PlumCrazy's Beater DD 4x4 Build

[Shran]

At least the tops of the mounts are rusted off and not the sides! The 93 I've been working on has big holes in the sides of the rear mounts and the core support mounts, and the core support itself, is basically just big flaky rust chunks now. Nothing is solid. The gas tank straps rusted in half and it's sitting on the skid plate now...and I can break off pieces of the skid plate by hand. It's sadly not the worst I've seen but it's pretty bad.

So what I'm getting at, is yours looks pretty good

 

[PlumCrazy]

At least the tops of the mounts are rusted off and not the sides! The 93 I've been working on has big holes in the sides of the rear mounts and the core support mounts, and the core support itself, is basically just big flaky rust chunks now. Nothing is solid. The gas tank straps rusted in half and it's sitting on the skid plate now...and I can break off pieces of the skid plate by hand. It's sadly not the worst I've seen but it's pretty bad.

So what I'm getting at, is yours looks pretty good

If I didn't have some sentimental attachment to this POS it would have been in death row for parts with the rest of them. I have parted out better lol

 

[PlumCrazy]

Gonna run the diff through the parts washer tomorrow, but got fresh joints in the shafts.

They were living on borrowed time from the looks of it. Quiet and smooth though.

 

[Shran]

Those needle bearings are still good, just clean the dirt out and repack them. They haven't turned to dust yet so that's how you know they're good.

 

[PlumCrazy]

Those needle bearings are still good, just clean the dirt out and repack them. They haven't turned to dust yet so that's how you know they're good.

If I didn't cut the joints apart to remove them from the stub shaft I would have considered it lol

 

[PlumCrazy]

Diff cleaned up really nice with a combination of ultrasonic and parts washer.

Reassembled the front end with fresh hubs and wheel joints without any issues.

Moved onto body mounts...

Removed the rotten mounts (some were worse than I had even expected
)

Had to modify the poly mounts a little. The rears were 1/4" too tall and all needed a chamfer on the ID to clear the radius of the factory inner sleeve.

Core support mounts got a grab bag of hardware. I used 2.3 head bolts and some body mount upper washers to reassemble with the poly mounts.

All mating surfaces and most hardware were stripped down and coated with cold galvanize paint before reassembly. Everything will a get afresh coating of Fluid Film soon.

 

[PlumCrazy]

Added an additional relay/fuse box for some upcoming lighting upgrades.

Ideally I'd like to add some long range driving lights, some sort of yellow fog lights, power the strobe on the cap, and potentially some auxiliary switched backup lights.

Used some 3/4" angle off of the factory fusebox bracket to mount up the new relay box.

Recycled some aluminum I bought from the state department to make a switch panel and move the mic for the radio. And wired up everything with connectors and pins that were phased out at work.

Not 100% sold on the orange...but time will tell.

Also started mocking up some end caps for the TJM bumper

Finally got this thing thoroughly Fluid Filmed too

Made few hundred mile round trip for some goodies to burn off all that over spray as well lol