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Above 1200 Sq/FT Ernie's Place

Wokspaces above 1200 squarefeet.

drivesitfar

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Sounds like your neighbor is a great guy. A woodworker next to a welder can get a lot of cool stuff built.

Your trips look amazing and hope you’re staying cool now that our weather is about perfect again

This spring might have us down your way so crossed fingers we can get out of this drizzle for a bit.
 
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StormcrowAz

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For the rear-mid body mounts, I had already done some of the repairs 10 years ago when I first started this project (that hurts to think about). The OEM mounts were pretty flimsy affairs, and prone to bending over under stress. Basically just a piece of bent sheet folded over and welded to the top of the frame.
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I had found some ¼” wall square tubing, capped it, and welded those on as replacements.
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Considering this is what was in there before, the new bushings and hardware should be an improvement.
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Not knowing better, or planning for the size of the Scout II bushings, I originally drilled the cap to just accommodate for the bolt size. Had to enlarge this for the new bushings.
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The square tube was also not big enough for the lower bushing to fit. Thought about replacing the whole thing with a larger mount, but figured it was just better to rework this one. Plasma cut a notch in the mount and ground down the bushing to fit. Still plenty of bushing left and still considerably way more there than what it originally had.
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So then it was time to line the frame and body up to see if I measured everything correctly. First issue I encountered was lining up those middle mounts to the body. I had upgraded the mounting surface on the body as well, boxed similar to the frame mount, and at the time thought it was be a good idea to weld in a captured nut so I could just run the bolt in from the bottom and not worry about having to throw a wrench on the nut all the way up under there. The reality is that trying to line up the frame to the body and then getting those bolts lined up exactly right in order to even start the thread was problematic at best. I ended up reaming out the threads and plasma cutting a small window in the box to allow a wrench to sit on the nut inside it.
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The rear outer mounts went a lot smoother, and got those in without issue in the stock locations. 53003082689_fc26613054_b.jpg


So now the frame and body are together and squared away enough to figure out the front-mid mounts under the new floor pans. Happy with how the c-channel turned out and should be a solid mounting point for a new bumper with a swing-away spare tire carrier.
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StormcrowAz

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Drives - You read about those horror stories about bad neighbors and was really hoping to not live through a version of that. Fortunately they ended up being good people and am happy with the outcome.

Weather has been relatively cool up to this point, but we're now just starting to break into the 105° plus weather. The swamp cooler in the shop has been helping a lot, but probably won't last much longer once monsoons start to hit. I wouldn't mind a drizzle now an then, enjoy a little of it for me!
 
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StormcrowAz

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The new neighbor came over and we worked on his cantilever gate.
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Still need to clean the welds up. When it reaches this point inside the shop, my motivation to stay out there starts to decline a bit.
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Also made some decent progress on the Scout.

While the new floor pan body mount supports were still tacked in place I drilled a pilot hole for the bolt location. Cut the tacks and pulled them off the vehicle. In order to give it a little more support I’m going to sleeve them so there shouldn’t be any collapsing of the tube if the bolts are over-torqued. Used a hole saw and cut out a hole in the support. Found some pipe and cut a couple pieces to fit. Also cut some 1” strap to cap the ends. Weld-filled the pilot hole from the hole saw remnants and cleaned those up. Those pieces will cap the open side after the pipe sections are dropped in and welded in place.
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All welded up.
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The original floor pans had a recessed section where the bolt head inside the cab was.
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Presumably so you didn’t stub your toe on it. Instead of doing that, I thought I’d just go with carriage bolts, figuring the nice rounded head shouldn’t be an issue down there, no sharp corners to catch your sneakers on. After hand-finishing the welds on the mounts I drilled the full sized bolt holes and squared up the one side for the carriage bolt to drop through.
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Test fit on the truck and realized I didn’t compensate for the angle of the dangle on the passenger side support as it stuck out into the engine compartment/transmission tunnel. Had to cut off an end and shorten one side.
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Drilled holes in the pans and squared the holes up.
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Seems fairly unobtrusive.
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Good to go.
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Did I mention that welding upside-down is no fun? I got the hang of it at just about the same time I was done with burning both sides in.
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Also added these sections of pipe for some triangulation gussets on the new rear c-channel cross-member. Plasma cut some sheet metal to accommodate.
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From the factory, that channel was just bolted to the rear of the frame. Couldn’t really think of too many negatives for just welding it place instead, so made it permanent.
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Decent progress, I think, until the triple-digits drove me back to the house for some AC.
 

drivesitfar

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Hey buddy I hope you’re sitting down about every 30 minutes or less in that heat and drinking water or favorite beverage.

That gate you’re doing is very cool. Did you say that your neighbor is a woodworker and he’ll be filling in between Your cool metal and welding with maybe wood?

Stay cool (if you can) and keep up the good work.

Btw I’m not sure you have seen Vieux thread? He’s our Russian member that repairs more rust buckets than anybody I know in case you might need any help. That said from my chair your work looks amazing.
 
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StormcrowAz

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Dan – Yessir! I chug a lot of water, and maybe a couple Gatorade’s (what plants crave, plus it’s got electrolytes), whether thirsty or not. Especially this time of year. This water cooler is probably one of my most-used pieces of equipment in the shop when it gets hot out:
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And speaking of the water cooler- just yesterday I had to replace the plastic line right after the brass valve as it split and sprayed water all over the wall. This is also why the little step ladder lives next to the cooler. Easy filling platform.
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Drives – Yep, the occasional break usually includes standing in front of the swamp cooler. ;) And yes, the neighbor is going to fit those openings with wood of some sort. I forgot exactly what he’s going to use, but he did mention cutting, plane, and glue work will need to be done. Once he gets the pieces ready we can figure out where to weld the mounting tabs. I haven’t seen the Vieux thread yet, I’ll check it out. Thanks for checking in!


JGG – Personally - anything over 105° just plain *****. I’d like to say that being born and raised here in the desert has given me natural immunity to heat, but it’s really more about getting out there early while it’s relatively cool and making as much progress as you can before escaping to the house in air conditioned goodness. I can only spend so much time on the couch, though, before going a little stir crazy. Need/want to get stuff done and I do think there is some therapeutic value in Quality Shop Time.


Scott – Envious of your location. Plan on heading up to Pinetop this weekend to do a little riding.


Bob – Up north is a bit closer to the sun, but it also usually means more trees. I’ll take 90’s in the shade of a pine forest versus being stuck here in the valley surrounded by the concrete and steel heat-sink of the city!




Mini-update – Not a big fan of going places or out of town on holidays, too many people. Instead I took advantage of the day off and got up early to prep for riding this coming weekend. Pulled the toy hauler out and did some PM to the Can Am.
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drivesitfar

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Vieux thread name is “A very small garage in Russia” snd when I first found his thread years ago he was restoring a car that had been in a fire. The last year I bet he’s repaired 10 cars with rust damage so bad there didn’t seem to be any solid steel to attach a repair to and he always seems to manage.

Keep up the great work and of course STAY COOL!!
 

PugetDude

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US 60 was closed due to a wildfire yesterday; we made it all the way to the Salt River Canyon when they started turning everyone around… back to Show Low then down the mountain through Payson… 2-1/2 hour trip turned into 6…
Level 1 Red Flag Fire Restrictions in the AZ high country right now.
Enjoy the trip - stay safe; it’s as dry as a Tinder box up there- all that spring rain produced a lot of fuel.
 
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StormcrowAz

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Talked to my cousin last night (who I'm going riding with) and he had a similar story about heading up through Globe and having to turn around at some point due to road closures. I think he's in the San Tan Valley area. I'm coming from the far west of the valley and planned on taking the 87 through Payson anyways. Hopefully it's clear. Google says it's about a 4 hour drive.
 
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StormcrowAz

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Had a good trip up to Pinetop. My cousin has a nice RZR and we went out exploring some forest roads. Still a little bit warm, but I’ll take 90° over 115° any day.
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Brought my buddy along.
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A lot of forest roads, nothing technical or difficult, but certainly nice to get out of the heat and into some clean air.
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And it finally happened. Tried to load the car into the toy hauler without checking first and broke the antenna. Didn’t run the whip this trip because of trees.
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Upon closer inspection it looks like it caught the trailer just right and simply pulled the top section of the antenna apart. Loosened up the set screw, re-inserted, tightened, and good to go. Lucked out!
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Had a little bit of excitement when putting the toy hauler away in the back acre. Was doing some clean-up work on the trailer and heard that “not playing around” bark from the dogs. Looked over and saw them barking at a coiled up snake. I called them back and herded them to the back yard and checked for punctures. Fortunately it doesn’t look like they tussled with it at all, just making noise. Went back to check on the snake, could have sworn I heard it rattle, but there was no rattler on the tail. Probably just hissing or shaking its tail. I’ve read gopher snakes can do that to imitate the sound.
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From the quick look I got before it dove into a gopher hole, the head wasn’t very wedge shaped like a rattler, so thinking (hoping) it’s a gopher snake of some sort. If so, I welcome it to stay back there and keep the pocket gopher population at bay.
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drivesitfar

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I love your comment about going to the mountains and getting some cooler weather in the 90’s.

Good thing antenna was on good enough to make it to the trailer and just loose enough not to break.

I also love nature and yesterday two eagles were circling above our house and rose maybe 500 feet without a ring flap. Also while I was in my driveway an osprey flew over my house about 15-20 feet above me with about a foot long fish in its talons. Of course we still have the noisy PITA crows but for some reason they and other critters are leaning my brides garden stuff alone.

Stay cool or maybe I just should say survive another summer in the desert.
 
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StormcrowAz

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One of our neighbors had given me a box of their used horse shoes a number of years ago, so I cleaned up a few:
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And turned them into this for a birthday present.
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Looks like I forgot to take a picture of it all nice and painted before boxing it up. :( Imagine it all shiny black with the brand painted red. The brand isn't oriented correctly, I know...but since this is just a display piece I thought it would be nice to read the letters without them being backwards.



Did the there-and-back drive for Don’s shin-dig. Met a bunch of GJ folks in person, which was cool.
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There was a blacksmith on site and he was working the forge. Handing out rings made out of horse shoe nails and these customized shoes . Neat stuff. The wife promptly hung this at home when we got back.
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Got lots of stuff to do in the shop, but finding it difficult to get motivated to endure the heat. Scott mentioned a dashboard thermometer a while back...here's a recent snapshot of the car exterior/interior while at work.
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drivesitfar

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I couldn’t make the shindig this year at the party garage but happy to hear you and a few other members did. Don and Anne gave my brid me and I a personal tour about 5 years ago and they were amazing. Of course the Party Garage was too snd he was just in the talking phases of the western town and many other projects.

We went to Universal Studios in Hollywood the day before and Party garage was a far better experience. It looks like you took a drive to use your AC and get a bit cooler in California too.

Looks like maybe next summer you should make a trip to the PNW cause I bet high 70’s and 80’s when you get here in July or August would be just about right.

Nice work on birthday present.
 
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StormcrowAz

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Fixed the plasma table (mostly) this weekend. Had issues with the PC randomly disconnecting from the table. After doing everything I could think of, and read about on the forums, I contacted Langmuir and they sent me a new motion board. No fuss and at no cost. Good customer service. Had to replace this white circuit board.
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Did a bunch of dry runs and everything looks good. First test cut:
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This bracket is for a vent fan on my folks ’65 Airstream. What looks to be the original fan is starting to give up the ghost, making a bunch of noise, so thought adapting one of these computer fans might be a good idea. Old mounting bracket is the top one.
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Next I cut out this pinion yoke removal tool.
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Had to turn off the torch height control feature as it was giving me errors. Need to read through the troubleshooting guide and figure out what’s going on. Still seems to cut good without it, just need to feed it flat material until then, I suppose.



On the Scout, I am trying to keep the stance as low as possible but I think having just a small body lift will help with a couple potential clearance concerns - the engine swap, bigger tires, aftermarket fuel tank, etc., etc. So think I will try a 1” body lift and see what happens. Started with cutting these pucks out of 1/8” plate.
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On the band saw, I cut these sections of well casing pipe.
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Then the neighbor came over and we spent some time working on the posts for the cantilever gate. Made a jig to keep everything square and true when setting the posts in concrete. Forgot to take pictures.



And this last thing is kind of goofy, I think. First a little background - A while back, before it got insanely hot, I went out shooting with the guys. We have a very remote, and safe, spot out in the desert and usually make a day out of it. Being the desert, there’s not a lot of shade so we typically each bring an EZ-Up with us. I bought a brand new one for this outing as the old one was, well, old. It ends up looking like a mini tent city when all set up.
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Now, we’ve been doing this a number of years and have a system which has been pretty solid, up to this point. It can get a little breezy out there and to combat this we don’t use the little wimpy tent stakes typically provided with these pop-ups. We have some beefy 1” metal stakes we pound about a foot into the ground and duct tape the tent legs to. Gorilla tape is good stuff. This particular day was seemingly perfect. Not windy, temperature was warm but not unreasonably so, especially in the shade. Just after a lunch break, Mother Nature decides to intervene and sends what I can only describe as a micro-burst, or possibly a big dust-devil, our way. Bizarre that there was no warning, it just appeared directly in the middle of our tent city and carried it away in a fury of twisted tent legs and tarps. This was the kind of thing you see on YouTube or whatever and I wish I had a video of it. It was an odd localized chaos that happened quickly without warning and died out after a few shocking seconds. Fortunately nobody was hurt, all of the tents stakes were pulled straight out of the ground and the mass was twirled up and away from us. Had to hike about 100 yards to retrieve my brand new tent top. All of our tent legs were mangled beyond repair.
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So long story short, I have a brand new EZ-Up tarp without anything to put it on, and couldn’t bring myself to throw away. Figured I’d toss it over the plasma table to keep the dirt and grinding dust off of it. Kind of goofy looking, so if you see this monstrosity in the background of pictures...that’s what’s going on.

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drivesitfar

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I’m guessing the tent legs in the back of the truck might be used for future projects?
Hope your plasma issues get worked out which I’m guessing they will. Blue tarp looks like a big easy chair in your shop.

Stay cool!!
 
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StormcrowAz

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Drives – I thought about it…but most of the straight sections were fairly short, and overall these tent legs are fairly thin material, so opted to pass and sent it all to the dumpster. Gotta draw the line at some point or wind up on one of those hoarding shows.


Scott – I missed that thread. But if you’re at a place where a tarp is your fix for a roof leak, then you probably need this tarp more than I do. ;)



Continuing with the body lift pucks - Made a little sandwich, bolted it snug, and tacked it together.
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Burned it in
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Cleaned up on the belt sander. Not spending the time to blend welds 100% flush. Leaving a little extra for strength and plus these will out of sight and mind anyways.
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Moving on to more rust repairs. Drivers side, just behind the door, someone did a patch repair that was partially brazed in and gobbed over with body filler.
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Cut that piece out
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New piece prepped
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Similar spot on the passenger side, just a bit higher up in the panel. No patch piece here, just a hole.
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Sectioned out and new replacement patch sized up.
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The good folks at International put these “X” brace stiffeners on the tub, inside the fender-well area. There’s little weep holes in them for drainage, but inevitably dirt collects in there, traps moisture, and promotes rust. On the drivers side, someone “fixed” this by cutting off one section of the “X” and putting another one of those partially-brazed patches.
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“X” stiffener cut out and ground smooth. Cut out old patch and a new one will be welded in.
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The passenger side had rust issues on the “X” as well, but did not look like any holes broke through to the inside.
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After getting into it, I found that there was dirt/rust was still packed into the low spots. This was hiding another decent sized through-hole into the cab. Same as the drivers side, that got cut out and a new patch sized for replacement.
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That’s all the time and stamina I had for Scout work over the weekend. Swamp cooler and fans helped suffer through the heat.



On Sunday helped out the neighbor with the cantilever gate posts. He had already dug some good sized holes in preparation for this. Ran down and picked up Quikrete and a mixer. There’s a ton (literally) in the one-ton. ;)
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Earlier we had prepped the posts and welded these pipes top and bottom to maintain them in plane and to be parallel to each other. Measured and added the half-inch square tubes to the sides to be butted up against the block wall. That spaces the posts out perfectly for roller and gate clearance. Used ratchet straps top and bottom to the pipes and ran those back behind the wall to spikes we drove into the ground. Should keep the assembly from moving while the concrete cures.
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Fortunately the area we’re working at was under the shade of a big tree close by, so with the mixer doing all the hard work for us, it wasn’t too bad of a job. Will give it a week or two to cure before throwing the rollers on and testing out the gate.
 

j p smith

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Hey Todd. I just finished catching up, awesome work on the gates and your Scout project. I hurt my right ankle & calf and so I have more time in front of the computer, TV & reading. Would you post a picture of the beautiful gate showing how the cantilever works.

Also on your bumper project, I use these wedge washers on the carts I build for the Hit & Miss engines. If I need a wider surface, I cut a piece from the short leg of a scrap of channel, cut to fit and flip it over to square things up. Usually have a dozen or so 3/8 & 1/2 wedge washers on hand if you need a few for a project.
Locally I get them in box quantity from Phoenix Bolt(30th Ave & w Thomas Rd) or Mcmaster if i have a bigger order where i can justify the shipping.
Later, Jeff
 

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drivesitfar

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I agree great work on the new gate and your old scout.

I actually have a bunch of 4 inch 3/4 bolts that came with those washers or levelers or whatever they are called.

Keep up the great work and I know it’s hard when it’s maybe 100 in the shade. Stay cool.
 
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StormcrowAz

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Dan – I plan on seam-sealing and fully coating everything I can to prevent any future occurrences. Hopefully it will live to see another 60 years or so! That pic was semi-planned, I guess? I was working/standing right there when I cut the section out and noticed how the flag showed up nicely through the hole. Lined the shot up for maximum effect. Glad someone caught that! ;)


Jeff – Bummer to hear about the injury, that’s never fun. Rest and heal up!

Good info on the wedge washers, thank you. In retrospect, and had I known, I probably would have just gotten those instead of going the DIY route. At the time, though, sitting on the floor in the shop realizing there was a problem, my first thoughts lean towards: “how can I fix this”. Like right now. I think I tend to get tunnel vision on making forward progress towards getting the job done instead of maybe taking a beat to evaluate and consider the situation a bit more in depth.

Regarding the cantilever gate – will certainly follow-up with more pictures on how (and if) this works. Maybe next weekend if there’s time we’ll bolt the rollers on and do a test run. In the mean-time, here’s my crude 3D model of how it’s supposed to look.

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Drives – We’ve had a small reprieve in the weather these past few days. It’s dipped below 110° for a bit but should be back up into the teens by the end of the week.
 

j p smith

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Todd thanks for the picture, I see how it works, I had a different picture in my head, blaming it on the heat. I picked up a 55 ton Norco shop press yesterday and was grateful for the help loading from the seller and his son. Now I just need to get healed up and back to work.
 

drivesitfar

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Since we don’t have AC here at our home when it gets above 90 we suffer a bit but thankfully it’s only a few weeks each year. I can’t fathom having temps at midnight over 100 but I bet during your summers you spend a lot of time outdoors in short spurts so you can get back to AC.

I bet that neighbors new gate will be amazing so best of luck with the technical stuff
 
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StormcrowAz

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Jeff – Congrats on the new shop press! If anyone asked, I would definitely say that new tool acquisitions are a critical part of the healing process. ;)


Drives
– I can’t imagine not having A/C here in Phoenix! And yes, this time of year I only spend a few hours out in the shop on the weekends. Get up early and almost never work past 2pm out there.



Minimal progress on the Scout this weekend. My parents drove up for a visit on Saturday, but I did manage to get a little patch work done before they showed up.

Behind the driver side door. Has a little heat warp to it, but not too horrible. 53100588000_644f5099e5_b.jpg


Only had time to tack this patch in the driver side foot well area. 53100588030_5872d06d2e_b.jpg



On Sunday I picked up these up from my friend I go riding with. He has an X3 and got some new wheels and tires for his rig. Tread wear isn’t the best, but still some life left in them. One does have a plug in it and leaks down over a couple weeks. The wheels are beadlocks, though, which I didn’t have until now. And free is always a good price. :)
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After that, I went next door and cut off the support structures from the gate posts. Put the lower rollers on and leveled them out.
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Lugged the gate over and set it on the rollers
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And quickly came to a disappointing conclusion
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Turns out when I made the 3D model (see previous post) that everything was built to, I neglected to take into consideration that the block wall jogs down in the middle and it’s one course shorter towards the gate opening. The posts are about 8” too short for the top rollers to bolt to.
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Funny thing is, the posts were long enough to begin with but when we first test fit into the hole we noticed it stuck out about a foot over the wall. Thinking these posts should be hidden behind the wall (like in the model) we had dug the hole an extra foot deeper so they were level with the top of the wall. Now I get to go down to the steel yard and get a couple more feet of 4” square tubing so I can weld on some extensions for the rollers to bolt to. Should have double-checked measurements before we poured the concrete. Good news is that the gate fits otherwise, length wise and he is happy with the height of the gate itself. Seems to roll pretty nice as it sits now and think overall function will be good once we are able to capture the gate between both sets of rollers. It’s always somethin’…
 

Finallygotit

ALLIANCE MEMBER
Joined
Jul 6, 2013
Messages
4,079
Location
Tucson, AZ
Todd, it's like they say, it really isn't about the boo-boo but how you recover from it. I'm sure that the project will look great when it's complete. Hell, it looks great as it is!

:beer:
 

PugetDude

ALLIANCE MEMBER
Joined
Mar 13, 2013
Messages
22,348
Location
Superstition Mountains, AZ
Todd, it's like they say, it really isn't about the boo-boo but how you recover from it. I'm sure that the project will look great when it's complete. Hell, it looks great as it is!

:beer:
Last week at Home Depot:
Cashier: "Are you a Pro?"
Me: "No, when I make a mistake I don't try to hide it. I fix it."
Cashier: "A lot of truth in that statement."
 
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StormcrowAz

Well-known member
Joined
Nov 3, 2011
Messages
750
Location
Phoenix, AZ
Dan – True, true…and I do plan on fixing it. Appreciate the vote of confidence!


Bob – I suppose so, still no fun spending more time on it than needed. Live and learn. And as a buddy of mine says: “We have a sewing machine for metal”, so I’ll just stitch a bit more on there.


Scott – Hah! I’m definitely no Pro. I think this would be funny to get framed and hung up in the shop somewhere:
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The other saguaro in my front yard took a dive the other day. Don’t recall it being that windy at any time, but when you sleep in the basement sometimes it's hard to tell. Looks like it might have been a combination of wind and birds, judging by the holes in it.
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So, back to the gate mishap. Went down to the steel yard and rummaged through their scrap pile and came out with this short section of 4” post. Also picked up some 2” angle iron.
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It was either this piece at .25" thick or buy an entire 20 foot length of the same-sized .125" wall post that we sunk in concrete. Bigger is better, right?
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Cut up 8” sections of the angle iron to plug weld into the inside of the post. Figuring I would also plug weld the post we sunk in, just to reinforce it a bit. Started drilling holes when I remembered the plasma cutter. Using the stencils is not as clean and easy as I had imagined it would be, but it worked and probably saves some time/effort versus the drill press.
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Welded the angle iron half-way inside the tube at one end and cut out some cap plates for the top. Figured I’d weld a nut to the inside of the cap so he could bolt something up top if needed. Not sure what, but thought it would be nice to have the option.
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Didn’t get to work on the Scout, but did make some progress…

Drove out to Tonopah and picked this up
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My original plan was to go with a 4BT, but that was 10 years ago when you could still find them in bread trucks for a reasonable price. Seems like those days are gone and I just can’t justify the expense for them now. So…LS it is. I don’t really know what I’m doing but it looks like everyone else has already cracked the code on these and there’s a ton of info out there, so shouldn’t be too much of a mystery to get it going. Just a bunch of work.
 

drivesitfar

Well-known member
Joined
Oct 23, 2013
Messages
36,004
Location
Pacific Northwest
Loving the YouTube expert sign or maybe a patch on your shirts.

Great idea for the extension to strengthen it up a lot more than a bit. Best of luck with the fix and I hope your neighbor appreciates all the work you’re doing.

Sorry to see and hear about your big cactus failure and I had a similar issue with our beautiful pine tree when a branch just dropped out and I ended up cutting down the almost 30 foot tree with my 10 inch Ryobi 18v chain saws.

I’ve never replaced an engine so I’ll watch and learn.

Stay cool!!
 

Kasal

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Joined
Nov 21, 2017
Messages
735
Location
Galicia, España
Drives – I thought about it…but most of the straight sections were fairly short, and overall these tent legs are fairly thin material, so opted to pass and sent it all to the dumpster. Gotta draw the line at some point or wind up on one of those hoarding shows.


Scott – I missed that thread. But if you’re at a place where a tarp is your fix for a roof leak, then you probably need this tarp more than I do. ;)



Continuing with the body lift pucks - Made a little sandwich, bolted it snug, and tacked it together.
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Burned it in
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Cleaned up on the belt sander. Not spending the time to blend welds 100% flush. Leaving a little extra for strength and plus these will out of sight and mind anyways.
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Moving on to more rust repairs. Drivers side, just behind the door, someone did a patch repair that was partially brazed in and gobbed over with body filler.
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Cut that piece out
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New piece prepped
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Similar spot on the passenger side, just a bit higher up in the panel. No patch piece here, just a hole.
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Sectioned out and new replacement patch sized up.
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The good folks at International put these “X” brace stiffeners on the tub, inside the fender-well area. There’s little weep holes in them for drainage, but inevitably dirt collects in there, traps moisture, and promotes rust. On the drivers side, someone “fixed” this by cutting off one section of the “X” and putting another one of those partially-brazed patches.
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“X” stiffener cut out and ground smooth. Cut out old patch and a new one will be welded in.
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The passenger side had rust issues on the “X” as well, but did not look like any holes broke through to the inside.
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After getting into it, I found that there was dirt/rust was still packed into the low spots. This was hiding another decent sized through-hole into the cab. Same as the drivers side, that got cut out and a new patch sized for replacement.
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That’s all the time and stamina I had for Scout work over the weekend. Swamp cooler and fans helped suffer through the heat.



On Sunday helped out the neighbor with the cantilever gate posts. He had already dug some good sized holes in preparation for this. Ran down and picked up Quikrete and a mixer. There’s a ton (literally) in the one-ton. ;)
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Earlier we had prepped the posts and welded these pipes top and bottom to maintain them in plane and to be parallel to each other. Measured and added the half-inch square tubes to the sides to be butted up against the block wall. That spaces the posts out perfectly for roller and gate clearance. Used ratchet straps top and bottom to the pipes and ran those back behind the wall to spikes we drove into the ground. Should keep the assembly from moving while the concrete cures.
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Fortunately the area we’re working at was under the shade of a big tree close by, so with the mixer doing all the hard work for us, it wasn’t too bad of a job. Will give it a week or two to cure before throwing the rollers on and testing out the gate.
Excuse my ignorance, but I would like to know why the first row of blocks is placed horizontally, I had never seen that system.
 
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StormcrowAz

Well-known member
Joined
Nov 3, 2011
Messages
750
Location
Phoenix, AZ
Hello Kasal - If you're talking about the row of block at the bottom of the wall that have holes in them...it's for water to pass through. We have irrigation out here, so both their front and back yards are flooded from the canal that's out by the street, in front of the house.
 
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StormcrowAz

Well-known member
Joined
Nov 3, 2011
Messages
750
Location
Phoenix, AZ
Drives – I’m leaving the cactus for now. Will let it dry out and should make it easier to move. I’m gonna call it yard art for now. ;) And while I guess I technically have replaced an engine before, it was in my friends ’67 Scout and it was just the physical fab work to make it fit. He took it home afterwards and got it to run. This is a larger scale for me and all the wiring and such is a bit intimidating. Fortunately there’s a lot How-To’s out there for these engines.


Jeff – Thanks! Almost to the finish line!


Justin – I’m certainly looking forward to the horsepower, but still like the concept of the simplicity and lack of computers in the 4BT. Hopefully after I start digging into the new motor and learn the ins-and-outs it won’t be as intimidating.




Fairly productive weekend. Welded the fence post extensions on and did our first real trial run on gate functionality:
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Gate rolls great until the last foot before closing. Think we need to adjust the top roller gap and possibly add some counter-balance weight to the end. With some tweaking and de-bugging I believe it will work good.



Made progress on the Scout. Pulled the exhaust manifolds off. These won’t fit the Scout due to firewall clearance issues. I noticed several broken-off exhaust bolts before I touched it, so pre-soaked them in Break Free for several days. Two were proud of the head, and came out without an issue with some vise grip persuasion Still have 3 that broke off inside the heads and will try to weld them out. I had read this was a common issue so was not surprised.
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Pulled the wiring harness off. There’s some good tutorials out there for re-working and cleaning it up to be a stand-alone harness.
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Cut out some motor mount pieces out of ¼” plate
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Looks like it should work.
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Worked on some more rust patching. Driver side foot-well is done.
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Passenger side.
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This area behind the passenger door fought me.
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Turns out while it doesn’t look bad from the surface, there is a larger area behind the panel just forward of the patch that is really thinned out. I struggled for a long time trying to patch up holes where the little tack welds kept blowing through. Finally concluded it will be just better to replace a larger section as my “repair job” was looking horrible. Had to walk away at that point.



I wanted to end the weekend on a more positive note, so figured I’d get one more little thing done. I plan on running electric fans so need to remove the mechanical one off the front of the engine. This one has a broken blade, so would need to come off regardless. It’s attached with this nut to a bell which rotates together, assuming this drives the water pump.
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The bell has little holes on the front of it so I made this tool out of half-inch square tubing and machine screws to hold the assembly stationary while I wrenched on the nut.
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Success. Someone probably makes a specialized tool just for this, but there’s some level of satisfaction to DIY.
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Felt better walking away with a small win versus a rusty set-back.
 
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