Rebuilding the 80

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Joined
Aug 6, 2007
Threads
45
Messages
2,863
Location
Raymond, MS
Ran out of talent at the Southern Cruiser Crawl this past October and the 80 took a bad hit with a tree and suffered serious damage. My wife and all 4 kids were in the truck when it happened and luckily aside from my wife having a hurt back and me a swollen ankle all of the kids were injury free. It could have been a lot worse. It’s days on the rocks are over and once the rebuild is complete it’s time for me to add a buggy to the fleet.

A little back story on this 80. I purchased this truck in December of 2006 after moving to Mississippi from Virginia in April of 2006 without a vehicle as I left my 94 with my dad as it was broken after catastrophic wheel bearing failure and couldn’t make the 1000 mile trip. Like with any 80 purchase it didn’t take long before it was on a 315 then 39.5 Swampers and then 40’s back before it was the norm. Have been running 40’s since the middle of 2008 before it was cool. LS swapped since September of 2016. Have owned many of other 80’s during this time but this one has always had a spot in the driveway.

This build will involve a complete body swap and a complete renovation while it’s disassembled. I now have the opportunity to start with a blank canvas and will be able to correct mods made over the years that I was not fond of later down the road. The replacement body is not going to be cut and I will be running flares. That being said the 40’s have to go and will be replaced with 37’s. Build will be geared more towards overlanding/exploring vs rock crawling. I want to make it something that can be used and enjoyed by family for many years to come.

Build thread may be slow as all work will be done in what little spare time I have with a full time job and 4 youngins. Have been in the Cruiser world for a couple decades and want to document everything for myself as I go along. Feel free to follow along.

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Damn Rob. Glad you and the family are ok. The LC did its job.
I’m glad everyone is ok. The 80 definitely did its job. I now know the weakest part of the body.
 
I guess it’s time to update this. May 20th the rebuild started. Worked on it in the evenings and over Memorial Day weekend.

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Started by pulling the front sheet metal minus the core support as it was not damaged.

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Then stripped the rest of the body of salvageable parts to add to my stash.

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Decided to go ahead and cut the roof off to make dash removal easier to manage solo.

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At 10 pm this is what remained and I called it a night.
 
May 21 was spent digging through the wiring of the 80 and the Holley Terminator X and running all engine harnesses back through the firewall into the engine bay.

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Being that my donor body was stripped completely bare due to a diesel swap gone rogue where they were trying to install a Ram 2500 dash into an 80, May 22 was spent stripping down to bare firewall and drilling spotwelds for various brackets that were hacked off. Also starting removing body bolts.

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Started May 23 getting the donor body staged for the rollback to come pick it up out of the driveway.
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Then I was able to finally lift what was left of the old body off the frame.
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Spent the next hour or so cutting the old body up and loading it in the bed of an f250.

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Now that the old body out of the way it was time to clean up the chassis.

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Wanted to get the donor body staged for removal from the chopped up frame the following morning. It actually rolls pretty good with a floor jack under the driver side tow hook and I was able to drag it into the shop.

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May 24 the donor body is off the chopped up frame and lowered down onto my chassis. Had to remove the rear flares as my OG 4x4Labs bumper was not notched for flares.
If anyone is hunting a rear axle or frame sections let me know as the donor chassis is available.

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May 25 was the start of assembling from piles of parts. I decided to go ahead and start with the HVAC and dash. Also went ahead and removed the passenger airbag and used the new found space to mount the Terminator ECU.

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May 26, 27 and 28 were spent reinstalling sheet metal and getting the body lines just right. Also ran the body harnesses and wired up the terminator ecu. Around 8:15 pm it fired up. Spent the next few hours installing seats and tying up loose ends. Drove it home around midnight. Recharged the AC at work the next day and have put 200 miles on it so far. I forgot how much I enjoy driving this 80. Next step will be a full interior with sound deadening, new carpet and fancy widgets I’ve been collecting over the last year and a half.

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Nuts. I would pay for these. Freaking world apart though..
Never had any luck with re-homing sheet metal. This was the second one that went to the scrap yard. Had a complete rust free shell a few years back that I ended up giving to a friend of mine. Instead of having it lingering indefinitely I cut it up and made it disappear. In case anyone is wondering an 80 shell with 1 front and 1 rear door and 80mil of Noico weighs in at 600lbs and brought $42 at the local scrap yard.
 
Sure, I get it, didn't mean you did anything wrong. It's just that here in Czech, I paid USD 200 for a single corner with a piece of A column and half of the bottom door hinge (it even had the whole sill cut off) from the scap yard. Every rusted out left or right fender you can find will go for 300. Then you pay a welder to fix it, of course. The full body skeleton, without damage, without door and all front side, without anything inside goes for 4000 ish. In your state, I guess at least 2000.. but alas, it's some 8500 Km from here to Raymond, MS :)

Tough luck. I very much envy rust free places on this earth :)

Oh, and beautiful job -- and of course, very glad you and your family are all okay. My LC saved us too, but from my own idiocy -- didn't see a tram coming from the right side..
 
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