GamblerBound - '93 IH/Ward Toyhauler Build

[kidharris]

Originally Posted by Mr4btTahoe

Well after testing several ways to pull rivets, I decided the air hammer method works best/cleanest. Chisel must be sharpened to a point and plan on resharpening often.

Anyways... Got one of the ceiling sheets down and the old insulation removed... Then the mess cleaned up.

Plans are to finish gutting the interior over the long weekend and hopefully start disassembling the rear in preparation to move it forward 10'.

Anyways..





This is the method I used.

https://youtu.be/7NEs9i8Bmoo

What is the discoloration of the insulation?

Did your roof leak? Appears to be rusted metal.

[Mr4btTahoe]

Originally Posted by kidharris

What is the discoloration of the insulation?

Did your roof leak? Appears to be rusted metal.

The insulation was glued in place which is the black discoloration. The hatch leaked pretty good for some time so I've got some cleanup to do around it.

[kidharris]

Originally Posted by Mr4btTahoe

The insulation was glued in place which is the black discoloration. The hatch leaked pretty good for some time so I've got some cleanup to do around it.

Were there visible signs that the hatch was leaking before you removed the metal?

[Mr4btTahoe]

Originally Posted by kidharris

Were there visible signs that the hatch was leaking before you removed the metal?

No but I hadn't been on the roof. The hatch was cracked around the base pretty good so in a heavy down pour we had last week, it was dripping before gutting the roof. It apparently had been leaking for a while but went unnoticed.

[Mr4btTahoe]

Well, MT643 trans is on the way! IH Reman from LKQ with converter for $645 out the door with me arranging shipping. Trying to sort out how were gonna put it in. May cut a hole in the floor and use a hoist instead of trying to lift it from below. The floor needs repair anyways so wouldn't be a big deal.


Already have the correct flex plate sitting in the shop.



Anyways... more to come.

[cadillackid]

I slid mine under the bus... used 10k ratchet straps, 2 of them to get it up high enough to wheel a harbor freight tranny jack under it.. ratchet strapped it to the jack platform with thinner ones.. horsed it around a bit.. floor wasnt smooth so I used one of the 10k straps to the front axle frame of the bus to get it on my guide studs. (two 6 inch and 2 4 inch bolts with the heads ground off them.. used grade 5.. youd rather bend them than break them if something goes wrong.. adjusted the jack platform tilt as needed while I drew it in with the ratchet strap pulling the jack forward.. till I then could get a couple 2 and a half inch bolts in that drew it far enough in where the factory bolts fit in.. tightened it up all 12 and pulled out the jack.. and done...


-Christopher

[Mr4btTahoe]

This MONSTER showed up 24 hours after ordering. That's impressive.


You weren't kidding... still wrapped in the plastic from being rebuilt by IH.














One heck of a deal!

[Booyah45828]

Is the parking brake going to work?

[Mr4btTahoe]

Originally Posted by Booyah45828

Is the parking brake going to work?

Not sure yet. Will know in an hour or so.

If not, I'm not stressing over it. I'll setup a hydraulic parking brake and use wheel chocks (which is a wise idea anyways).

Sucks that I bought the kit though before knowing if it would work... Live and learn I guess.

[cadillackid]

moire than likely you'll fine that the flange on the 643 for the yoke sticks out further than the bolt-holes to flange relationship on the 545... pop the little plug out on the left rear of the tailshaft and shine a light down in, snap a pic lets see if you have a speedo gear or a tone ring


-Christopher

[Mr4btTahoe]

Originally Posted by cadillackid

moire than likely you'll fine that the flange on the 643 for the yoke sticks out further than the bolt-holes to flange relationship on the 545... pop the little plug out on the left rear of the tailshaft and shine a light down in, snap a pic lets see if you have a speedo gear or a tone ring


-Christopher

Looks to be setup for a gear.






As for the parking brake... no go. The bolt circle is quite a bit larger on the 643. I doubt there is enough meat on the parking brake assembly to drill the new pattern.

[banman]

That's an awesome price on a rebuilt xmsn!

I gotta ask -- was the shipping more or less than the xmsn?!

Can you make an adapter ring for the parking brake?

[Mr4btTahoe]

Originally Posted by banman

That's an awesome price on a rebuilt xmsn!

I gotta ask -- was the shipping more or less than the xmsn?!

Can you make an adapter ring for the parking brake?

Shipping was $180 through my work's fedex freight account. I was quoted $250 by LKQ so not terrible.


As far as the adapter goes... maybe. I'll play with that a bit later.

[kidharris]

Originally Posted by Mr4btTahoe

Shipping was $180 through my work's fedex freight account. I was quoted $250 by LKQ so not terrible.


As far as the adapter goes... maybe. I'll play with that a bit later.

Where did you buy the transmission?

[Mr4btTahoe]

Originally Posted by kidharris

Where did you buy the transmission?

LKQ Heavy Truck in Marshfield, MO


https://www.lkqcorp.com/location/lkq...ck-marshfield/


Just call their parts department and talk to Jason. Keep in mind it isn't a bolt in and go swap for a 545. Have to have the correct flexplate and parking brake, etc. Speedometer drive can also be an issue. I got lucky and got the one I needed but they don't know what they have.


They are all remans from IH.

[ol trunt]

I use a small Esab plasma cutter with a built in air source. It is OK but no great shakes. I had a self contained Miller that went with the shop when I sold the business and it was very good. I've found that scribing a line through the paint down to the metal makes the inexpensive plasma cutters like my Esab work much better. Looks like a fun project.
Jack

[Mr4btTahoe]

Hey alls...


Haven't been on in a while. All the nonsense going on has put the big bus on the back burner since we likely wont be making any long trips this year (not until late fall anyways).


Hoping to get back on it soon. We did finish stripping the interior and we scored a 26' parts camper (fairly new with everything working great). Got all of our insulation and such sitting here waiting for me to catch up.


More to come soon hopefully.

[Mr4btTahoe]

Back again and finally back to work on the big bus.


We nailed down our layout and framed the back wall this weekend. Also made the window delete panels (from repurposed interior skins).




















Turned out decent fit wise. Still have to secure them and seal them (why they look loose).








We ended up with 12' behind the wall (which means we'll only need to add a 2' dove to fit the jeep nicely on the back). By moving the wall forward, we put more weight over the rear axle of the bus.



That gave us a little over 13' from the back wall to the back of the driver's seat.


Here is the layout...



The area marked "SEATS" is the small bench seat that will be directly behind the driver's seat facing rearwards for the kids. Everything marked in red is movable. The main bed will pull out from the couch.. the ends of the sink and stove areas will have fold out counter space/tables.


It's snug.. but has everything we should need.


More to come. Going to finish deleting the roof hatch tonight or tomorrow and then start skinning the rear wall. Once the metal work is buttoned up, I'll be pressure washing the living space... spraying everything down with rust prep... and giving the floor a nice heavy coat of oil based paint.

[Oscar1]

That's a great looking layout you've come up with for having such a large garage area.
Keep up the awesome work.
Cheers

Oscar

[Mr4btTahoe]

Going to be resealing windows and such tonight... hopefully will get the door situation for the rear wall sorted this weekend.


Then it's on to the floor. Thankfully the living space isn't full length considering plywood prices currently. Should be able to get away with 4 sheets. Still kinda steep.. but oh well. It's gotta be done.


Pictures to come as progress continues.