The "Donkey" build/rebuild

[Bracket racer]

Just got back from a 4 1/2 hr run. Awesome brakes!

 

[Bracket racer]

Found another problem, one of the tips to hold the outer pad is broke off, that’s why I lost the outer shoe.
So, more Hackery,lol.
Water plus grease is mud..

 

[Bracket racer]

Went for a test drive (another 5hr idle through the woods in low range) and I could smell coolant. Stopped and popped the hood and the header tank on the rad was cracked and leaking. It was broke before and I JB welded it, well poo, have to turn around I guess. Actually, the rad hose is hard and when I moved the cap a bit, coolant came out....huh...ok, watch the temp gauge and carry on. Stopped an hour later and the rad is dry? Weird.
Then I remembered I just dumped head gasket sealer stuff in the rad before we left, I’m thinking it sealed it up?? This thing has been eating coolant for a year now, put two different types of rad sealer/head gasket sealer in it trying to stop it. (Pretty sure a head is cracked)

This time I put in cast iron block sealer... seems to work!

I’ll check coolant levels today and see if it lost much.

 

[mnewman]

This was a fun thread to read.

 

[Bracket racer]

Thanks, but it ain’t over yet! Lol!
So, long story short, still eating coolant. Doesn’t seem as much but I always need to give it a couple cups full before heading out.

waiting for parts for the 4 wheeler and when that’s done pulling another ranger in the shop for the kid. (On Road or off road isn’t determined yet)

I’ll start a separate thread for it.

 

[Bracket racer]

Alrighty now... in the general section I started a thread about windshields, asking about what years fit a 91.
Threads done, got my questions answered and am now going to install it.

This is where I started;

 

[Bracket racer]

Since the windshield was broke and popped out of the hole and the A puller was pushed back and inwards about 6”, I used a hyd frame kit to push it out so the broke windshield would fit. (Ish)
I siliconed (bathroom, waterproof) all over and glued it into place.

Now I have to cut out the broke window and get it out around the exoskeleton.

huh, no metal underneath...need more silicone!

 

[Bracket racer]

Windows out, everything is cleaned (not really ) and I put some clear silicone down to glue it in. I’ve got like 5 tubes so no problem.
Ruh roh...I got the correct windshield but the cab is out of square worse than I thought, we got us quite the gap!

 

[Bracket racer]

Great!!!!! I got 5 tubes of silicone...the other 4 are not clear, they are BLUE!!!!!!
Frig it, not going to town just for that, I’ll paint it later I guess.
I’ll just use some wood to jam the windshield into the hole so it takes less silicone. Exoskeleton has another purpose! Ha!

 

[Bracket racer]

How big was the gap and how much silicone did I use??

Found this when I went inside to check glass alignment. A big blob fell on the column so I guess I had lots on the cab as I pushed the window in huh??

 

[Bracket racer]

And now we wait............................

 

[alwaysFlOoReD]

Nice work. Im interested in seeing how it works. Im thinking forcing it into place will mean there is a lot of stress on it. Probably crack quite quickly. Hope not tho, i wouldnt mind being proved wrong.

 

[Bracket racer]

The condition of the cab, I’m thinking it will flex to fit the window!
No, I didn’t “press” it into the hole putting tension or flex into the window, I just added a bit of weight so it would push down on the silicone. Also, I think the silicone will let it “move” around a bit, it’s not like factory stuff that makes the window a part of the cab structure.

we’ll find out, that’s for sure! Just checked and it has a solid outer skin on it but if you push in the thicker parts, it still mooshes around. (Mooshing is the official word of gooey silicone)

I think I’ll leave it until tomorrow before I look too closely at it.

 

[alwaysFlOoReD]

Ahh, i misunderstood your use of the wood.

 

[Bracket racer]

Well after waiting for a day because of rain and cold weather I thought the following day I’d check it out.
Good news is, during the massive downpour, I didn’t see any leaks, bad news is, this was the weather the following day (9 may 2021)