Now that the carburetor is changed over and working good.. It’s time to address some of the other things. And the first and somewhat urgent fix is the exhaust leak at the bottom of the header, where it joins the two into one pipe . It’s never good to have a leak in the exhaust system. Plus it can be noisy.. this wasn’t too noisy but you could hear it. So I thought it was simply the gasket that goes there.. And while trying to get the very rusted nuts off we sheared the studs.. Oh boy now we got a can of worms.. But I looked at it as an opportunity to remove the exhaust manifold and remove some more of the not needed stuff . So we pulled the both pieces of the exhaust out. And this turned out to be a very good thing.. because the leak was not the gasket ..but a crack in the pipe.
The crack is right up against the weld.. That will not do so I welded the crack up and drilled and tapped out the studs… got new studs & nuts.. Also welded shut a hole where the pipe came off for the silly reed valve.. ( pollution control stuff). The new carb has no place to hook up that stuff.. so it’s doing nothing but taking up space. Plus it could be another exhaust leak down the road.. When all is done I should have a very quiet Raider.
Isn’t that pretty ! This is going to put the rest of the motor to shame.. You can see my plug for where the pipe was.. Oh and the heat shield will not go back on.. it’s only real purpose was to provide warm air to the air intake.. Again no place for that.
Well I’m all done that job.. and the exhaust is going out the back where it should.. That crosses a few things of the list.. It’s good to drive till the weather is warmer.
Nov 2017
Well I did get the brakes done,, And used the Raider for most of the summer.. then I put it up[ for sale.. It’s sold now to someone I know and he wanted a good hunting buggy.. Prefect.. That chapter closed !
It’s February… Late February.. And the Carb kit is here !
And this is what I got.. A conversion kit. I would not say complete, because it’s not.. I’ve had to make some bits and buy some bits. So I made room in the shop for the Raider to sneak in.. And set to work removing all the crap that the Mikuni carb needed to work.. All the vacuum lines and electric sensors… gone.
This is after I installed the adapter plates for the Weber. And that was after I plugged some holes. The old carb had coolant flowing through.. so I had to plug those off. I got nice little nipples to plug the vacuum manifold. And I needed to deal with the return vent line from the fuel tank. I bought a new fuel filter that had the place for that vent line so problem solved. But there’s more things to figure out. Despite being told this kit worked for the auto transmission.. there was no way to hook up the kick down cable to the throttle. I had to invent something ..
A bicycle brake cable with a crimp on terminal.. hey it works! Took me an hour to figure it out.. But I was determined.
So here’s how it all looks .. that round thingy is a fuel pressure regulator.. adjustable too. The instructions don’t say much ..but they did say that fuel pressure needs to be 2.5 psi.. so that is the solution. One power wire to the choke and we are off and running…
Test Drive:
WOW.. I can’t believe the power now.. That old carb was a dog. The Raider is zippy.. and the shifts are good too.. initially the idle was too high. The spring was having trouble pulling the throttle back.. so I tweaked the cables a bit and got that to work. The motor idles at 800 rpm like it should now.. So back into the shop to tidy things up and check it all over.
And that is where we are at.. Here’s the finished install. I fixed a few other things while the Raider was warm and dry.. The wipers would never park properly. . So I pulled the motor out and repositioned the drive arm.. fixed ! I also installed the day time running lights that I’ve had for a bit.. last fall I wired the switch up and now we have lights too.
The replacement for the mini truck ! And the Rav 4 too.
It’s quite nice.. more room, automatic, goes faster, has more power. Could seat 4, and the steering wheel is on the proper side. This is a 1987 Dodge Raider.. or Mitsubishi Montero. 262657 kms. While not the prettiest girl in the room.. but maybe the most capable. As a 4×4 these are reportedly as good as a Jeep or Landrover. I’m not a fan of Mitsubishi motors. But this one runs great.. These 2.6 liter 4 cylinder motors were used in a few dodge vehicles from the eighties. So I’m quietly optimistic.
I like the full door on the back. Makes getting things in and out easy. And a trailer hitch is needed for what I do.. because this is not a pick-up I will have to tow a trailer for packing yard waste and mowers. Those are heavy steel bumpers too. The black paint is faded but not rusted. I’ve only driven the Raider a short distance. Today I will go get it and bring it home.. that’s about 40 kms on the highway. So we will see how that goes.
I put just a one day permit on the Raider.. mostly to get it home from Greenwood. It did ok on the highway.. not too fast. As expected it drove like a true short wheel base off road vehicle. The tires are old , so there’s some handling due to that. I drove it around town today.. and in town it’s great. In fact I went down a very rough road. That suspension seat is so cool.. Wow. great ride for the driver.
Check out the “inclinometer” in the middle… yes it tells you when you are going up hill.. down hill.. and tipped ! Jeep don’t got one!.
Now for the stuff this Raider needs. The first is New tires! I got a good deal on all weather / all terrain tires. So as soon as I get them mounted.. then that will not be an issue. The carb will need some tweaking .., the choke is staying on too long., Are the gauges telling the truth? if so then the oil pressure is a bit low. The coolant temperature shows low.. but the motor seams hot ? The transmission fluid should be changed.. as well as the diffs. It’s good to “reset ” these things so there is no worries. It looks like the wiper motor was replaced .. but the wipers don’t stop in the park position.. so that will be a little project.
So I suppose this was considered a good stereo 30 years ago ? But it sucks now. I don’t think I can find my old cassette tapes ! Do I want to .. ? Any way the speakers are tired.. and I would like to use my satellite radio. Maybe next year I’ll deal with this. It wouldn’t be hard to change. However the mechanical stuff is top on the list. I also need to make sure the Raider is good for the trip to Quesnel. That is where my good friend goes hunting.. and this I’m going too.
Oct 6 2016: The new tires are on and I’ve checked out the brakes, tie rods, suspension and bearings. We also adjusted the choke and idle.. As well I’ve installed a mount for my off road GPS. and I’ve set up my Sirus radio too.
Oct 8 2016: I got a bit carried away while cleaning up some things… and installed a winch, LED flood lights, a second power plug, a USB charging port, and while I was at it .. a switch and wiring for my daytime running lights. ( yet to come),.
This is temporary , till I build a nice mount and bush guard.
The center console was the perfect place for these new conveniences. I now know how to remove the lower dash. Handy when I change the stereo, install the keyless locking system…
Carry on:
I drove the Raider to Kelowna and back on Sunday.. that was a good test for long hauling.. Found out that the fuel gauge is not much help.. It goes rather quickly to a quarter tank.. and stays there for awhile. But I got to test fuel consumption. The 60 ltr tank should get me about 450 kms.. on a good day. so I’ll make sure to record the kms and reset the trip. The choke is still an issue ! I either have cold start ability and high idle… or low idle and no choke.. I’ll keep trying to get it right. I replaced the fan belt today.. and I checked out the hubs.. to make sure they work.. Good to go. In two days I leave for a 10 hr drive to were my friend is camped.. towing the small trailer with my quad.. we will see how that goes.
Oct 24 2016:
Well I’m back from the Caribou adventure. Despite the minor inconveniences, The Raider did very well. I was towing a trailer with my quad in it. Weighing at least 800 + lbs.. The Raider can pull that.. but it really slowed down on the hills. Also fuel consumption was high. And since the gauge is not a lot of help.. I stopped lots for gas . Also for cold starts I would manually move the choke on, and then back it off once the motor was running good. This works good.
Here’s a photo of a different Raider. I took the Raider up to the hunting camp near Barkerville. We only spent a week there, I got to do some quading and some roaming around in the Raider too. Here’s the video I made….
And here’s the second one..
Raider in the willows
Most of the trails were badly over grown with willows.. Thank goodness for the skid pans ! The Raider can just push through. I’m impressed with it’s ruggedness. I drove through deep water.. up steep hills .. and over rocks.. no problem.
Things to Fix:
Fair enough.. you can’t buy a 30 year old vehicle and not expect to do some repairs. After driving the Raider for a long trip.. I find a few things.. So let’s start with the “much needed” and work down to the “just annoying”
The choke and vacuum lines: This should be working and it’s not.
Front brake rotors: Warped badly
Wipers won’t park: could be the relay.. or an adjustment .
Noisy exhaust system: Should be replaced.
A few rusty spots to fix ( holes) : Next spring
Stereo ! would be nice to swap that out.
Rear washer: you can hear the pump but nothing comes out.
hazard light switch: missing in action
Squeaking seat: needs to be removed and fixed.
Jan 2017:
After driving the Raider quite a bit since the trip up north, I’m getting used to the routine of setting the choke then backing it off. But it’s still annoying. Shouldn’t have to do that.. So I did some research and found a replacement carburetor kit for my 2.6 motor. It will cost me about $450. BUT it will simplify things tremendously. An electric choke.. not vacuum. And it comes with a new serviceable air cleaner. I can take all the electronic / vacuum crap and toss it. Money is tight so I’ll have to save up.. and that will fix the first and most important thing on the list.
I finally got the Raider into my Nephew’s shop.. He’s a mechanic with his own business. Normally any vehicle I get would have been in there way sooner.. But the Raider is driving fine .. even in the very cold winter we are having.. He wanted to clean the carbon out of the motor with the Motovac system.. Knowing that the Raider was driven with the choke on.. and dieseling a bit, he figured this would be a good place to start.. Well turns out there wasn’t much.. The dieseling is mostly caused by the high idle and the choke problems. We’ve got the plugs out so why not check the compression of the motor ? I was surprised to find 150 psi right across all four cylinders.. I think that’s good. The motor has 260,000 kms on it.. maybe it was rebuilt ? Well whatever .. this explains why it runs good.. no mater what the carb is doing. And not consuming lots of oil..
While there on the hoist .. it’s a great time to look things over.. The driveline is tight.. no bad rust.. no leaks.. I only found a few things:
Since it got cold the brake master cylinder is leaking.. So that needs to be replaced.
I’m missing the last foot of the tailpipe.. I knew this already. and it will get fixed too..
The exhaust seal between the header and the first pipe is leaking. That’s and easy fix..
The right side rear shock upper mount had been broken off.. and there is wire holding the shock on ! seams to have worked but I will fix..
That’s it ! well aside from the front brakes needing to be done.. And I would be sure to check the rears as well. I could start work on all this stuff if I finished up what’s in the shop now.. but It’s been cold and my ambition level is low.. Spring could be very busy !
Also of note: I’ve been collecting some of the bits and pieces I need to “pimp” out the Raider.. I have the keyless door lock system now.. and I bought a used but nice Kenwood stereo. AND I got some nice LED running lights . Once I get the carb kit.. I will start the fixing up.. and that will start a new page for this post..
I have the Weber Carb kit now.. so let’s start a new page… shall we.
That makes the little guy mine.. OR.. Rob’s creative corner.. where I “pimp” my ride. I’ve already done some “pimpin” like the keyless locks, the new stereo. But.. I’ve got all the supplies to build a covered canopy for the back. Also I’ve got a new winch, the wiring and the metal for building a plug-in winch / bush bar.
Here’s is some of the stuff for the winch set up. The winch will be mounted to a hitch extension. This allows for a snow plow to still be plugged in.. or whatever ? This winch could be used on any vehicle with a 2 ” receiver. It will be operated by wireless remote, and just needs power.
And this is what I’ve come up with. looks a bit strange, but it’s designed to …. 1 – not hide the front license plate. 2- not sick out from the truck any further that necessary. 3- bush bar side extensions are plug-in and can be removed. The roller fair head mounts to the front, and of coarse you can still plug in a hitch.
Aug 2016:
Well I’ve put about 100 or more kms on the little bugger.. and there is a tiny oil leak .. I think from the oil filter.. Everything was on hold while we had our Camping / family reunion.. And the Carry was there..
But not pulling the fifth wheel.. Before I get back to finishing the Carry up.. I need my little trailer built so I can fetch tractors with the Carry.. So I’m pausing to do that …
Small Tilt Trailer
So I’m in no hurry to do those extras like the winch.. I’m using the truck every day for work.. I’ve done a new oil change and that fixed the little leak. Checked the timing , the hoses.. everything is good. And it’s running good too. This weekend my little truck will be in the car show at the City Park..
Here it is.. no prizes.. However someone saw it that wanted to buy it from me.. And a month later I have sold my little truck to a very happy guy. So on Sept 27 th 2016 I watched it drive away.. Going to miss it for sure.. was really handy. But time to move on..As I always do..
Well here it is.. with the tie – down rails removed. First thing.. weld the many holes up.
Color Scheme:
On the first page I had a mock-up of what I would like to see.. Since then I worked on the plan a bit more. And of coarse the frame ended up black. But I still would like some gray too. So the head rack, hitches, winch mount and stake pockets will be grey. The bottom of the truck will be Orange as planed. Like this….
The plan is to build a removable winch for the front that incorporates a bush guard. It could be moved to the rear as well if needed there. The winch will be wireless remote. Better get back to working on the box..
Using a combination of Por 15 and undercoating, I sealed up the underside. In the photo you can see I have primed the parts that get the orange paint.
And this is the first coat of orange. I will flip the bed over to second coat. The weather was not cooperating , It was cool and the paint took forever to cure. so it’s an overnight job now. also the paint is very thin for covering.. even after 4 coats you can see through it. Very frustrating.
So I fought with the paint.. wasted a bunch.. got a fifth coat on there.. but it’s not smooth.. I said enough and will leave it like this.. It’s a truck.. I like the color of this Orange.. so I’ll buy more and carry on.
I’m using spray on box liner that comes in a spray can.. it’s great stuff, and I can do the job quickly. I did run out with only a small patch left to go.. GRRR. Off to get another can.
With the bed of the box done.. we got busy and put it back on the truck. The wiring was all improved and a new trailer harness was installed. I’ve drove it around a bit and it seams the smoke has cleared. Once the rings and other bits get seated in this should be the case. I still hate the orange paint job on the side of the bed. I’m switching over to good old enamel paint. And I’m taking the time to brush it on carefully. Same for the orange.. I had a quart mixed to a bit lighter orange, and that’s what is going on the truck… by brush… carefully..
Here’s the tailgate with the first coat of orange. The white is done, three coats. I have also taken most of the dents out.. so it’s looking good. I’m thinking a black pin stripe dividing the orange and white.
Ok the box sides are done the stake sides are done..
The black pin stripe on the line between orange & white looks great. The spare tire is back in the proper place. Both batteries are hooked up. Still some little things to do.. but it’s usable now.
In fact there goes two bags of garbage… I can hardly wait to get going on the canopy.. But first there is more details.
The rear trailer hitch has been reworked. Lowered so the spare can be accessed, painted grey and mounted with heavier metal. Six bolts instead of Four. There’s my handy bumper / step plugged back in. Today I also got the aluminum plate cut and mounted to the tailgate.
Nice eh ! easier to load and unload over the tailgate now.
At this point the truck is done.. drives… got it’s bits and pieces back.. So everything now is fluff.. just stuff I would like to do but not really necessary. Like: tarp canopy, winch, I plan to finish the orange paint next month. I’m starting to build the winch mount.. We will CARRY on.. to a new page for this “extra” stuff.
Well not quite the same as the other projects. I have the good paint for the frame.. And it’s black. yup decided to keep it simple.. If I was to change to grey I would have to do a lot more painting. And the black undercoating that is all over could be a problem. As for the box.. need to fix the dents , paint the bottom orange, paint box liner inside, install stake pockets. I have also purchased new rims and tires for my little friend..
With a new motor and these.. we will be stylin.
Update on Motor:
So as it turns out it’s not easy getting parts for the motor in this truck. Apparently several of the internal parts were changed over the years …so.. the pistons I have take a longer connecting rod, narrow rings and a pressed in pin. The ring set that came with the truck are the wider / newer type. So I ordered a new set of pistons that the rings fit.. BUT the rods I have won’t work with the new pistons. Solution ! Get my old pistons machined to fit the new rings. And that only took an hour and $30. Wow ! Now it’s going back together.. So a new plan is to get the motor ready for install .. then do the frame. and today we got quite far.
Here’s the motor so far.. Still more bits to go on.. but it coming together quickly.
June 26 2016:
It really is time to get this truck back on the road.. So I’ve backed it into the shop and I’ve removed the fuel tank …getting ready for painting the frame. I’m using Por15 paint.. it’s the best at sealing the rust. Plus it’s a hard finish..
Here’s just the first coat. And with that I concentrated on the rusty parts. The important thing is to get the motor & trans back in.
Here’s the new battery box for the right side. This will hold another tractor battery and give me extra power for the winch. I’m installing a tube across the frame after the trans is back to hold the cables. No more attaching them to the underside of the box.
All painted now.. with the new wheels on the back. And the fuel tank back home , ( with four bolts instead of three). Ready for the motor… and the motor….
Is ready for the truck.. Tomorrows job ! The transmission is back on and most things ready..
The motor is in and running ! Ya hoo. Took a bit of fussing with the timing to get it running , but it’s all good now. Will it smoke ? Will it leak ? we will see. Here’s a new video..
Now there’s a few vent lines to hook up and some electrical stuff to do.
Electrical Stuff:
I had to remove the dash… which was a good thing.. Not only easier to get the wiring proper.. but the nut had come off the washer nozzle and very hard to reach. So that is fixed. I’ve installed a new stereo, a switch for the running lights , and new 12 volt power outlet.. and my favorite “keyless” locking.
I still need the find speakers that will work. I’m thinking motorcycle / ATV speakers would be a good choice. Because the space in the cab is tight.. And I decided not to put them on the door. So they have to be found. But for now everything is back in working order.. We even improved the battery hook -up wires. And better ground. So the box is next… New page for that…
Soo.. I actually bought this little truck for my business. I’m doing a lot of running around picking up repairs and getting parts.. Using my big truck with the BIG motor is costing quite a bit. so now I can buzz all over the valley for cheap. The little truck has business insurance on it. On the first day of having it I went out and picked up a lawn tractor for repairs.
Look at that.. actually fits with a bit of room to spare.. but shows how small the truck is.. Both Dave & I with the tractor.. no problem. so for the business Perfect !
Side by Side ?
Ya.. It can be. This little truck has a 550cc motor with a low geared 4 speed manual transmission. 4×4 with hi / low range, diff lock, auto hubs. It’s lifted two inches. Has 12 inch wheels like my quad.. but they are skinny.. The whole truck is only 54 inches wide.. Narrower than some of the side by’s in our club. So fitting on a trail.. no problem. Now here’s the bonus ! cab heater ! licensed for the street ! Rain is no problem.. No one wants to steal it daily.. Yes that’s a problem with ATV’s.
Poor Man’s ?
Ya.. With side by’s costing 14 grand and up.. and even a used one is more than $6000. This little truck is a bargain. These are quickly catching on with the hunters.. because they carry more. It’s fun to drive too.. and does not need a trailer to pack it home.
About This Truck:
The odometer shows 24700 , but there is no sixth digit. And since no one drives these much on the highway, we will presume the worst would be 124,700 kms. That makes sense due to the motor needing new rings. The motor is a three cylinder 550 cc Suzuki ( not a motorcycle engine) but similar to what was in the Sprints and Swifts. These little motors rev very high to produce the power needed.. So the rings tend to be the first thing to wear out. The motor uses a carburetor and simple points ignition. NO electronics ! not even a warning buzzer for seat belts or key left in the ignition. Very simple to work on.. I would say the only complex parts are the tons of vacuum hoses from the carburetor and the relays / solenoids that activate the differential lock and front hub lock. YES push button hub lock.. don’t have to get out and turn in the hubs. And it all works perfectly.
The interior is in perfect condition.. Just the way it came from the factory. I will change out the “mono” AM radio for a better “stereo” and two speakers instead of the one. I’m going to change the cigarette lighter out for a proper power point plug. Also I’ve added LED day time running lights to the front with a switch on the dash. Not much room in the cab.. so have to be careful what I add.. cup holders would be nice.. but I haven’t found a place yet. As far as the body goes.. there is very little rust.. nothing like the rust holes in a Sidekick.. or any of the north American models. These seem to be better steel. Just a bit of surface rust that rubs off.. Not bad for something 26 years old. I have a few dents to take out too.. So away we go….
A bit of Fixing :
I had some spare time ..and I wanted to polish the doors and box sides before I put decals on. But I got a bit carried away and did some touch up painting too. Just to get rid of the rust.
May 24 2016:
Time for a Motor Makeover:
I’ve been driving around for a few weeks now.. I love it.. fun to drive.. And it runs great. I’m getting used to the right hand drive. But It smokes ! a lot. and I don’t want to plaster my name all over a smoking truck.. So now that the shop is free. and clean.. Time to fix the motor.
There are two ways to get the motor out of the truck.. Fastest is to use a hoist and drop the hole shabang out the bottom. The other is to remove the box, and remove the transmission and slide the motor out the back. Since I have no hoist in my shop… I’ll remove the box.
And that is just what I did.. Look at how easy it is to get at stuff.. Plus I want to clean the dirt and the rusty bits while I can.. even throw some paint on the frame.
Even though the truck is simple compared to newer vehicles.. there is a rats nest of lines to deal with.. Next step is to give this mess a bath.. And some short videos too.
I’m not the fastest mechanic by any means.. so I expect the truck to be out of commission for a least two weeks. I have other things to do.
May 27 2016:
All the bits are here now. The new 13″ alloy rims, the gasket set for the motor. The power keyless locking system, The stereo too. So I’m not waiting for anything.. Right now the transmission is out on the floor.. and the motor is coming out in a day or so. I’ve also been thinking about some painting. My logo will be on the truck.. and I would like to improve the look. And be unique ! So I’ve come up the idea of following the Kubota color scheme. Orange and grey. I’m leaving the cab mostly white.. But I’m painting the frame and it’s parts grey. Then running an orange stripe down the side .. which includes the lower part of the box. Here’s a mock up of the idea.
I haven’t drawn the frame in the picture .. but it’s the general idea. I also included some wood side boards. I would like to do that too. So add to all this the nice new rims.. and we are stylin !
I’m thinking the motor work should be on a new page.
Motor Work:
Now that the motor is out and in the work stand.. Time to talk about that..
Wow that’s a huge motor ! And.. it was very easy to pull the motor out the rear.. onto a piece of plywood.. once you remember to disconnect all the hoses. In fact it was faster than I thought.. Took longer to get it mounted to the work stand. And so I did a lot of careful removing of the bits..
Here’s a short Video on the progress…
So the motor sat there on the stand for a week… maybe a bit longer.. Seems I’m busier than I want to be..
June 7 th 2016:
Finally got at the motor.. Dave came and in a few hours we had nothing but a naked engine block. Everything is laid out carefully on a table. It’s sure hard to tell there is anything wrong with the motor.. The cylinders are perfect. All we did was a quick honing to take the shine off. Dave’s gone away for the week, so the plan is when he comes back I will have all the parts clean and painted.. ready for re-assembly. All new gaskets / seals/ rings and main bearings. The top of the motor was done so not touching that.
As you can see I’ve cleaned and painted the block. Yup Orange. ! That’s part of the color theme for the truck.
Here’s my table full of goodies.. And …
Here’s the new & improved oil pan.. Grey.. once again following the color scheme. A lot of cleaning , polishing and painting.. but look at the bits & pieces !
As before the whole motor block is orange. The exhaust is completely painted with extreme high heat silver ( better than rust) . I decided not to paint the transmission.. It’s aluminum.. but I did paint the rusty steel parts. I am ready for re- assembly on Monday.
Monday June 13 2016:
We got the crank back in with the new bearings and seals.. But when we were changing the rings we ran into problems. The new rings do not fit the pistons. ! So I did some phoning and will have to wait now for genuine Suzuki rings to come. So The motor will have to wait once more .. But if I’ve gone this far I only want it done properly. I’ll switch gears on the truck and fix up the frame and box.
All Primed and ready for the color. I had trouble getting the color I wanted. So I settled for a Honda Civic color .. interestingly a slight orangy kind of red.. very different. Lots of pearl in this red.. so I’m hoping I like it.
So far I do ! Have to wait 30 min and then the clear coat..
This is where I realize I’m not a good painter.. In my lust for laying the clear on .. I got a few runs ! Damit.. ! On the second coat. So Hopefully they will polish out.. This color is going to look different… in different light. looks orange here.. after I turned off the halogen work lights. Going to be interesting to see it outside.
Anyway It’s looks good with the black trim. You would have to take apart stuff to know it was once white.
May 10 2016:
The Suzuki got kicked out of the shop for a month while the lawn tractor repairs were happening.. And now I have sold the blue Tracker.. and have potential buyers for this one too.. So ! Finally got the Suzuki back in the shop.
Welcome back.. time to Get R Done. I’ve transferred the insurance from the sold Tracker to this guy.. so once we are on the road I can get a new window. and I’m determined to keep the momentum up on the finishing. I’ve now got the exterior all back together.
Bumpers, grill, rocker panels and mud flaps on done. And the mirrors too. So now I’m moving to the interior. The power locks are first.. The carpets and the rear door panel all done now to.. I’ve been working on the dash.
Had to wire in the locking system.. and install the new muti-media stereo. The ash tray is going back. Only a USB port and a 12 volt power plug. I’m keeping it simple.
May 19 th 2016:
I’ve been busy.. Got most of the interior back in.. and the locks working good… just the door panels and the seats to go.. When I tested the electrical I found that none of the rear lights work.. Then I remembered I skipped over the broken wire behind the left tail light.. sure enough the connector was in bad shape.. So I rewired that and all is good.. Here’s a new video..
All Done !
I really put in a full day and got all the rest of the Sidekick finished up. All that’s left is to take it to Kelowna and get a new windshield.
Looks good runs good.. time to sell it.. and move on..
Half way through March now.. Still waiting for the power locks to show up.. but I can carry on with the interior. Big job changing the all white to all black. Well not all.. but lots. what’s not covered with a panel or trim.
Needs a second coat but you get the idea.. I don’t want any white showing..
Here you see the black panel that surrounds the door and windows.. I like this accent, it justifies the black interior. Again once this paint is cured the doors go back on and the side windows too.. I now have the power locks to install in the doors.. I can put the headliner back as well..
Here’s the headliner back where it belongs… All clean and the two little rips repaired. And it smells better too.. I found mouse poop up behind the liner and yucky batting for sound proofing.. All good now.
I have tinted the rear windows and they are also back where they go.. The plan here is to seal out the dust and make it easier to mask off the windows. There is still lots to do inside .. but it’s time to get to the last of the body work and get the Zook painted.
March 23 2016: Exterior fixing.
Today I got busy and installed the rear door gasket, and the door sill moldings. Then set to work on the fenders. The new left side fender went on without a hitch.. fits great… no more binding on the door.
It’s always a pleasure working with new parts that FIT ! The right side fender however was a bit of a challenge. There was too much gap on the lower part of the door. I made the bolt holes a bit more oval.. and got that gap to a reasonable one. Banged out some dents and it fit good.. The hood did not fit good. So I removed it and made some adjustments to the hinges.. Fixed the hood prop too.. I can now move on to the yucky stuff.
Turned out not too bad. In two days I had all the bodywork done.. I’m not being fussy with the rocker panels because they are covered with the plastic trim. And the rest was easy too. Talk about color change !
I decided to paint the yuckyness inside the fuel filler. Normally I would have used the black here… But I had some red spray paint… so it may not be a perfect match to the red I have mixed for the body… but I can live with a little difference. I saw a nice yellow Tracker for sale . Nice until you open the door and the original light blue color was everywhere. Not Cool ! One more video before painting
First I need to finish taking things apart. got the dash out..
Some house cleaning needed here.. yuk. Now it’s easier to see the floors. The only thing I found behind the dash (other than dust) was a stereo install gone terribly wrong. Doors and hood next. Oh and the ECU is clearly visible on the right. Totally original. No rebuild writing on the top and I have a spare.
Feb 13 2016:
I’ve had the Sidekick for a week now.. and making good progress.
All the doors and hood are off. The rear windows are out and in a safe place. Bumper covers off. I even got the headlights out. It’s been warm enough outside to use the hose. So I washed the dash, the bumper covers and the heat ducts. Those are things I can stash away where they will stay clean. Here’s another video…
Feb 16 2016:
It was so warm outside that I was able to paint the underside of the hood in the sun. I’ve also removed the two fenders and the front cowl.
Which leaves a very naked looking Sidekick. I now have the opportunity to clean and paint all the nooks. I’m painting inside the motor compartment as far as I can reach. I also built a new Battery tray.
The old one was in bad shape. This one will have the proper hold down and a rubber mat. As far as the fenders go… I’ve ordered a new left side one. The one that I took off is cracked and bent.. and not worth fixing .. A new one is cheap.
Feb 27 2016:
I’ve done a few things more.. but it’s been slow.. Distractions ! lots.
I’ve got most of the floor patches done. I’ve built new seat belt mounts on the rear fender wells. Welded in place. when I start chipping away at the rust more of the metal disappears.. So the patch ends up bigger than planned. That’s ok.. Surface rust you can grind and treat .. the Rotten stuff needs to be cut out..
All done the interior patches now… and I have a new favorite tool.
The air / hydraulic riveter.. yes. I rivet a lot of the pieces in.. cause it pulls them tight. Generous amounts of sealant.. and good to go.
Here’s the floor patch on the passenger side.. I also got the rear wheel wells painted with spray on box liner..
There’s no covering for these, so this is the way to keep them nice. Never used this product before… we’ll see how this works out.. it’s pricey stuff.
March 6 2016:
Last week we pushed the Sidekick outside and covered it to make room in the shop.. The Argo 6×6 snuck in for a quick fix.. and is still there.. but there’s lots of room to work on the doors.
Here’s the right side door.. I started on that one because the door skin was loose from the door and needed to be welded back in place. Other than that.. it’s in good shape.. Two dents to take out and some black paint and good to go. I’m still waiting for the locks to come.
so changing a white door to a black door is no big deal. The semi-gloss black is very nice.. hides imperfections better than gloss. I’m dragging my heals with the doors because I’m still waiting for those locks ! Weeks and weeks .. go by. Oh well I’m finished the right side door.. It’s all assembled ( except locks)
So it gets put by the door.. for later. This time I put the weather stripping back on before the final paint.. I’ll mask it off and it will keep the paint from dusting the door frame.
March 14 2016:
The doors are all painted and rebuilt , ready for the power locks. So I’ve put them aside tidied up a bit and moved the Sidekick back into the shop. Next is painting the interior. Time for a new page:
