You might do well to find someone with a mobile "abrasive pressure washer service" . This is the baddass pressure washer that siphons blast media and they do a dustless water/sandblasting/media blasting to remove all paint rust and filler. Bring it all to bare metal. Then prime it all and weld patch metal in from the backside. Reprime and then perhaps some glass and fill to level. The old talc based bondo wicks moisture to stell under it. Need to get it out to make sure rust doesn't come back for a number of years............Someone did most of what I'm talking about before in a country where labor was cheaper than the cost of new steel body parts..
Builds The "Red Rocket" Troopy (4 Viewers)
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Time to just order the rebuild parts.
In the end it will be worth it.
In the end it will be worth it.
- Thread starter
- #1,823
Haven't touched the troopy for about 2 weeks now, just kinda stuck. Don't know what to do or how to move forward or source a windshield frame. Tried many routes but all led to dead ends. If anyone has any leads or capabilities to offer help it would be the greatest help to date on this thread.
I hate rust, so much. If this has taught me anything it is that if I plan on having another forever vehicle, it NEEDS to be rust free. or just mostly. I obviously had no clue how bad the troopys rust situation was, even up until 2 months ago when I really started digging into it, and even then had no clue that most of the metal in the windshield frame was long gone and had been replaced with brass and bondo.
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In a less negative tone I have picked up a new daily driver for dirt cheap, 1981 240D. Selling my Isuzu Pup, it has served its duty with me immensely well.
I hate rust, so much. If this has taught me anything it is that if I plan on having another forever vehicle, it NEEDS to be rust free. or just mostly. I obviously had no clue how bad the troopys rust situation was, even up until 2 months ago when I really started digging into it, and even then had no clue that most of the metal in the windshield frame was long gone and had been replaced with brass and bondo.
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In a less negative tone I have picked up a new daily driver for dirt cheap, 1981 240D. Selling my Isuzu Pup, it has served its duty with me immensely well.
Dude…. The 60-70 year old single females are going to want you…. Badly.
You’ve got that market cornered now with the Merc.
You’ve got that market cornered now with the Merc.
- Thread starter
- #1,825
I'm working full-time at the Mercedes dealership now as well. SURROUNDED BY THEM.
They will lose all interest the moment they see the interior, this 40-year-old West German horse hair is giving my legs some odd rash too
but hey at least it's diesel
Love the Mercedes! Interior is a tad rough though, usually the MB Tex holds up a little better than that.
Regarding the windshield frame, those brazed joints will have to be cut out entirely or have the silicon bronze washed completely out with a torch in order to weld anywhere around them. Any bronze in the weld will contaminate it, assuming it will even weld at all. Another option would be to do brazed repairs anywhere in the vicinity of the original brazed joints. Here are a couple of brief but hopefully informative posts I dug up on this topic:
The complex geometry of those parts will be a challenge to fabricate from scratch, though it is feasible. There are some great panelbeating how-to videos on YouTube, and even though many implement some fancy tools they're still very helpful in teaching the concepts of how to move metal to achieve the desired results. Most everything can be made with basic sheet metal tools and a lot of practice. I would highly recommend getting some scrap sheet metal, a forming hammer, making a forming stump and start practicing the basics like shrinking, stretching and folding edges.
Regarding the windshield frame, those brazed joints will have to be cut out entirely or have the silicon bronze washed completely out with a torch in order to weld anywhere around them. Any bronze in the weld will contaminate it, assuming it will even weld at all. Another option would be to do brazed repairs anywhere in the vicinity of the original brazed joints. Here are a couple of brief but hopefully informative posts I dug up on this topic:
How to approach brazed joints
So apparantly Volkswagen loved brazed joints in a handful of spots in the 1980s to sweat in a couple of panels. Normally I have been able to work around it, but it looks like now I am having to hit it head on.. So as I am hoping can be seen, there is a few panels that are...
www.spiuserforum.com
Weld Repair Across Braze Joint? - Pelican Parts Forums
What problems am I going to run into welding in patches for these rust repairs where it runs across the braze joint at the fender flange (and what do
forums.pelicanparts.com
The complex geometry of those parts will be a challenge to fabricate from scratch, though it is feasible. There are some great panelbeating how-to videos on YouTube, and even though many implement some fancy tools they're still very helpful in teaching the concepts of how to move metal to achieve the desired results. Most everything can be made with basic sheet metal tools and a lot of practice. I would highly recommend getting some scrap sheet metal, a forming hammer, making a forming stump and start practicing the basics like shrinking, stretching and folding edges.
gilmorneau
SILVER Star
PM inbound.
Buy new parts. Most of the troppy stuff interchanges through the years. And a decent parts guy can figure out something for you.
Or invest a year or so of your spare time welding the grinding. I am too old for that.
The MB seat has to be leather, not MB Tex. You're right, the MB Tex usually holds up much better than that. The leather often gets neglected and is nowhere near as durable. One of the rare cases where nobody wants the leather and everybody wants the fake stuff.
It was called 'Baby Benz' or 'Bauern Benz' (Farmers Benz) in Germany.
Baby Benz, because the 240D was the smallest engine available in this model. Typical was the 300D or even 300TD.
The model was popular with farmers as they could fill subsidized 'agricultural diesel' intended for their tractors. Mostly they couldn't afford the bigger engines, though.
Great vehicle. Enjoy it
Cheers Ralf
And 4speed? I had one of those. In the family for 17 years. No reliability issues, no breakdowns other than a old battery failing to start on a well below zero Montana morning.I'm working full-time at the Mercedes dealership now as well. SURROUNDED BY THEM.
They will lose all interest the moment they see the interior, this 40-year-old West German horse hair is giving my legs some odd rash too
View attachment 3664834
On the brass and Bondo: before Bondo people used lead to fill with. I guess brass brazing is another method of repair but hard to fill and make smooth. Lead and brass are substantially stronger than Bondo, and I don't think they'll re rust and bubble out in lack of Bondo to wick moisture. Brass brazing is not as strong as welding steel, but it is very strong. Many quality bicycle frames were brazed together up until the 80s.
If it was me and it was impossible to get a new windshield frame: I think I'd sandblast what's left, reinforce structure on the inside welding strips of plate, repair as much as possible with cut and weld or torch braze as it will adhere to what you have, use a filler on primed metal hat doesn't absorb water(marine grade filler? Resin based filler? Fiberglass, Lead). The time I repaired rust that didn't bubble out it was fiberglass covering very heavily ground and primed perforated metal with Bondo over glass.
gilmorneau
SILVER Star
jblueridge
SILVER Star
I agree with new parts or big chunks chopped out of a non-rusted donor.
I have bought all sorts of new body panels for my MGB project.
Impossible to fabricate from scratch.
I have bought all sorts of new body panels for my MGB project.
Impossible to fabricate from scratch.
- Thread starter
- #1,834
OK! 1 month later update... wow that went by FAST. The Alu-Innovations poptops arrived in Cali a couple days ago. I have one good lead but much help that has been offered to me. My one good lead is from a great friend of mine who is OM606 swapping an 80 series (its already on 1 tons and has a 6 liter LS in it lol) he has a friend overseas in Aus who said it should be no problem for him to get a rust free windshield frame cut out for me, gonna have him cut out a left rear quarter panel since mine got crunched in by a rock and then kicked out by me looking like it has 10000 pimples on it lol. Only issue is the guy is on vacation in Greece, should be getting back this week. Will keep yall updated if that plan falls thru or not.
I can't thank you enough for reaching out, this is the route I will go if I can't get a graft from overseas to weld in, the new parts stuff is just VERY pricey for my 22-year-old wallet. However if it comes to it, I will save up and fork the cash out. May be in touch soon!
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A few quick updates with photos since everyone loves photos not just 10000000 words to read through
The troopy has looked like this for about a month now as it was wasting space just sitting in the shop doing nothing. Primered it and now its under a car port outside, gonna be lots of little creatures living in it whenever I'm finally able to resume progress.
I've put about 1,500 miles on the 240D now, got a new interior, averaging 35mpg. Need to do tie rod ends badly and the remanufactured alternator has failed (big surprise) Still been driving it for the past week with the alternator not charging, just push start it and I'm good to go. Has enough voltage to make some dim turn signals and headlights when needed.
and helped my buddy swap the engine and trans out of his old Rabbit pickup truck
Thats really about it, this summer has sadly been extremely uneventful and just really hot and sweaty. Wake up at 7am get off work at 5pm and work on cars on the side till about 9pm, rinse, repeat, every day... wish I had more adventures to talk about or update the thread with
I appreciate the wealth of information, I just don't think I have it in me to try and fail 10000x with bodywork especially with a frame that is so far gone. Even if I got it somewhat looking good I bet the windshield would leak like a siv. Still tho great knowledge to know, thank you
Yea... I'm 22 now and too old for all the welding and grinding
I can't thank you enough for reaching out, this is the route I will go if I can't get a graft from overseas to weld in, the new parts stuff is just VERY pricey for my 22-year-old wallet. However if it comes to it, I will save up and fork the cash out. May be in touch soon!That's an awesome bit of info I bet none of us would have known, thanks for the German knowledgeIt was called 'Baby Benz' or 'Bauern Benz' (Farmers Benz) in Germany.
Baby Benz, because the 240D was the smallest engine available in this model. Typical was the 300D or even 300TD.
The model was popular with farmers as they could fill subsidized 'agricultural diesel' intended for their tractors. Mostly they couldn't afford the bigger engines, though.
Great vehicle. Enjoy it
Cheers Ralf
yup wish it was a 5spd but I doubt it would have enough power to even use an overdrive efficiently haha. I'm starting to feel like just a younger version of you, it seems like every car I acquire, you have also owned in the past and have tons of stories about them. I love it
As mentioned above, yes it would be the best way. As a reoccurring theme with this thread since I started it when I was 17, my money has always been stretched thin, primarily due to the Red Rocket. 5 years later and ITS STILL EATING THRU MY MONEY hahaha. I will go this route if there isn't a cheaper (but still good) option to choose from. Just hoping this buddy of my buddy is Aus can pull through for me.This. It's the best way forward. Contact @Japan4X4 He might know a "decent parts guy".
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A few quick updates with photos since everyone loves photos not just 10000000 words to read through
The troopy has looked like this for about a month now as it was wasting space just sitting in the shop doing nothing. Primered it and now its under a car port outside, gonna be lots of little creatures living in it whenever I'm finally able to resume progress.
I've put about 1,500 miles on the 240D now, got a new interior, averaging 35mpg. Need to do tie rod ends badly and the remanufactured alternator has failed (big surprise) Still been driving it for the past week with the alternator not charging, just push start it and I'm good to go. Has enough voltage to make some dim turn signals and headlights when needed.
and helped my buddy swap the engine and trans out of his old Rabbit pickup truck
Thats really about it, this summer has sadly been extremely uneventful and just really hot and sweaty. Wake up at 7am get off work at 5pm and work on cars on the side till about 9pm, rinse, repeat, every day... wish I had more adventures to talk about or update the thread with
We just want to see pics of cute girls. 
. We don’t care about the trucks. True story. 
Keep yer head down and do good work, homie.
. We don’t care about the trucks. True story. Keep yer head down and do good work, homie.
Don't wish being like me on anyone, but if that bad luck is on you......don't make a mistake like this: i failed to invest $10,000 in Bitcoin 12 years ago when it was about $25 per coin because I didn't understand it ...swing for the fence and take chances..OK! 1 month later update... wow that went by FAST. The Alu-Innovations poptops arrived in Cali a couple days ago. I have one good lead but much help that has been offered to me. My one good lead is from a great friend of mine who is OM606 swapping an 80 series (its already on 1 tons and has a 6 liter LS in it lol) he has a friend overseas in Aus who said it should be no problem for him to get a rust free windshield frame cut out for me, gonna have him cut out a left rear quarter panel since mine got crunched in by a rock and then kicked out by me looking like it has 10000 pimples on it lol. Only issue is the guy is on vacation in Greece, should be getting back this week. Will keep yall updated if that plan falls thru or not.
I appreciate the wealth of information, I just don't think I have it in me to try and fail 10000x with bodywork especially with a frame that is so far gone. Even if I got it somewhat looking good I bet the windshield would leak like a siv. Still tho great knowledge to know, thank you
Yea... I'm 22 now and too old for all the welding and grinding
That's an awesome bit of info I bet none of us would have known, thanks for the German knowledge
yup wish it was a 5spd but I doubt it would have enough power to even use an overdrive efficiently haha. I'm starting to feel like just a younger version of you, it seems like every car I acquire, you have also owned in the past and have tons of stories about them. I love it
As mentioned above, yes it would be the best way. As a reoccurring theme with this thread since I started it when I was 17, my money has always been stretched thin, primarily due to the Red Rocket. 5 years later and ITS STILL EATING THRU MY MONEY hahaha. I will go this route if there isn't a cheaper (but still good) option to choose from. Just hoping this buddy of my buddy is Aus can pull through for me.
----------------------------------
A few quick updates with photos since everyone loves photos not just 10000000 words to read through
The troopy has looked like this for about a month now as it was wasting space just sitting in the shop doing nothing. Primered it and now its under a car port outside, gonna be lots of little creatures living in it whenever I'm finally able to resume progress.
View attachment 3690794
View attachment 3690795
I've put about 1,500 miles on the 240D now, got a new interior, averaging 35mpg. Need to do tie rod ends badly and the remanufactured alternator has failed (big surprise) Still been driving it for the past week with the alternator not charging, just push start it and I'm good to go. Has enough voltage to make some dim turn signals and headlights when needed.
View attachment 3690792View attachment 3690791
and helped my buddy swap the engine and trans out of his old Rabbit pickup truck
View attachment 3690793
Thats really about it, this summer has sadly been extremely uneventful and just really hot and sweaty. Wake up at 7am get off work at 5pm and work on cars on the side till about 9pm, rinse, repeat, every day... wish I had more adventures to talk about or update the thread with
Those seats in the 240 look great. 35mpg is awesome for that. 28-32 was our norm.
I hope you can get your troopy useable for college party shuttle bus service this year it seemed to be a good moneymaker for you.
jblueridge
SILVER Star
Good news about the windscreen frame!
- Thread starter
- #1,838
windshield frame update again! The guy said he is out actively looking for a donor troopy to take from, hoping I'm getting close.
with the troopy out of the shop, I have started rust repair on the 96,000 mile 4runner.
Also remember when my buddy and I drove my neighbor's tacoma that had a blown head gasket to pick up the 2nd 3B engine from @nuclearbeef , 2 years ago? Well we made it, just kept had to constantly top off the coolant. Well finally I got the go ahead from him to do the head gasket on it. Most all the coolant ports in the block and head were totally blocked and the head was extremely warped. Got it machined, threw it all back together and it runs great.
one thing I noticed was that all the pistons had "3FE" on them, then my monkey brain awoke from the dead and I put together that 2/3's of 4 liters would be roughly 2.7 liters... the exact displacement of the 3RZ I was working on. Did Toyota just use the same pistons between the 2 motors? Maybe had lots of leftovers after the production of the 3FE stopped. Thought it was interesting, maybe someone has an answer or some inside knowledge.
Skilz development program. You want to replace the HG on my girlfriends Honda Civic? Two short ferry rides, and I can be there before a hurricane hits...
- Thread starter
- #1,840
Also would like to give a massive shoutout to @cruiserinsanity, he sent me a link to a facebook marketplace listing of some 70 series doors. The crucial feature... DORITO WINDOWS!!! The Red Rocket will finally have "A/C" at least when the car is moving haha. They are practically brand new take offs from a local (to him) place that armors 70 series for war.
If anyone is going from Alabama to anywhere in NC anytime soon please let me know! I'll pay you a little extra to pick them up and bring them to me. Gonna see if there is a mudship out there maybe.
If anyone is going from Alabama to anywhere in NC anytime soon please let me know! I'll pay you a little extra to pick them up and bring them to me. Gonna see if there is a mudship out there maybe.
I do too! It was a good and really fun way to bring in money. Meet tons of people, I have tons of crazy stories I've never even told on here. Having to tackle a girl out of her mind on cocaine trying to gouge my eyes out while ripping my shirt and hair, old inbred Appalachian man holding me at the end of his 12 gauge for parking 2 of my tires partially in his yard waiting to pick up some girls, having to punch some extremely intoxicated frat dude after he threw me to the ground for not letting him in the troopy to physically harm his ex-girlfriend.... the list goes on. Every night always had something interesting going on, I miss it.
