I was finally able to put a few hours today into working on the pig, and I got quite a bit done.
First order of business was to cut out some of the rust that's been taunting me so I could see just how extensive the damage was.
The first place I cut into was the rust right below the passenger rear door, and it wasn't really as bad as I thought it would be.
Here's what the stuff looks like that comes out... mostly red clay and sand.
Then I hacked and slashed into the driver's fender
As you can see behind the dirt, the fender brace is pretty much dissolved as well, so I'll be fabricating part of the brace too.
Here's a shot of the floorpan seam in front of the rear seat.
The whole center of the seam, along with the corners next to the door sills needs replacing. You can kinda make out the hole right in the middle of the photo. The corners are going to be fun to fab, since it's such tight quarters.
About this time I forgot about taking pictures, and just jumped in headfirst.
I also cut out some of the rust in the driver's floorboard, and the rust patch in the driver's rear quarterpanel. From there, I decided to tear into the tailgate and figure out what was going on there. I had to go from the battery straight to the terminal block due to wiring problems, but the window rolled down immediately. Thinking that was too easy, I rolled it back up, and then down again, and that's when it hung up about halfway down, and I had to help it.
One thing I noticed right off was the passenger-side roller on the rear window wasn't attached to the metal part across the bottom of the rear window, since the little stud it attaches to had broken off. Luckily the stud was still attached to the roller track, so I can probably weld it in. The other one broke off as well when I was trying to tap the track off the window after removing the key. I was able to pry the metal and rubber holder off the bottom of the window glass and then removed the window. I removed the actuator assembly, took the cover off the window gear and it's split in three places (aren't they all).
This is when I discovered what the nylon strap was for that was dangling out of the bottom of the tailgate... the previous-previous owner's 'door handle'. Unfortunately the tailgate handle is broken (another thing for the list), so the PPO tied a nylon strap to both of the tailgate latch linkages, then pulled them open with the strap. You can see the strap in the photo of the rear of the pig. It's dangling right across the bumper. I also discovered why the tailgate window switch wasn't working, because the ground wire had popped off of it's pad on the switch. So I rebuilt the switch, resoldered the wire, and it feels like new.
I gave the tailgate a good wire brushing and aside from being a little pitted, the tailgate steel is in great shape without any rot.
I poked around under the hood a bit too. The carb is a Carter, though I'm not sure what model yet. I found a sticker on the inner fender right above the Advance Adapter sticker that says "Jeep Conversions, Sacramento, CA", along with a phone number and address, so it appears that the V-8 conversion was 'professionally' done. That gives me hope that the conversion was done correctly, and there won't be any scares as I go through the drivetrain.
One odd thing is that the current Delco Remy alternator that's attached to the engine has it's fan fins pointing leftward as well, which means that either my definition of clockwise is all bass-ackwards, or for some odd reason there's already a counter-clockwise alternator on my clockwise drivetrain. Weird...
I then pulled some more of the headliner out, and the insulation too, and about that time it was time to get ready for work.
All in all, it was a pretty productive day.