Early start to the weekend. Cold camping in the Sierras.
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What Did You Do with Your 80 This Weekend?
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Idaho Savage
GOLD Star
Did you do the flare removal yourself? This would be my numero uno wishlist item but it seems like such a PITA.
Flair removal was straight forward, just unbolt and unclip. Even doing it by hand I had a couple of those nut inserts break but wasn’t a big deal since they weren’t going back on.
The only piece that’s somewhat annoying is the door has a riveted bracket. So it’s just there until you decide to drill it out.
The rest is just welding the holes shut if you want and then body work. I can weld but can’t do body work.
I used plastic body fasteners to temporarily plug the factory flair holes.
The roof is another animal that I did not do.
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While some will acert that welding is the only way to fill the holes. I would beg to differ. I weld, have all the equipment, weld well and I still chose to fill the holes with fiberglass impregnated Bondo. I also did this when I remover the roof rack. I have had zero issue using this method. you don't have worry about rust issue where you can't get to the inside to repaint after the welding burns off the paint. I was also able to get the roof rack removal done without removing the the head liner
The fiberglass Bondo is water proof has epoxy in it and if done correctly just does not fall out. I did mine 9 years ago and not one hole has popped out.
gooseberry mesa - start of a 3-6 month road trip west of the rockies!
i had been hunting an intermittent non start issue - over last few years the 80 was driven once or twice every 2 weeks.......checked input voltage to starter motor that was fine (so no relay bypass needed), load tested battery that was fine - now I'm driving it every day no issues at all (and the reman yota starter i bought now gets lugged around with me.....hey ho!)
Also the wolfbox tri pro dashcam i installed is no longer cutting out randomnly - seems these trucks dont like sitting around waiting to be driven!
Had to replce the charcola cannister - got 8 or so years out of the last one!
i had been hunting an intermittent non start issue - over last few years the 80 was driven once or twice every 2 weeks.......checked input voltage to starter motor that was fine (so no relay bypass needed), load tested battery that was fine - now I'm driving it every day no issues at all (and the reman yota starter i bought now gets lugged around with me.....hey ho!)
Also the wolfbox tri pro dashcam i installed is no longer cutting out randomnly - seems these trucks dont like sitting around waiting to be driven!
Had to replce the charcola cannister - got 8 or so years out of the last one!
I'm glade that your no start issues are gone ! My rig sets for weeks to a month or more at a time without the issues you speak of
What cannister is that ? part number ?
Def not the only way. Use this for the inside to protect from rust after welding.
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I’ll never use fiberglass ever, and I’ll leave it at that, but good to have options.
I would guess that most people use bondo to fill those.
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I'm glade that your no start issues are gone ! My rig sets for weeks to a month or more at a time without the issues you speak of
What cannister is that ? part number ?
this was someone else's idea - check my build thread to see how I installed it - slight mod needed but nothing longer than 10 mins
ACDelco 215-153 Original Equipment Vapor Canister for GM Vehicles 1971- 95
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Now my son’s daily. Got a chance to take it out with him for some light Okie wheelin at Gruber ORV. Pretty fun little spot. You forget how capable these things are when you haven’t had them in their element for a bit.
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Love that area. Took a 93 Range Rover there about 18 years ago
Fiberglass Bondo and regular Bondo are not the same.Def not the only way. Use this for the inside to protect from rust after welding.
Amazon.com: U-POL UPol WELD/AL WELD-2 353 g/12 Oz Zinc Rich Primer - Grey/green : Tools & Home Improvement
Buy U-POL UPol WELD/AL WELD-2 353 g/12 Oz Zinc Rich Primer - Grey/green: Primer - Amazon.com ✓ FREE DELIVERY possible on eligible purchaseswww.amazon.com
I’ll never use fiberglass ever, and I’ll leave it at that, but good to have options.
Have you ever tried the fiberglass stuff ?
And some of the holes you can’t get to the back to paint
Not having to remove the head liner to do a roof rack delete is a huge plus.
If you’re going to weld the holes you will be removing it.
Huffed a little too much bootleg loctite and dropped a roll pin into a freshly FIPG'd H152. Magnets were no help so as a last ditch attempt to not open the transmission again I picked it up and shook it upside down until the roll pin miraculously fell out into the oil receiver chute.
Just one of those 1am "what am i doing" car enthusiast moments
but it all went back together smoothly after that.
Just one of those 1am "what am i doing" car enthusiast moments
but it all went back together smoothly after that.
Fiberglass Bondo and regular Bondo are not the same.
Have you ever tried the fiberglass stuff ?
And some of the holes you can’t get to the back to paint
Not having to remove the head liner to do a roof rack delete is a huge plus.
If you’re going to weld the holes you will be removing it.
Lol that’s why I said “fiberglass” and not just bondo.
Yup the headliner is the absolute worst.
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COS80
SILVER Star
I welded my roof holes closed. I didn't want to take any chance of a leak developing in the future. Lowering the headliner wasn't bad. 
Filling the fender holes, though, body filler makes a lot of sense to me.
Filling the fender holes, though, body filler makes a lot of sense to me.
That would be the Eastern Sierra/Inyo/White mountains, my Mecca.
Or just some auto zone bulk gasket material. I might actually have a couple but I would have to check.
Where were you starting to smell gas (and pressure in the tank) at higher elevations?
yeah - and then when I opened the hood I could hear odd noises coming from the canister for several minutes