ships winch to overheat. Especially on a highway, or did I get it wrong again. A fully functioning cooling system direct or electric should not allow this,

I don't like big winches, but I would not blame them for overheating either.
My 2C worth
George
 
No, but maybe next Thursday. You know, the third Thursday of the month. The day the RMLCA meets.
 
Hi

What did you do with the battery terminals?
The ones you called temporary are the standard here, what's wrong with them, and what so you prefer?
(Sorry for the side track...)
 
They work fine really but there are more robust and simple designs. The one I have in mind is similar but your cable (with a crimped and sealed eye on the end) connects to the bolt that squeezes the post.
 
Thanks alot, sounds reasonable, I'm just trying to pick up all the little upgrades.

Btw, I love your work, wish I had your talent, tenacity and opportunities.
 
Last Tuesday I re-assembled the transfer case. Went pretty easy. Used about every tool I own and made a mess. Still less messy than knuckles.

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Can't recall what I did the rest of the week. I know I was tinkering with various things. Did I mention the bumper took 18 tons of perssure to bend it straight. Thats like 36,000 lbs with a point load in the center and blocks about where the frame rails are.

Filled the tranny and transfer with oil yesterday (Sat). Bought a 20L pail of generic gear oil, nothing fancy. Funny, 5L was $24 and 20L was $59. You do the math.

The fill plug on the transfer case was hands down the hardest part of the whole rebuild. I noticed during cleaning that the head was stripped from a wrench or two slipping off. Without a good way to hold the case on the bench I had left it for after assembly which was a good idea. I would never have gotten it off on the bench with it flopping around. I started with the proper 17mm socket and the socket would just twist off when I applied force. Switched to my best round jawed vise grips and even with them crazy tight she wouldn't budge. Just made the hex round. Okay. Pipe wrench? Why not? Got the 14" pipe wrench I inherited from the FIL and cleaned out the well used jaws. First few attempts the pipe wrench would just pivot off plane and slip. Eventually had to wedge a 2x4 between the pipe wrench and the tubular cross member to keep it straight. Took my full not insignificant weight to break it loose. Even then I was yanking on it to increase torque. (There is a sig line for ya!)

So the fill plug was toast. Lucky I had the 5spd/ splitcase in the 45 not 8' away. I never put oil in them did I? Nope. Don't think so. Pulled the trasfer plug out. Nope, no oil. So I pulled the fill plug out and swapped the brand new transfer case plugs with the old ones in the 42. The 4spd in the 42 was leaking from the drain plug washer so I may as well use the brad new drain plug from the 45 right? I pulled the plug out of the 45 and new oil starts spewing. In my surprise I fumbled the plug down into the mess of 2x4's and scrap parts and couldn't see it. So there I was doing my Dutch boy impression with no plug in sight or within reach. Good times. Lucky I had laid cardboard under the 42 and there was one of the various plugs sitting on top. I could just reach the cardboard with a foot and after some 40 series yoga I got the dike plugged.
 
I also flushed the cooling system yesterday. I'll do it again in the summer. After two fills and running the motor in between draining I was still getting brown water but I've run out of storage for the used fluid so it will do for now. I dunno, maybe one more time if I can find another bucket. I haven't put in the good stuff yet.

So the only thing left is the rear brakes. I did the right side first. New wheel cylinder and shoes from Kurt. Pretty straight forward really. I tore apart blasted and painted the bell crank assy.

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Then the left side. Thats where the brake job came to a halt. I have a bolo out on a used replacement but may need to buy the new one for $92.

The fabled OOP inspection is booked for Tuesday with an alternate for Wednesday.

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I love this thread and it's reassuring to see that a truly skilled professional like yourself still makes the odd silly stuff-up (because I certainly do).

:beer:
 
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