Category Archives: Other Projects

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1990 Suzuki Tin Top Page 5

Painting the Exterior…   RED !

Back to the first page.   Back to page 4

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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 orangey kind of red..  very different.  Lots of pearl in this red.. so I’m hoping I like it.

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So far I do !   Have to wait 30 min and then the clear coat..

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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..

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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.

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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.

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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.

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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.

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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.

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Looks good runs good.. time to sell it..   and move on..

 

 

 

1990 Suzuki Tin Top Page 4

Painting the interior:   Black !

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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.

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Needs a second coat but you get the idea..  I don’t want any white showing..

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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..

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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.

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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.

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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 !

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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

Time for a new page..   Painting    Page 5

1977 Argo 6×6

Jigger’s , Bazoo’s and Argo’s… oh my !

What do they all have in common ?  SIX  wheels .  YES.. but they also FLOAT !

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Honest hon… it followed me home… no matter how fast we drove..  it was still there !   But seriously it was planned.  I traded one of the Terra Jets for this Argo 6×6.   The 1970 Terra Jet  that  I did not get totally finished last year.   Too many Jets not enough 6×6’s.  The Jigger is gone now..   So room to fill..   We’ll see.  Now that I have one ..I thought I better understand these ..  And the more I understand the more I like them.

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Facts :   Argo is a Canadian company started in the sixties.  still here in Ontario, still making them…  still has a dealer network !   They make six wheeled and eight wheeled versions.  A new one starts at $14 grand..   The body is made of thick poly plastic like a kayak.  They are tough..  they float and go anywhere.   These are favored by hunters all over..  There’s room for two adults and two kids..  or a lot of gear.

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I really like the controls ..  easier than the Bazoo or the Jigger..  Steering is simply done by pulling back on the lever that’s in the direction you want to turn.  Go straight  is just the thumb throttle..  like my quad.  You can see the gear selector in the photo.. Reverse, Neutral and two forward speeds..   What’s not to like about that..  The tires are looking a bit worn out..  but this one came with seven newer tires so no worries there.

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An extra rim too..  Not sure how I’m going to change out 8 inch tires .. All the tire changers I have access to won’t go that small.

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Anyway it found it’s way into the shop.  I figured since I was waiting on the door locks for the Sidekick … I would take a few days and sort out the few things that prevented me from just going for a drive.  As you can see in this photo the first thing  is the missing wheel.   I had to order the proper wheel nuts , then I’ll put that wheel back on.. It’s flat but that will do for now..  Here’s a video I made….

Most of the stuff I talked about in the video is done.. I never found a carb kit for that carb.. but there was enough good parts and a new carb to get things working..  The motor runs good..  So here’s a new video ….

Still in need of a new choke control.. Then the motor cover can stay on..   Soon I’ll have to give it the boot from the shop so I can carry on with the Sidekick project.   So what to do. ?

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If I’m to use it I would want to address a few things..   To take this on an ATV ride  may not be the best thing.. It’s slower than all the Quads so they would be waiting for you to catch up.   Plus Argos have no suspension so my old body would protest a long day of only the tires and seat to absorb the bumps.   However the seat is soft and if the tires are inflated properly it’s not bad.   If a ride is to a small fishing lake..  then the Argo carries on where the Quad guys stand on the shore watching.. That’s cool.   But in order for me to consider going on a long ride I would want to fix a few things..  Now that we have looked it over, and used it  here’s my list.

  • New motor..  I have a 15 hp OHV new still in the box. comes with a new key start to replace the old mower key switch. Not that the Tecumseh is worn out.. but it’s old , can’t get parts and the charging is questionable.
  • Replace any worn out bearings and axle seals
  • Replace the chain tension idlers
  • Fix the filler tube for the fuel tank
  • Replace the throttle cable. ( it’s a bit short)
  • Replace the choke cable. ( it’s crap)
  • Re-route the muffler out the side. (it’s in the wheel well now)
  • And of coarse install the new tires on re-painted rims.

Most of that work would require removing the top deck from the Argo.. no big deal.. but it’s the way to do it..  Big job… and cost for parts.  On the up side… I would have a perfect Argo.

For now I’ll put it in storage:

2019:  I did sell the Argo shortly after this post..  SOLD

 

 

 

 

 

1990 Suzuki Tin Top Page 3

The Bodywork..  Fixin Rust:

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Frist I need to finish taking things apart.  got the dash out..

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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.

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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.

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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.

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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.

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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.

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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.

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Here’s the floor patch on the passenger side..   I also got the rear wheel wells painted with spray on box liner..

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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.

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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.

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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)

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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:

On to Page 4..

 

 

 

 

 

 

 

1990 Suzuki Tin Top Page 2

The Mechanical Stuff:

Back to the first page..  HERE

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I’ve ordered a new exhaust system, and a valve cover gasket.  So far.   Tomorrow we do an oil change and a complete inspection.  Who knows what else we find..  I do know there is an oil leak,  but not sure where.  I’ll clean the K & N filter..  turn down the idle, and see what happens.

At The Auto Shop:

Really the only things revealed from the inspection was the front CV axle boots, ( 3 of the 4) and the exhaust header gasket.  Since there is a little play in the CV joints, it’s a better deal to replace the axles as a complete assembly.  So we are doing that tomorrow as well as the gasket.  It’s a big job, so we need all day.  Today we replaced the muffler and tail pipe.  I also changed the oil and filter.  Then we tackled the valve cover.  When we removed it we discovered a broken gasket.  It was leaking oil out both rear corners.  Perhaps 90% of the oil we see all under the motor was from there..  Some other oil may have been coming out the drain plug!  the plastic washer was broken.   After installing a much better looking valve cover I had with a new gasket..  We fired up the motor and turned down the idle.  It ran smooth !  Really smooth.  Why the F**K was the idle so high ?  Who the F**K changed the oil last ? After all that I could not find any other things needing fixing.   We even got the plugs out of the diffs and the transmission.. oil in those is good.

Feb 11 2016:

I went to the shop early.  And while waiting for my help I decided to clean the underside of the Sidekick.. motor, transmission and parts of the frame.  All have oil on them.  Now that it’s clean any leaks should be easy to see.  While cleaning I discovered a loose U-Joint on the front drive shaft.  So I had another sent up.  Dave arrived in time to see me removing the drive shaft.  We pressed out the old and pressed in the new.  Done!  Then set to work on the exhaust gasket..  Took till lunch just for us to do those two things..  But we did get the two axles replaced by the and of the day..   The Suzuki is back in my shop.. mechanically sound … mostly..  I’m sure something else will pop up.

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So here we have the motor .. looks much the same except for a better looking valve cover.   Runs way quieter !  And idles like it should.  So what got done?

  • New muffler and tailpipe
  • New front CV axles with boots
  • New valve cover and gasket
  • New U-Joint for the front driveshaft
  • New gasket on the header pipe flange
  • Oil change and filter.

With the known mechanical stuff out of the way..  it’s time to Pimp..  No wait I’ve some holes to fix…. and other stuff.

Feb 12 2016:

Good news (so far) NO oil leaking onto the floor.  NONE.  Lets hope we have all the leaks fixed.   Onward to other things..  The seats have been a real thorn in my plans..  It would really blow the budget to have them redone.  So we came up with a solution.  Since this is the one I’m fixing to flip.. and I’m keeping the Tracker.. then the nice seats from the Tracker will go in the Sidekick..  and these bad seats will get seat covers for now.  I’ve ordered them, and I’ll install them semi permanently.  Now I feel I can make some color & design decisions.  Here’s what is planned for the sidekick:

  • New Red paint job exterior, with black trim.
  • Paint the exposed interior metal semi gloss black.
  • Re-upholster the door panels and rear panels in black.
  • install keyless power locks
  • New stereo and new speakers
  • LED interior lights.
  • LED driving lights
  • Tint the rear quarter windows.
  • Transfer the alloy wheels over from the Tracker.
  • Transfer the front seats over as well.

So all that said.. lets start a new page for the bodywork..

PAGE 3

 

 

 

1991 GMC Tracker Page 9

Final Page – End of the Project:

Nine pages!  could have been shorter if I want each post page to be longer.  But I don’t like to scroll down so far..  So this last post is a wrap up.. and thoughts on my second Tracker project.  The first being the 1989 Tracker I restored in 2008.  Please note this is the third Tracker I’ve owned.  I had a 1989 back in 2001.  I really like these little 4×4’s.  And I’m not alone ,  They are very popular, and when in good shape command a higher than normal price for a 26 year old vehicle.   Anyway I took this:

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Sad, beat up , not running , rusty and un-loved Tracker..  To this:

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Happy, bright blue, running, rust free and much loved Tracker.

It took three months of my spare time, and a modest budget to get to this.  I had a lot of help when I needed it from my good friend Dave and my Nephew Peter.   I was able to use Peter’s Auto shop for some of the mechanical work.  And his parts discount for all the parts that had to be purchased.  Otherwise this would not have happened.  I don’t have a hoist or the vast amount of special tools for auto repair.  I do have what it takes to make stuff look good..  I’m by no means a good body guy.. or even a good painter.. but I can do it .  Pimping things is what I do..  I tried to be reasonable with the pimping.. so I kept it to things I had on hand,  Like the LED running lights, and the power locking system.

I would like to do a recap list of what this Tracker is and what’s been done to get there.  I started with a :  1991 GMC Tracker 4×4, auto trans, power steering,  removable hard top, convertible.  First the Mechanical stuff :

  • Used but good motor swapped for non running one.
  • New timing belt
  • New belts
  • New battery
  • New valve cover gasket
  • New front rotors and brakes
  • New front axle boots.
  • New exhaust tail pipe.
  • New rear shocks
  • Used alloy rims installed
  • Service Transmission / flush and filter
  • Run injector cleaning  for 30 min
  • Oil change and filter
  • New spark wires, cap and rotor

Then there’s the stuff that makes it look pretty.  Remember I wrecked out a free 89 Suzuki .  These are the things that it donated:

  • The motor
  • Both doors
  • Hood
  • Tailgate
  • Dash and gauges
  • Steering wheel
  • Tailights
  • Speakers
  • Door switch
  • Heater fan rheostat
  • Front seat frame

And this is the other stuff I spent money on:

  • Used left headlight ( expensive)
  • New winch with remote
  • Repaired upholstery on the front seats
  • New lift cylinders for the rear gate.
  • Newer spare tire
  • New trailer ball
  • Sound deadening foam and rubber
  • Under felt for carpet
  • Lots of paint and undercoating
  • Power keyless locking system
  • USB, clock and power plugs

There was a few things that I had in my shop already.  I had bought them a while back.  Like the LED lights and the bush guard.

Although I’m  now driving the Tracker and consider it done..  There is a few things still that need attention and replacement.  The Anti lock brake sensor on the differential is broken. This causes the brake warning light  to come on.  They are hard to find.. and even harder to remove the old one.. WE TRIED.  The other thing I’ve noticed is the throttle kick down cable for the transmission is frayed.. not broken yet.. but could.   And I would like to service both of the differentials oil, but the plugs are seized bad. The windshield needs replacing as well, but that needs to wait till spring.  These things will be fixed as I get to them.

Conclusion:

The total cost for this Tracker is half of what it would sell for on the market today.  So the temptation to make a profit is there.  But this one and it’s features are on the rare side..  I much prefer the automatic to a standard.  And the power steering makes zipping around town so easy..  and I’m certain that on the back roads I’ll like both those things even more.   The hard top will out last any soft top..  and those are not as cheap anymore because of our low dollar.  Also the hard tops are in demand, and folks are always looking for used ones.  A new hard top is over a thousand bucks.  I would like to make a Tonneau cover  like in this photo below:

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Because I don’t care about squeezing 4 people into my Tracker I’m not bothering with the back seat anyway.  Also I like the idea of the sliding rear window..  like a tiny truck !  A mini Avalanche !  Too cool.  Ah but that can come later too..  I’ve ordered a new stereo that is just a AM / FM media player.  No CDs.   It’s also Bluetooth , so this brings the Tracker even more into the times.

If you need to go back to where this all started ..   HERE

1991 GMC Tracker Page 8

Page 8  The final work:  Almost done

Go back to page 1 ,  or just one page back to page 7

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Here it is back on the new feet, and all done except the canopy.  We pushed the Tracker forward for room to work on the tiny canopy.

Fixin The Hard Top:

I removed the rear lift gate so It would be easier to fix a few things.

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One of those things was the rear window defrost grid.  Both the connectors were broken off..  So I soldered them back..  a little messy but they work good..  And since I went to the trouble to wire this feature back up..  it’s nice to have.  I also repaired two cracks in the plastic where the hinges attach.

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Then I needed to have a look at the problems with the top.

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Both rear corners have broken pieces that someone fixed with resin… But they cracked again because their resin did not adhere to the plastic ?  I could easily peel the patch off.  Maybe they did not sand and clean good enough.  These corners where the gasket goes is the only part holding the top from flexing.  The mount for the lift cylinders goes here too.  I’m thinking a long curved metal plate would add enough strength to keep the cracks form happening again.  But first I must try to resin and glass them back together.

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I could use aluminum and put the plate on the outside to make a sandwich with the lift mounts.   But !  once the repair was cured it was strong..  Not so with the repair on the door..  The way the hinge is mounted wants to crack.  so I had to go back and use fiber cloth to make it stronger.  And adding thickness was a good thing too.  The door was too low.   Here’s a video I just did .. remembered I had a GoPro..

And here’s two “after” pics..

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Still a few small details left..  And a day on the hoist servicing the transmission, installing new shocks, repairing the anti lock brake sensor plug and a bit more undercoat.

Jan 28 : Took the Tracker out for a drive with Dave today..  All’s well.   So I made another video after it can back in.

All done for now..  Let’s do a 9th page as a wrap up.. and final thoughts:     Page 9 The End

 

 

31 ft Challenger Fifth wheel

Found !
Found !

Aug 21 2015:

Love at First Sight …

Was dropping a driver off while fetching cars in Kelowna.. and I couldn’t resist checking out the trailers on the small lot.  And there was a really nice fifth wheel that caught my eye..   As soon as I stepped inside I was in love..  And in love with the price too.   So I took some photos , ( one above included)   And when I got home showed them to Mo.   She too was impressed..   Not new.. nope.. 1997 in fact..  but one owner.. and they took good care of this unit and it showed.

Two slides
Two slides

When you see it you would think it was much newer..   So we decided to go for it.. We had the cash.. and the price was low..  So Dave & I headed for Kelowna and had a closer look..  everything worked as it should..   This RV ticks all the boxes for me , Aluminum framing.. truss roof..  large storage..  bigger fridge.  good quality throughout..  Built by Damon Corp..  who builds coaches..

 

Big Room Slide
Big Room Slide

With a flat floor, and hide a bed,  Real nice Table too !

Oak kitchen
Oak kitchen

With lots of cupboards.. even a pantry

Real Queen Bed
Real Queen Bed

Not a RV queen..  bigger..  with an opening window at the head.  This room has a BIG closet too.

Toilet & shower
Toilet & shower

Neither is cramped..  lots of space here.   The sink is in the hall.

Mo's corner
Mo’s corner

A nice comfy recliner too !

Bedroom
Bedroom

A different view of the bedroom..  storage everywhere..

Storage
Storage

The Pass- through storage under the hall / bathroom is very large.  Won’t need the back of the truck.

Improvements:

Not that this RV is hurting.   It’s just that there are things I like.   Roof vent covers are a must in my world.  The Challenger was “challenged” in this department. So three new vent covers have been installed, this allows you to leave the vents open all the time.   Can’t figure out how for 18 years someone would have to run and close vents every time it rained..  In fact the trailer has no gadgets or extra hooks…  None.  And looking through the paper work I realized that this owner was not handy.  Everything done was by the RV dealer.. $$$  And so no extras.   I have a list of extra things ..  and those vent covers were just the start.

  • The next thing done was the HUGE 50 amp power cord that is total over kill.  Those are only needed if you have two AC ‘s or a washer / dryer.  It’s heavy and takes up a lot of space..  So we took the twist off end and put it on a spare 30 amp cord I had.
  • I bought and installed a better handle for the entrance.  We now have three steps up … and getting older..  much better than the little handle that was there..  Most new trailers have these bigger handles.
  • New Handle
    New Handle

     

  • A nice wireless weather station was bought and hangs on the wall by the door.. So I know how cold it is out.. before I go out..
  • The very “dated” RV stereo / cassette player had to go.
Bye Bye
Bye Bye

Replaced with a nice Pioneer CD / multimedia  stereo,  USB charging ports and a volt meter.

Much Better
Much Better

And the stereo has a remote too!  Now that is very handy..  And I can see my battery condition at a glance.   On order are more things to improve the trailer..

Things that I ordered for replacing,,,

  • Plumbing vent for the roof  ( Done)
  • New city water hook up.  ( Done)
  • New water tank filler.  ( Done )
  • New Door keeper ( Done)
  • A ball / wheel for the top of the door so it won’t hurt canopy ( Done)
  • Outside shower.  ( Done )
  • New improved hot water tank bypass ( Done )
  • New outside 110 volt plug with new cover ( Done)
  • Longer gutter spouts
  • 5 new LED lights.

One of my pet projects was to modify the TV shelf in the bedroom..  there’s no way we would ever have a tv in the bedroom.. so I removed the side panels and made a sliding door.  Using deep tinted plexi glass I had been keeping forever.

Doors for cabinet
Doors for cabinet

This means we can put stuff in here and not see it or have it fall out..  Notice the nice clock too..  I like to know just how long I’m sleeping in.

Handy to have
Handy to have

The other pet project was installing an outside shower.  I had to move the plug over to make room.. so I installed a new one of those too.  This is where we always set up a table.  So having hot & cold water here is going to be mighty handy.   The Hot water tank works on 110 power as well as gas..  so I will most likely use it more.. seeing as your paying for power anyway.

Bought a 3rd Terra Jet

This is also a 453E  like my second one..
Has a body
Has a body

But unlike the second one .. this one has the body.  And the tub is original except for the missing bottom !   Yes someone cut the bottom off intending to replace it and ..never got far.   No biggy that’s half the work done.

Not floatable
Not floatable

All the parts & pieces are in bins.. ALL  taken apart..  Again that’s half the job done !  Win Win..  So what’s missing:

  • The motor.   However I got with it a 20 hp Honda.. Yessss
  • The Clutch..   which was most likely still on the motor.
  • The seat cushion..   But I got the frame !
A Hood !
A Hood !

Now… more importantly I got some things that I did not have !  Even though the 453e I got last fall has most parts, it’s was missing :

  • The Body !  and the motor hood
  • The fuel tank
  • the seat frame
  • The cover for the chain.

I was pretty stoked to see a fuel tank.. then not so much cause it’s cracked..

Tanks Alot
Tanks Alot

Fixable ?  I’ll try.  If nothing else it’s a good template to make a steel one.   The body like everything else needs repair..   I thought I was just buying some spare parts.. but I’m thinking this is a repairable Terra Jet..

All the terra jets are stored for the time being..  future projects when the mood strikes me.

Sept 2019…   This is the one that I chose to restore..  even though the bottom of the tub was missing I would replace it anyway.  The post for  That is  HERE

Terra Jet Page 6 ( The Re-Assembly continued )

It’s the beginning of March and it feels like spring out there..  But I carry on with getting the jet together..

The Rims
The Rims

I did get the tires off the rims.. and I did order new tires..  but about these rims.. the two on the left are real Terra Jet rims..  12×12 with a 8″ off set.  The other two are different..  I’m thinking that this Jet being the first production model they hadn’t figured a few things out yet.  Like the length of the rear axle.  Let’s just say these rims compensate for that nicely.

new tires.
new tires.

It’s very hard to source the proper tires that are used on the Terra Jet.. these come as close as I can..  and they are a good price.   Should arrive in a week.  Also waiting on more chain..  I used all ten feet on the front drive.

New chain tensioner
New chain tensioner

The new drives chains are on and we made a new idler sprocket for adjustable tension.  There is new nylon in the bottom of the chain trough too. So many parts & pieces were missing from this Jet..  Having to make a lot of things from scratch…  But that is also a chance to do it better .

Mid March:

And this weekend I went and got another Terra Jet all in pieces..   So here’s the Post for that..  HERE

I think it’s more than just pieces, I’m thinking a third Terra Jet.. could be had… the important stuff is there … I may just take two of the rims & tires..  and the best two tires I have from the 400E and keep the new ones for one of the other Jets..

Got the tires all mounted on the nicely painted rims..  Tubes in the tires will keep them good..  And I put the wheels back on and pushed the Chassis out the door for a photo.

Rollin rollin rollin
Rollin rollin rollin

YES..  getting closer to that drive..   That’s the proper Terra Jet fuel tank in the front.. needs a repair..  but that’s where it goes.

Drive System in
Drive System in

Getting closer.. If I wasn’t so lazy.. and took less breaks.. I might just have finished the jet today..  but it still needs wiring and the brake caliper installed.

Unfortunately this is as far as I got before the yard work was calling. It’s full on spring now and lots to do..  So I moved the Jet out of the shop and tucked it away.   Fully intending to get back to it in the fall.

Feb 2016…. Update:

In the fall I agreed to sell the Jet to a friend in it’s un finished condition.  To be picked up this spring..  So it was left under cover for the winter..  I had a look and it’s all good.. tires are still up and only a little surface rust on the bare steel bits.   So very soon it’s off to it’s new home..  Kinda sad I did not finish..  But I have a newer Jet that I can work on next winter.

1968 Jiger 6×6

Jiger
Jiger

Once again I could not resist a deal on something weird..  or cute.. or Yellow.  no wait my favorite color is blue.   Oh whatever it’s still cute..  it’s still got gears and chains and a motor.  I love it..  Don’t need any more projects..  This one runs.. not great but it runs.  Drove it into the back of my truck..  That beats winching or pushing  it into the truck !

It small as AATV's go
It small as AATV’s go

shorter yes… But it’s wider than 4 ft.. cause two wheels had to go over one wheel well.

  So welcome my little yellow friend to the place where old things get made new again… When I have time ..
New Home
New Home

Fact:  jigers where the first AATV’s made.  Fact:  made in Canada EH.  It is believed that these were the reason Argo’s were made..  And Argo’s are the longest production AATV.

Yes that's a piece of wood for a seat
Yes that’s a piece of wood for a seat

This little yellow guy is the last of it’s kind..  speaking of production that is.  1968.. last year for the jiger..  It’s just a tad longer than the first Jigers. (can’t imagine it shorter).. and it has a hydrostatic drive.   I’m a fan of hydrostatic stuff..   However..  this one I may not like..  as much..  Being old hydro units.. they are not as “refined” as the newer stuff..  They seam a bit “jerky”  Now this could be something else like the chains driping with oil .. yup ..  Skippity Do Da..  Or maybe the sprockets are worn..  Skippity Do Da..  Or when you break a linkage to one of the hydro units.. and are trying to drive with power to one side only..  and that side want’s the other side to help too…  Well maybe..  I guess I’ll know when I fix that.  YES I drove it about  50 ft from the truck when I noticed that the right lever was not doing anything…  Kinda drove in a big sweeping curve..  So Here’s what we have :

  • Newer 12 hp 2 cycle single motor , runs good , pull start only 🙁
  • Re Engineered ???  levers, with a twist throttle.
  • Wheels adapted to 5 bolt 8″ trailer wheels…  Yes Good
  • Good fiberglass body.. No repairs needed.  could use paint.
  • Missing seat ?   not hard to make one..
  • Key switch not hooked up.. ? I’m good with electrical.

Plus there is a few details that I could look after..   It’s one of those things you fix and use or really get into..  yes… restoring…  or maybe improving !   It will never be original again..  the T-handle control is gone.   I like the new lever set up that is there..  with a few improvements it may be great little runner..   OR maybe this is the one that gets the “Toro Treatment”  And by that I mean taking the drive system from this ……

EL TORO
EL TORO

And putting it in THIS…

EL JIGER
EL JIGER

You know the Toro Zero Turn is just a 6×6 that’s missing four wheels.  BUT..  the Toro is a proven work horse..   with sturdy bits.  The Toro goes fast.. and can change speeds and wheel direction in an instant.   Not so my little yellow friend… it protested when asked to do that..   The Toro has no hoses or cooler..or extra pump..  and the V-twin 16 hp Vanguard motor is both electric and pull start.

Power to spare
Power to spare

Power enough to run the hydros and a triple blade deck..   This is all very tempting..  The deck on the Toro is almost wore out..  I do not use this mower it was my Nephew’s  .. he has no more grass..  I have my Kubota..   He did use it for plowing snow ..but now has a blade for his Jeep..  so Toro sits … and Jiger sits..   And here’s another BUT.. I should give the Jiger a second chance..  Fix the linkage..  Clean and aline the chains.   Speaking of those chains… and those sprockets.

Chain Layout
Chain Layout

This is a diagram right out of the service manual.. and this is one side of the drive chains..   I see 4 sets of chains.. each side..  I also see one of those sets is unnecessary.  But only from my point of view.  Extra chains means extra points of failure.  I think this can be done with 3 chains and 2 less sprockets..  But it is what it is ..  and unless I’m totally changing the drive system it will stay like it is.

Update:  Feb 2016..

The jigger sat broken under a tarp for most of last year..  just too much going on..  when the chance to trade it for a broken Yamaha quad came.. I did just that..   It went back to the guy who owned it several years back..   He knows how to fix it.. In it’s place is an:

Argo 6×6

 

 

 

Terra Jet Page 5 ( The Re-Assembly )

We are almost finished restoring all the bits & pieces..  But enough to start putting things back together..

Frame back in
Frame back in

Back together again..  The newly painted frame goes back into the (painted a month ago) tub.   First is to get the axles , bearings and housings bolted back together.

Rear axle
Rear axle

The rear axle is in and sealed..  this is the drive gear side… Interestingly it’s adjustable for chain slack.  For the very short chain from the jack shaft.  This Terra Jet has three chains.. Something not found on 1973 and up models.. which only have one chain running between the front and rear axles.

Other Side
Other Side

This is the other side..  New bearings & seals.  The front is next.  Plus stuff like the jack shaft.

Meanwhile back to the steering:

Can’t assemble the front axles with first fixing the steering.  As talked about on page 4.   I saw a friend with a metal lathe today and made 4 new collette’s.

TJ76
New Collette

Here is one sitting where it goes on the steering tube.  Once the bolt is adjusted correctly the allen bolt will lock it in place… SLICK.   There will be a hole made and the collette will be welded in place.

Where they go
Where they go

This is how the 1/2 ” bolt will hold it all together in the outer steering cup ..  on the left is a collette test fitted..  Much better than a nut.. That flat surface is important for smooth steering.

Steering tube
Steering tube

Here above you can see the newly welded in place colletes.   Big gobs of weld.. Have to be strong.  Now isn’t that better than nuts welded on.   Time to clean up the mess and paint them..

Drive side (right)
Drive side (right)

Today we got the front hubs back on.. and the new steering bushings work great..

Left side
Left side

We also straightened out the rear  wheel hubs..  they bent a bit when we were using the puller to get them off the axle..  All better now.. I will be installing new wheel studs.   Imagine… have all the nuts on each wheel… so many things I’ve brought home have missing wheel studs or nuts..  Not happening..

Oh Oh…  I noticed a problem..  The front sprocket is not in proper alignment.

It's hiding in there
It’s hiding in there

If you look at the above photo.. you can see a bit of the front sprocket hiding in there..  and you can see that it’s too far to the right.. That means the chain will hit the welded nuts.   Oh darn !  The only way to properly fix this is to remove the front axle.   I assumed that this sprocket was in it’s proper place.  Not so.. And this may explain why there was no chain on the front drive.  It most likely broke.   So we had to take apart the front again..  Sigh.

your out !
your out !

Of approximately 3/8″ .. See that distance up to where the E-clip goes..  ya..  that’s a lot.   Tried to hammer the sprocket into place.. nope.  So off to the press and we pressed it off the axle.  Out comes the emery cloth.. and cleaned  everything good .

New set screw
New set screw

And I don’t want this to happen again.. so I drilled and tapped for a set screw.

Ready to go
Ready to go

Just need to slide the sprocket up to the E-clip.. and lock it  now.. and Then.. back together.

March 3 2015:

We got all the front axle back together ..and the steering too.

Complete front end
Complete front end

No play in the steering.. solid as can be..  It’s true rack & pinion steering..

The steering guts
The steering guts

Lots of grease on the parts..  Even did an EYE BALL alinement.   And we got the threads fixed on the rear axle and the hubs …with their new wheel studs are on..

Rear hubs..
Rear hubs..

Wee ha.. got a rolling chassis now..  if I put the wheels on…  They need the paint first..  … And this post is getting long.. time for

Page 6…  continue the re-assembly:

 

1994 Chevy 2500 4×4

Feb 2015:

1994 Chevy
1994 Chevy

I’m at it again…  changing vehicles.  After watching all the new ones on the lot.. come and go.. and driving the Dodge for six months.. It was nice to drive… yes..  But I’m seeing a lot of problems with all the gadgets in the new vehicles.   I’m seeing too much crap..  TPS sensors..  back-up warning sensors..  All very exspensive to fix when it starts screwing up… I’m going back to simple..  I bought this truck back in January… it was a good trade.. looked after well.. and I got it cheap.   So I just took it home.. parked it while I thought about what to do.. WELL  I’m keeping it..I’m fixing it up… and I’m going to use it !   Here’s the details about the truck:

  • 1994 Chevrolet Silverado 2500 4×4
  • Regular Cab Long box.  Seats 3
  • 350 V-8 with 4 speed auto , 4:10 gears
  • 213, 000 kms.  New Transmision
  • Features:  power windows, power locks, siding rear window, AC, Cruise, chrome bumpers & grill, box liner. towing setup.
I love to pimp out my ride !

And everything listed above is a good place to start. I’ll be adding :

  • Keyless remote locking
  • New multi media stereo with touch screen.
  • Back up camera.
  • Gull wing tool box.
  • Reworking the rack to include side rails and a removable rear rack for the kayaks.
  • Installing the fifth wheel hitch.
  • New pull out towing mirrors.

I know what your thinking… Rob your adding all those things that you said would break !  No.. not all..  and what I’m adding will be better quality.. and independent systems..  New vehicles have computers that run all those gadgets..  And to replace some of those things… the back up camera on the Dodge costs more than $300 to replace.. The very nice one I bought was $24.  The new stereo I’m getting is a Kenwood  for $250.  The remote locking system was $26.  The truck already has the power locks.. I’m just installing a box with an antenna  that will flash the lights and it has a little security light.

Remote Locks
Remote Locks

Here’s the lock system…  I have bought and installed these before..  they work good..   And these fobs are better than others I’ve seen.

Camera
Camera

And Here’s the Camera that I’ve chosen.. Color / night vision..   The housing is all metal not plastic..  and on the screen are the lines that help with the distances..   Only the price is cheap.   And !  factory back up cameras are just that.. they only work when you are in reverse..  Very annoying when you are maneuvering to hook up a trailer,  and that is what I want the camera for..  Therefore I will be having a switch on the dash to turn on the camera when I want it.

Mirrors

These are the mirrors that should be arriving any day.  Not power..  They fold away, and you just pull them out for towing…  Perfect !

It was a slow day at work so I brought the truck in for an interior wipe down.  And I took a few photos.

Window Guard
Window Guard

These photos are of the way I got the Chev..basically untouched.    That wood box has got to go..  And that mesh screen too.  I doubt I’ll be carrying things that would break the window..   I would rather have a good view.

Interior
Interior

All I’ve done is wipe it down a bit.. the carpet and seat need a good cleaning.. But that’s all.  As you can see it’s in great shape. And my favorite color for a “easy on the eye” interior…  Brown. 🙂

More Interior
More Interior

The only piece I found broken is the cover for the fuses. It’s missing a tab.  I can fix that.  or find one at the wreckers.

Door Panel
Door Panel

What no drink holder in the pocket !   you’re lucky to get any for this year..  but there is two (pull out ) on the dash,  so no worries.  Even though it looks great there is so much fixing up I could do to this truck..  The tailgate has a little bend in it..  The passenger side window is pitted from what looks like grinding too close.   The lights could use a polish..

Fender Trim
Fender Trim

And these fender skirts could use new paint..  Satin Black  of coarse.  And I would give the rims a fresh coat of paint too.  All this will be done in time.. But first it’s getting the mechanical stuff dealt with.  And once I’ve collected all my goodies I’ll set to work one day “Pimp’n”

The truck had it’s service and check up..  No problems !   Wow.  I thought for sure there would be something needed..  The steering is just me expecting it to be as nice as a new truck..  And the loud exhaust is just that … a loud after market muffler..  combined with the holes in the fire wall letting all the noise under the hood into the cab..  and Yeah.  It’s noisy.   I can fix quite a bit by sealing up those holes and adding some sound deadening in key places.

New Mirrors
New Mirrors
The last thing a bug sees
The last thing a bug sees

The mirrors came today and I had time to install them too.  A perfect fit and not too to hard to do..  These will be sooooo nice when towing a trailer. Remember they are manual adjust.. and you pull them out for towing… so cool and simple.  These same mirrors ( but power of coarse) are found on newer heavy duty trucks.     I’ve also picked up the new Kenwood stereo while in Kelowna ..  and I bench tested it last night.. Also  Perfect.  Just what I want.  But I’m not going to like it with the crappy factory speakers..  So I’m searching for some nice replacement ones..  I also got a smokin deal on a tool box for the back..$25.  Yup.

 

 

Terra Jet Page 4 ( the Frame Part 2)

Jan 19 2015:
Onward like we know what we are doing…

Today we did a compression test on the cylinders.  The results were good..  110 psi in both.  not the best but good.   We decided to fire up the motor again and see how well it would run with a gas tank.  I had the GoPro ready but pushed the wrong button..  so once again no video.   🙁   We ran it for a good minute and had to stop the gas flow to shut it down…  Then tried to start it again… nope. It’s flooding very easy.   Once the carb kit is in and the carb adjusted good that should not be a problem.   So I went back to reassembling the drive line and hooking the controls up.

Finished trans, clutch & brake
Finished trans, clutch & brake

Here’s the Transmission all done and secondary  drive, disc brake too.   I need a castle nut for the brake adjustment, but everything works good..

It bothered Dave that we could not re-start the motor…  So he wanted another try.   With this run the transmission is installed.

http://youtu.be/eHg8oGu8u5E

Here’s the promised video..  I think the belt is just a tad too wide..  it can stall the motor when you apply the brake.  Otherwise everything is working great.. as it’s supposed too.

Work has been slow as I think about the cables and try to find some ambition.

Brake & Throttle Cables
Brake & Throttle Cables

Got it..  Just a bit more welding and I’ll paint the frame..

I’ve also been working on the front hubs..  just to do something else.  They are all done now.  Cleaned re-greased and painted.

Front Hubs
Front Hubs

These are three times bigger and heavier that most Quads..  In fact these could work on a farm tractor..  The U-joints are the same as on my rear PTO on the tractor..  I can see how one could install locking hubs too.  Something to think about for the Jet I’m keeping.

Meanwhile back at the FRAME:
Improved Frame
Improved Frame

I’ve welded more seat support , a battery holder and new nuts inside the rear axle case.   Now it’s paint time.

Bottom painted
Bottom painted

Here’s the underside with a coat of Por15.  It’s a very hard frame paint for cars.  Not sure if this is better that good ole rust  paint..  After all the Terra Jet frame is protected inside the tub..  But water may be there too.. so. We’ll see.    Everything I do to this Jet is a test to see what will work the best..

Top side
Top side

All done now… And I’m reserving judgment till it’s cured.

Axles & Sprockets
Axles & Sprockets

I was in a painting mood.. so I got some of the other bits painted too.  And I turned some attention to the front steering.

Steering Boots ?
Steering Boots ?

Axle Tubes ?  Don’t know what to call them, and when you look in the Terra Jet parts catalog… they don’t either.  Suffice to say they hold the bearings and are an outside extension of the frame.  The steering pivots on these..   So yes they are very important.  The one on the left has one of the original collette’s still in place..  The rest are 1/2 ” nuts welded on !  What a mess.  No good…  I want to make new collette’s and have set screws to lock the bolts instead of someones holes with bent nails through them..  GEEZ.   These pivots need to be strong with a good surface area.  Think of the forces on here..   Continued on page 5

Terra Jet Page 5…  The Re-Assembly

 

Terra Jet Page 3 (the Frame)

Jan 1 2015:  

New years resolution…  to finish the Terra Jet..  for now..

The frame is a very important part of the Terra Jet puzzle.  Everything but the steering linkage is on the frame.  With a bit of welding you could add that too.  Then you could go cruising around no problem..  The tub is basically just the bottom of the body.. and the “boat” part too.  It’s a very cool design overall, and has stood the test of time.  I will be experimenting with a few “improvements” of my own, such as better pedals, linkage and a center floor board.

Seat position
Seat position

Here’s the frame up on jack stands ..with the steering wheel attached.  I’m testing the seating position.  Turns out a bench seat straight across will work best.  I was concerned that the steering wheel would be too far away for comfort.  And was considering a middle seat that was forward more.  Not necessary.

Old pedals
Old pedals

Also the pedals… these are just wrong!  However right foot braking will be necessary due to the narrowness of that part of the tub.  So a pedal on each side of the steering shaft.  But a better design, and just a bit closer to the seat.  The steel plate is just there to rest my heels on.  Plans do include a floor across this part of the frame.

Seat and Shifter
Seat and Shifter

Also turns out this is a good place for the shifter.  So I need to keep it here and I want to have the choke and key switch in this location too. Now it’s time to remove the unwanted stuff and weld on new stuff.

Control Freak:

I spent hours looking through my scrap metal and thinking about how to rig a better pedal set up.  I wanted them to be comfortable and the brake pedal to have good leverage.  I wanted the throttle pedal to be adjustable.  And both to have the leavers go down between the frame tubes.  I believe I have done all that!

Pedal set up
Pedal set up

looks a bit complicated..  If you took away the steering shaft maybe not so.  Yes ! I used an old brake pedal from a lawn tractor.  Upside down from the way it would be on the tractor..

Pedals
Pedals

View from the other side.. you can see the adjustments I have for the throttle pedal to make it comfortable.  The sheet of metal you see represents the floor and where it will come too.   So that should be fine..  But they have to hook up to the things they control.   So I figured I better mount the motor and the transmission and get all the linkages proper.  May have to weld more bits & pieces to the frame.   It’s looking like a cable would be better for the throttle.

The 340 CC motor.
Rupps / Kohler motor
Rupps / Kohler motor

Well here it is in place on the frame..  seams like a good place to work on it.  The Carb is off and the covers too.  The pull start and fan cover are missing.   I’m planning on making new ones..  because finding those would be hard.

Back of motor
Back of motor

This is a snowmobile motor !  Air cooled ,  high RPM , but very simple.  I hope the carb works good.  Before we get carried away though we need a few tests on the motor like we did with the BAZOO.   There needs to be good compression in both cylinders for the motor to run proper..  So that’s the first thing to check.   And spark !  won’t run without spark.

Tillotson carb
Tillotson carb

Here’s the Tillotson carb ready for a bath and inspection.   It was amazingly clean.  And the motor too…  I’m thinking it wasn’t very long ago that this ran.   Optimism builds.

Cone Clutch
Cone Clutch

Attached to the motor is of coarse the clutch..  this is an interesting one.  When I pulled the cover off I see there is these four plastic / weighted thingys..  I forget what they are called..  When the motor speeds up the weighted “Things”  push the two halves together engaging the belt.   Typical snowmobile stuff.   But usually they are metal rollers..  Hmmm.  This is very rusty and in need of lubrication..  Badly.  So I hope it will work.  I cleaned it the best I could and greased up the sliders.  Put it back together.

Jan 12 th :

Clean Motor
Clean Motor

Dave came over today so we could run the motor..   We could not get it to run for more than a minute… just whatever gas was in the carb.  But it fired right up…  so Thinking if we had a gas tank and proper adjustment of the carb.. away it would go..  I forgot to get a video to prove it.. so take my word.   But we now know that the motor will run..  I also found a throttle cable in my bike parts.  So that’s one of the next things to do.

The Transmission :

Same transmission as the Bazoo..  So I’m very familiar with this..   And like the Bazoo it works fine..  But the silicone job joining the two halves is poor and leaking.   So once Dave helped me get the secondary clutch disc off the shaft I was able to do a clean and Re & Re on it..

Cleaned Tranny
Cleaned Tranny

Is that clean or what..  I took my big sander to the two halves and flattened the surfaces good..  With better gasket stuff should be no more leaks.  Also the end of the change lever that rides in a grove was warn a bit so I built it back up with the welder and got a better fit.  These transmissions are tough..   This one is very old but works like new.

Like New
Like New

Ta Da…  Ready for installing..  after I put the secondary drive back.

Long Enough…. Continued on Page 4

Here’s the other Pages:
Page 1
Page 2