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Old 03-20-2012, 04:51 AM   #1 (permalink)
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Uhaul to Home/The Tech Thread

I'm revising/updating this thread for part #2 of my project. The other thread:

http://www.pirate4x4.com/forum/showt...php?p=13237870

What I started with:











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Old 03-20-2012, 05:01 AM   #2 (permalink)
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The first issue I tackled was repairing the aluminum floor of the box. There had been a mobile catering business inside and a bunch of prep tables and cabinets had been screwed to the floor as well as cabinets mounted on the walls(see 2x4's screwed in above the rails in the first post). The floor had quite a few holes drilled in it.



After using a small, round wire brush to clean the holes and steel wool to clean and rough the area around them, I cut small patches from a sheet of .25mm aluminum. Using 3M 5200 Fast Cure Adhesive/Sealant, the patches were "glued" to the floor. So far in the almost 3 months since this was done, walked all over, stuff dragged over them etc, the patches have held and not one has been pulled up from the floor. Plus, when this was first done it was 40 degrees. I'm very happy with the results.

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Old 03-20-2012, 06:13 AM   #3 (permalink)
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The next issue tackled was the floor of the cab and the seats. I have back issues and the bench seat that was in there smelled like old ass. It was even nastier when it was humid. The pics with the bench seat were on a memory card that went bad. Besides, you know what poo brown looks like anyway. I bought 2 air ride drivers seats from a couple of Peter Pan buses at the wrecking yard. The dirtiest one was still holding air even sitting in the back of the box. It's now the drivers seat.



I knew when I bought the truck in typical International form there were issues with water on the floor. The first thing I did when I looked at the truck was to lift that nasty vinyl flooring and sure enough, it was damp. However, a couple of months later even during a hurricane dropped to tropical storm winds I couldn't find a leak around the windshield anywhere. The floor was dry.

My most educated guess is that a rubber gasket that seals up a hole in the firewall that wiring passes through(behind the clutch pedal) is disintegrating(pic coming later) and the upper half is gone. The inner fenders have also been cut out. This allows water thrown up by the tires to enter that hole in the firewall. Of course all of this is aside from climbing up into the cab with wet footwear on. For a 23 year old truck it didn't look all that bad.





The big spot is really dry. It's the stain left where some antifreeze had spilled.







The former mechanic found that he could use at least one existing hole to bolt the new to me seats down with and did so on the passenger side then hooked up the air lines to both seats.





The seats were functioning as they should but both still needed proper holes drilled and bolted down. Other than a good sweeping of the floor this is where the project stopped back in December. I had to park the truck inside as the roof of the box developed a couple of small leaks.
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Old 03-20-2012, 07:04 AM   #4 (permalink)
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I took member mattamd xp up on his offer to do some metal work. He came out to look things over, drilled some holes for the seats, cut out the remaining brackets and made some templates for cutting patches for the floor. Last week he came out to finish up the seats and the floor. He did the work so that I'd be able to remove the seats later since there was still some more crud cleaning, painting and other work to be done to the floor. Sorry the pics aren't that great but since the truck is in a dark dungeon it's the best we could do.

He'll have to fill you in with the details for bolting down the seats. I forgot what size bolts he used and if the original factory holes did or did not have to be drilled.

The welder he used was this cool little Miller blue box that had some adapter for plugging into 110. It was wire feed and had a green gas bottle(Argon I think it was). After he really cleaned up the spots where the patches were going to be welded he found lots more holes.



He made patches to cover all the holes. These were cut from the bed of his pick up that he'd replaced. As a bowtie girl it's nice to have a little GM in my truck now.



I tried to grab a nice pic of the glowwy goings on but this was the best I could do. Yes, the warehouse is really that dark. It really messes with my depression.



After running a nice long bead and tripping the breaker(we both guessed this would happen it was just a matter of when), Matt was done and you get a blurry, dark pic. I'll get a better one later when I can find what breaker tripped and put my lights up. No more holes.



Thanks again Matt!
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Old 03-20-2012, 07:31 AM   #5 (permalink)
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There was also a fan mounted on the aluminum roof because of the prior mobile catering business and it stuck up about 8 inches from the roof. I didn't have a really good pic of it but it's since been removed.



We used a 24"x4" piece of .25mm aluminum for the patch to cover the ginormous hole. It was tacked down with some Flex Seal(for gluing purposes only, I don't trust it for waterproofing. Hey it was free!) and a ton of rivets(forgot the size). After I get the roof cleaned this spring the big hole as well as where the roof was leaking prior will be repaired and the whole thing will be sealed properly.

The air bags needed to be replaced as the cords were showing through one of the bags and there were so many cracks in both.





The ramp as well as the framing it slides in had to be pulled out as it was covering the air lines that needed to be disconnected from the bags. I'm not sure of what else they had to do as I wasn't there for all of it but Yager has a pretty good description in his thread.

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Old 05-23-2012, 05:40 PM   #6 (permalink)
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I started taking down the conduit and wiring that had been installed for the mobile catering business that had been in the truck at one time. The new electrical and lighting will be located in different places.





And while the vag might make a neat fanny pack, properly directed bewbages make neat ramps with which to direct loose screws to ladder trays. Yes, I know...

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Old 06-10-2012, 10:28 AM   #7 (permalink)
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Out with the old 960 cca 1 1/2 year old Energizers I destroyed:



And in with...my Precious...



So, $219 later I now have 1140 cca batteries. Fired right up like it hasn't been sitting since early April...

Someone was concerned with smoke(surveyboy?) on start up so I recorded it's inaugural start up since it last had enough power to start in April. This is about the same amount of smoke I get when it starts on cold days.



Sorry for the whacky link. For some reason it's not posting correctly.
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Old 06-10-2012, 10:58 AM   #8 (permalink)
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pretty cool. any plans for theoutside ? id just leave alone
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Old 06-10-2012, 11:01 AM   #9 (permalink)
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I'm leaving it alone other than installing the windows and doors I have now and replacing the roll up door with a wall which the bigger rv door will be installed in. Too broke for anything fancy.

Oh wait, I'll be spray canning the driver and passenger doors white. Gotta be stealth mode.
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Old 06-10-2012, 02:10 PM   #10 (permalink)
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Don't wanna announce the craziness in advance?

Oh, and here's your video.

Typical start up - YouTube
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Old 06-10-2012, 04:57 PM   #11 (permalink)
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Oh, and here's your video.
Thanks! Now I see what wasn't copying over from youtube. Wish my big ole fanger wouldn't have been in the way.
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Old 06-23-2012, 10:53 AM   #12 (permalink)
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mayhaps your lucky break lady. get the model and serial # over the phone before wasting a trip.
http://hartford.craigslist.org/pts/3036211103.html
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Old 06-25-2012, 09:42 AM   #13 (permalink)
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that looks funny to me.
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Old 07-22-2012, 04:35 AM   #14 (permalink)
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These corner plates were loose and the sealer was peeling away. The rivets were either broken or not fastened very well.



I peeled away what I could and used a metal painters tool to scrape away the rest.



These corners are pretty ill fitting once all the crap is scraped away.



I used a wire brush to clean the rest of the areas I needed to seal as well as evidence of electro galvanic reaction between the steel bolt and the aluminum plate.





I ran out of tips so I gobbed the sealer as best as I could. Since this will be under the raised floor it didn't really matter what it looked like as long as it sealed the big gaps up and keep bugs, termites and other vermin out. I'll have to leave the corners easy to access until I get to Buffalo because I didn't have the strength to screw in the self tapping screws to replace the rivets.



I also spread some sealer under the plate and in the hole to try and keep the bolt and aluminum separate.
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Old 09-01-2012, 05:36 AM   #15 (permalink)
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Okay, pics seem to be uploading okay. This is what the compressor leak looked like when I got to manche's.







After manche cleaned it up a bit and installed the gasket and some RTV:



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Old 09-01-2012, 05:45 AM   #16 (permalink)
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And after the Blue Beacon sprayed out the engine compartment:











So far no leaks which is pretty nice after it leaking around 2 quarts every 500 miles.
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Old 09-01-2012, 06:13 AM   #17 (permalink)
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When manche first cut the hole for the door I was shocked to find out that the wall was wet from the bottom to halfway up. I did not know that the bottom cut on the FRP is not sealed with anything:






Anyway, the door hole lovingly crafted with manche's leet circular saw and jig saw skills except the wet parts which became a real pain.



I'm really bummed at how wet that was and am very concerned about the potential for mold and/or mildew.
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Old 09-01-2012, 06:27 AM   #18 (permalink)
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And the first window:












Both the door and window were installed using 1" wide butyl "tape" and 3/4" #8 self tapping screws.
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Old 01-31-2013, 11:08 AM   #19 (permalink)
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The revival begins this spring. This will be a slower and more thought out process. Thanks to several PBB members my move to WA state was a success and I'm planning ahead for the resumption of part two of this build.

First some thoughts:

Despite a few hiccups, surprises and my sometimes overwhelming anxiety this rig did everything I asked it to do. Yes it slowed down on every grade but it wasn't excruciatingly slow. The only painful part of the process was learning that keeping it floored by having my foot through the firewall while clipping my toenails on the fan(as I had been accustomed to doing with those snazzy Series 60/10 speeds) was not a good thing. It had been so long since I drove mechanical anything, well I was bad.

The "I wish I had done it sooner" category:

If you buy one of these snazzy rigs CUT OUT THE SOUP BOWL ASAP unless you like to look cool rolling coal and smoking out everyone behind you when you hit a grade. After it was cut out I had barely any smoke at all on a hill.

I've been attempting to play with Google SketchUp and we apparently don't play very well together. If there is someone out there that wouldn't mind helping me get my sketches turned into something nicer/workable hit me up so we can discuss compensation. I'm working on my sketches now but that's all they are at this point. I won't have anything solid yet until I have the measurements for the flat deck replacing the box.
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Old 02-07-2013, 07:02 PM   #20 (permalink)
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I got nothing to add other than Hi Bustin.
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Old 02-08-2013, 05:58 PM   #21 (permalink)
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Heya Boo! How's things your way? Did you get hit by that big storm?
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Old 02-08-2013, 06:19 PM   #22 (permalink)
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There are some really good sketchup tutorial videos that you can find on their website. And, others on youtube.

If you just want the basic truck box. I can send you what I created. It's pretty basic and doesn't have details, like where the extrusions cut into the interior volume, but you are welcome to it.
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Old 02-08-2013, 07:16 PM   #23 (permalink)
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Thanks EH, I've watched a few of those tutorials and tried to follow along but something isn't clicking for me. The plans I want drawn up are sans box. It's going to be removed and a new deck and dwelling built in it's place. It's what I had in mind all along but now I get to skip the living in the box step.
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Old 04-04-2014, 05:40 PM   #24 (permalink)
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Bustin Loose

I just found and read your thread again. Hope all is well.

Next time you need to patch some rusty floor boards, skip the welding and just epoxy the patches down. Use a few screws, or rivets to hold the bigger patches down till the epoxy dry's.

I find the epoxy patching to be superior to welding for one reason. It completely seals between the two pieces of metal, not allowing any of the corrosion to hide and start again.

I learned this fixing floor pans of high end airport taxi's. Wet salty winter boots, and constant salt spray from below took it's toll.

I wish automotive body's were epoxied together between every piece of lapping sheet metal. Then they would not rust the seems out.

Epoxy is also a great way of attaching dissimilar metals together without corrosion. A nice thin coating is all it takes to isolate aluminum from steel.


Nat
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Old 04-04-2014, 06:36 PM   #25 (permalink)
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Just did an update earlier in the old but reliable thread(http://www.pirate4x4.com/forum/tow-r...onversion.html). Floor panels have to wait but now I live around people that weld so it's on the list when I get going again. Roof of the box is first and that's going to be around a $300 job or so. I can't climb ladders more than a few rungs so I'll have to hire that part out.

I'll spin this thread back up when I start having actual work done. First I gotta get the workshop here in shape to use as a storage shed and paint booth for awhile. Once all the cabinets are cleaned up and painted I can drag the rest of my crap out of the back of the box, rip out all the damaged lumber and get started on it again.

But even before that my DD is down for the count. Something bad happened on my way to the store the other day and it was brought home on the back of a wrecker. I found a certified mechanic that does repairs and such for the charity he and his wife run, which happens to do discounted repair work for women in need. He's coming out Monday morning thinking timing belt, I think it's tranny related. Either way, it needs fixed yesterday.
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