Post Hurricane IRMA brake and body work!

If it doesn't fit in the others but is 60 series related, post it up.

Postby richw » Sun Aug 05, 2018 12:59 am

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Progress in the BVI!
On the house front a new purple heart roof is sat nicely on new super strong cast columns and ring beam.
Even Irma's ugly sister will not be taking this roof, there is rebar cast through every beam.

At last I have a few days to work on the Patrol.
Since hurricane Irma she has been under wraps minus the soft top which blew off!
New canvas is on the way from 'Old Grouch' military surplus...but for now it is time for a brake service.
I got new shoes and cylinders from Aussie e-bay with no bother at all.
I really only needed new rubber wheel cylinder seals on the front but they are tough to find eh?

With only 55 K (Km) on the clock I found all the drums in great condition, a good start!
Getting into tomorrow so pics to follow.
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Postby mad4hws » Sun Aug 05, 2018 6:02 am

Nice progress!
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Postby RiverPatrol » Sun Aug 05, 2018 9:39 am

Nice to see that you've got some time to give the Patrol some love, and that you now have a roof to withstand the rest of the family.

Brakes are always seem to need attention on a Patrol. Yes, replacing the whole cylinder is about the only way to go anymore; individual rubber parts are so scarce to find. But then she should be good to go for a while. Thanks for the update, and pictures!
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Postby richw » Mon Aug 06, 2018 5:11 am

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OK, a productive afternoon yesterday.
Changing out the front brake cylinders is actually a very enjoyable job, the last time I did this was 25 yrs ago on my old 'more wood than metal' patrol.
If I was to pass on one tip it would be to hold the bare cylinder minus both studs for the top, just fit one for the sides...and fit the brake pipe first. It's so much easier to get the thread started with a 'loose' cylinder. If the pipe is not alligned perfectly it can be a real pain getting the threads started once the cylinder is bolted in place. You need the one stud for the side one because access is challenging to fit it later.


Happily the rear brakes were in such good condition I just cleaned them up. I left the old shoes on the front too, plenty of meat left on them.

So, onto the carb. Can anyone identify the make?
Once I took this off the first ting I checked was the accelerator pump. Wow, that thing shoots a stream of petrol down the intake like a water pistol!
I've never been impressed with the performance of PV382 compared my Patrols of old. I'm sure my Y60 with the same P60 engine had a stock twin barrel carb?
One reason for poor performance could be the perished base gasket, see picture.
There's that notch! Should I be making a flat gasket with no cutouts in it?
The old gasket was so bad it's hard to tell how it was looking.
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Postby Esteban » Mon Aug 06, 2018 7:28 am

Your Patrol is a beauty!

Good tips about the wheel cylinders installation.

Regarding the carburetor, it's a Hitachi VHA. Your's is the model fitted after Jan-74 (it's in the 1980 Parts Manual). From your pictures it looks like the bakelite insulator at the base (looks like a gasket spacer) is missing. With this type of carburetor, from what I remember, you don't need to make the notch in the gasket, since there's a opening at the base of the carb.

I used to have a 74, but with the previous version of the VHA, without the solenoid or the vacuum solenoid. One additional difference with your setup is the carburetor base at the manifold. First time that I see that. I was never impressed with this carb, and the plastic cam at the linkage always wears to the point of creating a flat spot during acceleration.

Interesting to see that in the Parts Manual, what you have will correspond to models aimed for Switzerland. Does your air filter is with a paper element inside or is the oil-bath type? Please post some pictures when you have a chance.

Also, after reviewing your older pictures from 2016, the remote brake booster seems to be gone. Was that connected to the clutch maybe? That's something I wanted to try with my 74 at one time.
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Postby richw » Tue Aug 07, 2018 1:58 am

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OK, another busy afternoon.
The brakes are done, bled and adjusted.
Because she has been off the road for nearly a year I decided to check all the lights ready for the vehicle inspection.
A real can of worms!
I started by pulling all the multiblock connectors apart looking for trouble and spraying them with 'Corrosion X'.
I didn't find anything terrible, still no lights.
Next to the fuse box, cycle all the terminals, check fuses, replace one.
Still no lights.
The floor high beam switch has alwyas been dodgy, I pull that out and find the switch action is not very convincing.
By connecting the high and low beam feeds directly to the supply minus the switch...on come the lights!
One floor switch needed!
(any ideas?)

I decide to pull all the lens covers off to check all the minor bulbs front and back.
Check out the 'IRMA'ed' rear lenses!
Our house was wiped out by a twister within the eye wall of Irma.
Winds gusts were in excess of 260mph.
Debris was blasted past this rubber seal into the lens at about the same time as our roof was being completely ripped off and concrete walls were flattened!
Crazy eh?

Does anyone know why they used a twin contact bulb for the front side light when only one wire feeds the fitting?

I had to make a couple of gaskets to get the carb sorted.
That's back on and working, thanks Esteban for identifying it!
You asked about the clutch servo, initially I thought this was a seconray brake servo but I was wrong.
It is indeed a clutch servo, it looks like it grew there, a very nice addition.
The one downfall is hat slave cylinder rubbers don't last long
'The candle that glows twice as bright lasts half as long'.
I'll replace the seals in exchange for having a light clutch!
I have found that NAPA brake cylinder seals for a mini moke fit the clutch slave cylinder, the bonus is that you get two in a box and they are only $5.
(when is someone going to find front wheel brake clyinder seals by accident?)

Slowly getting there!
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Postby Esteban » Tue Aug 07, 2018 8:42 am

Thanks for posting all those pictures. A lot to comment since your Patrol is unique in some details. However, what has shocked me is the incredible effect of Irma's wind on places like inside the rear lamps. :shock: :shock: No wonder the extensive damage to the island. Hope everything is coming back in track.

Great tip about the seals for the clutch slave cylinder. It must be included in the compatible parts section.

Regarding the floor headlight dimmer switch, a quick search gave me a lot of alternatives. For sure you'll have to install a connector for it. A parts store should have one similar to this one:

www.amazon.com/ACDelco-D808-Professiona ... B000C9QXKA

The pictures and your description of the clutch servo are great. I can just imagine that soft clutch pedal in action. Now you're only missing the power steering! :twisted: Years ago I had my 65 with a similar servo, actually a Bendix Hydrovac installed in the single brake system, and over the years wondered how it will feel installed in the hydraulic clutch of later Patrols. You've answered all the questions. Whoever did that setup did a neat work.

The wheel brake cylinder seals can still be sourced. The reference I have is Seiken SC4518R. They are 1 inch in diameter.

The setup for the air filter housing and the spacer for the carburetor are definitely unique. I'm sure many of us are asking the question if our oil-bath type canisters can be replaced with the same paper element that you have although the housing looks slightly different. If you can measure the filter it will be greatly appreciated.

Thanks.
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Postby richw » Sat Jul 27, 2019 9:32 pm

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One year on, here we go again!
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Postby RiverPatrol » Sun Jul 28, 2019 10:43 am

Looks like some significant work being done!
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Postby richw » Thu Aug 01, 2019 8:42 pm

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Onwards I go.
It's hard to believe but there's a tropical wave off the Cape Verde islands that threatens us next week.

I hope that does not come to pass!
So, I have decided to attend to all things originally painted blue.
That means front wings are off and just about anything else in the way of getting a honest coat of paint on all the blue.

I'm learning more about the vehicle as I stripped it down.
Mr. Japanese original owner must have been an engineer. Any nut that would be an issue if loose has a splodge of yellow paint on it.
The clutch servo installation was almost like he worked with factory access, the clamps and the general installation looked like it had 'grown there'.
He was a 4WD buff because the stickers were still on the tailgate from annual meets.
I'm convinced it must have spent 99% of it's life in a garage, there is no rot.
Judging from the ashtray I think he must have died from the effects of smoking, leaving a family who had no interest in the vehicle and so it ended up in an auction house.
That's after a quick spray job and underseal liberally applied in thick sheets.

I have a new master cylinder on order and clutch slave and master in hand to fit.
There's a week long BVI holiday coming up, I have all the materials ready...I just need the storms to stay away.
here's a few pics.
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Postby RiverPatrol » Fri Aug 02, 2019 10:11 am

A vehicle previously owned by an engineer is a special find. It's nice to see your Patrol getting the preventative attention.
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Postby richw » Fri Aug 02, 2019 10:08 pm

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Another good day moving forwards, AND 'invest 96' mid Atlantic has fizzled out, happy days.

Here's some more pictures.

I really did not want to remove all the original paint but I guess nothing lasts forever.
It's a 43 year old coating. Sanding it back every blemish turns into a 'worm cast' of corrosion/failed coating.
I can't blame hurricane Irma for all the problems, I had already noticed rust pinnacles from the moment it arrived from japan.

I had presumed it had been sprayed over before being listed on the auction site, I still think that was the case but they single coated, no primer.

Whatever, it all has to be sanded back, inside and out, a lot of work!
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Postby richw » Sun Aug 04, 2019 4:08 pm

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Onwards we go.
I've used ospho in the marine trade for years but I have never used it on bare panels once they have been stripped or sanded back.
I left the sprayed coat of ospho on the bonnet overnight and was impressed to see every rust blemish neutralized into a raised hump of iron phosphate.
Wow, just a light sanding and ready for primer before the tin worm leaps for joy with all that metal laid bare!
I am now convinced that 'old blue' had been 'tarted up' for sale.
Spot repairs along the windscreen and front wings then a deftly applied clear coat.
The underside was just plasted with thick rubbery underseal, the upper floorpan the same but a green zinc phosphate primer went on first.
That stuff sticks like shit to a blanket!
Anyhow, it's all gone.
Of course I would love to be unemployed and wealthy enough to remove the body at this point and deal with the shitty rubbery/crazed underseal as well as having the whole lot shot blasted.
instead I'm simply taking what I can back to bare metal where it's needed and putting honest coats of quality paint on.
Can't do better than that.
The tart up job left rust trails and burst outs everywhere.
Hurricane Irma was probably a blessing in disguise revealing the worst of it.
It's not like we have a zero humidity climate here, but at least we don't need salt on the roads!
Frosts are very rare.

Now on to the exhaust system, I'm looking at importing 2" tainless components and then making it up as I go along.

A brake master cylinder is on it's way from Australia.
New clutch slave and master are in hand.
What could possibly go wrong?!
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Postby Esteban » Sun Aug 04, 2019 4:48 pm

Incredible amount of work you're doing. Great progress and tips. Definitely a thread to follow! :clap: :clap: :clap:

Maybe you should change the tittle... Some people might get scared of tackling their brakes after reading this!
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Postby richw » Mon Aug 05, 2019 9:11 pm

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OK, primer got sprayed today.
I'm still waiting for the doors and front wings to come back from being sand blasted.
They did wonders with the front grille, it looks like it has been primed but that's just the sand blasted finish.

I have ordered a 2.25" SS muffler from Amazon and two 2" SS pipe kits to make up a new exhaust system, it looks pretty straightforward.
I'm looking at a Motorcraft 2100/2150 carb with manual choke to replace the original. The engine will lose the original look and the big air cleaner but I'm hoping for better low range performance. The original carb is tired.
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