1990 short bed resto; TDi, 3-link, coilovers, doubler, JK axles

[A-man930]

Mocked up an inner fender liner over the last couple nights. Figured the best way to protect all this fresh metal is to shield it from direct punishment. 

This might not seem like a big accomplishment, but I enjoy at least knowing that details like this are at least past the "proof of concept" stage.

Used this stuff:

https://www.speedwaymotors.com/Colored-Plastic-HDPE-Sheet-10-Ft-Rolled-1-8-Inch-Thick,1557.html?sku=910041-BLK

 

 

[GonzoTheGreat]

That looks like a perfect fit. How was the material to work with? Did you have to score it to get the harder angles? Or just use heat?

[A-man930]

2 hours ago, GonzoTheGreat said:

That looks like a perfect fit. How was the material to work with? Did you have to score it to get the harder angles? Or just use heat?

Yes, I'm happy with the fitment. 

Material is easy to work with. 

I scored it to cut the roll in half. Using a fine tooth blade on a hackzall to trim, heat gun with light pressure in a brake for the bends.  

[A-man930]

Broke through the floor when attempting to invert the factory transfer case hump. A year later, it's finally (almost) patched 

 

 

 

 

 

[A-man930]

Coming together.  Gonna test fit the seat later today

[A-man930]

Glad I did a test fit.  Had to make quite a large contour for the seat bracket.  Ended up grinding on the seat side to clear.  

 

 

 

 

[A-man930]

Finally found a glass guy to come and remove the windshield.  Urethane was super hard.  

Back glass is the next session... neither one of us are optimistic it'll survive 

 

[Pete M]

it'll be fine.   go slow, be thorough, and for the love of god don't force the glass in any way.

[A-man930]

Not sure what I expected, but it looks like I've got some work ahead of me.  

 

 

 

 

 

 

 

 

 

[Salvagedcircuit]

Thanks for the photos! Now I know what to expect whenever I do mine

[A-man930]

13 minutes ago, Salvagedcircuit said:

Thanks for the photos! Now I know what to expect whenever I do mine

Hope it's helpful. I could not cut the urethane with the Harbor Freight Tool I had bought. It was simply too hard. Had a glass guy come give me a hand.

[A-man930]

On 7/12/2024 at 9:35 AM, Pete M said:

it'll be fine.   go slow, be thorough, and for the love of god don't force the glass in any way.

 

Can't believe how smooth this went. Took a bunch of time, two dozen razor blades, soapy water, and the Harbor Freight hook knife. As a bonus, the glass was already separating from the frame channels in a section, which gave me the confidence to peel it all apart.

 

 

[A-man930]

@KYMJ, are you still around?  

I remember you telling me when I bought the truck that your son had ran into the back of the cab loading a four wheeler and tweaked the window channel. Happy to report that it's fixed 

[A-man930]

Put guts back in the transfer case and doubler so I could fab the shifter setup for them. Couldn't be happier. 

 

 

[A-man930]

[A-man930]

[A-man930]

Trying to tie up all the "engine installed" mockup items.  The TDi radiator hose arrangement is awkward for most swaps. It is possible to flip the housing upside down (as I did), but it does create a clearance issue... good thing I'm beyond the point of caring about hacking away sheet metal 😁

[A-man930]

Wife's rig needed some new skins, so I get the leftovers:

 

 

[A-man930]

I decided to tackle a section of body work. Going to try and get the roof and cab down to just below the glass channels covered in epoxy. 

Impressively, I've discovered there has been rust forming below the factory basecoat... 🙄

 

 

[A-man930]

Used some junk tube for mock coilovers to get it supporting its own weight.  Oddly exciting. 

 

 

 

[neohic]

It IS exciting though! I love throwing junk material and parts at things to get an idea of what you’re working with. It’s like big kid Legos!

[A-man930]

5 hours ago, neohic said:

It IS exciting though! I love throwing junk material and parts at things to get an idea of what you’re working with. It’s like big kid Legos!

Well said.  

[A-man930]

Got the bed out of the way.

 

 

 

[A-man930]

The POR15 I applied a few years ago hasn't held up very well... 

The powerwasher and the air nozzle peeled off a bunch of the second coat and quite a few spots had rust penetration below the basecoat.

 

 

 

 

[89 MJ]

My dad used POR15 on the rocker panels of his 2000 Silverado plow truck. The rockers eventually rotted away anyways. We’ve started using Chassis Saver instead. It seems to work much better and is only a one part product.