Build BJ and my best friend Bear

[fullthrottle]

So, what have I been up to with old BJ lately.

Well, pulled the engine a gearbox housing out to assemble everything again. All new bearings and seals throughout for the gearbox and transfer.
Found the filler plug thread on the transfer as a bit stuffed, so managed to score an M18 recoil repair kit and 18.5mm drill bit. So will do both the filler and drain holes.
The casting on the filler plug is not a complete thread, so a bit weak. The new recoils will make them much stronger.

Anyway, getting there now.

Will then bolt the engine and fully rebuilt gearbox on the floor to do one last check to make sure everything mates up ok, before putting it all back in the truck.
Before it goes back in, I'm stripping back the engine bay, chassis and underside so it can be re-painted / coated. Bought some TEXOL paint stripper which should help with the job, instead of grinding all the paint off.

 

[fullthrottle]

Note to self....sensor specs for Haltech...

 

[fullthrottle]

I must say what an easy conversion from mechanical to electrical for the speedo with the Trail Gear adapter.

 

[fullthrottle]

BINGO!!! Did some measuring of everything and she has mated up perfectly. Slid on like a well oiled glove

 

[Broski]

Very nice work. Looks great !

 

[fullthrottle]

I feel like Mrs Mop, cleaning, cleaning and more cleaning. Almost 40 years of undercarriage goodness.

Just preparing the underside before the engine and gearbox go in. I am seriously considering just separating the cab from chassis as everything is out now. But would it be worth it???

Was planning on giving it a waterblast, degreaser, strip back to bare metal where there is anything surface rust (which there is bugger all) and a ittle coat of rust converter here and there to catch and small rust pits, spray with 2k epoxy primer, then a good 2k top coat, then a layer of dinitrol.

 

[fullthrottle]

So I'm planning to pull the cab off the chassis so I can really give it a good clean and paint. Was thinking it would be so much easier to mount the engine, gearbox, new fuel lines etc just into the chassis and then just drop the cab on top.

It seems logical and straight forward.....AND a good idea....maybe.

Are there any pitfalls in my mad method?

 

[OGBeno]

So I'm planning to pull the cab off the chassis so I can really give it a good clean and paint. Was thinking it would be so much easier to mount the engine, gearbox, new fuel lines etc just into the chassis and then just drop the cab on top.

It seems logical and straight forward.....AND a good idea....maybe.

Are there any pitfalls in my mad method?

I mean, that’s how it’s done at the factory.

 

[fullthrottle]

3 hours later....... I was actually surprised at how quick it was.

Removed the remaining dash, loom, heater unit and everything else bolted to the cab. Ready for lift-off.

Labelled and photographed everything.

 

[fullthrottle]

I'm on a roll. Trying to get at least the chassis all painted up before the last of the warm weather is gone.

Stripped most of it back to bare metal. Gees what a mission to clean the chassis up. 40 years of caked on crap.
Welded up some of the terrible factory welding jobs. So is all much cleaner and stronger now.

I've gone with two coats of Brunox Epoxy Rust Converter. Will then coat with 2 coats of 2K epoxy primer. Then a nice 2k black topcoat.

Overall the chassis was pretty tidy. Just some light surface rust here and there. I also flushed out the inside of the chassis to check condition, and just some light surface rust here and there. What little came out of the rails seemed to be river sand/stone, which would probably explain its pretty good condition. Hasn't been near much salt.

I'll run some cavity wax inside all of the chassis internals. Will use Dinitrol ML as the first layer, then a final coat of Dinitrol 1000. That combo should treat and stop anything for 1000 years

 

[Broski]

NICE !

 

[fullthrottle]

Nothing like some good autumn weather to finish the chassis.
Have managed to complete the 2k epoxy primer on top of the Brunox, finished off with a nice 2k black that the army uses. That stuff went on very nice and flattened out perfectly.

Will give it a few days to fully harden and then I can start putting it back together.

 

[fullthrottle]

Making progress....

 

[OGBeno]

Fũcking sick dude. Legit work homie. And you are doing a mechanical PTO.

Great work, @fullthrottle

 

[AirheadNut]

The paint job on that valve cover is awesome!