Yeah, yeah, I know, “I thought you were working on the floor bed?!?”
I was, but I looked at the upper tailgate and I know it’s gonna be hard to believe, but I found RUST! Shocking! Anyway, I thought I’d investigate and my OCD took over and then I was halfway through with taking it apart.
So what’s wrong? The inner tube of the lower frame is rusting BADLY from the inside out. Lots of surface rust on the outside but also rust has eaten through the steel inside out.
Do I have any hope at all that I can save it? A little, at least I’m gonna slow it down. This is one of those parts on a Range Rover Classic that rusts. Check the message boards…everyone has rust on their tailgate.
IF you buy a new upper tailgate protect it from rust immediately, do not pass Go, do not collect $200. If you don’t you will lose it to rust.
So the plan now is to paint it, I already have two coats of primer on it. The second is a daffy plan to pour rust preventative paint down the tube. Yeah, you read that correctly. I found a place to buy steel tube brushes. Justman Brush Company. I ordered the minimum of 6 brushes.
I’m going to run the brush through the tube until it stops the rust bits stop coming out. I’ve already poured “kitty litter”, you know the stuff that you use to soak up oil spills, down it until I was sure it wasn’t doing anything.
Once that job is done, I’ll reassemble. I’ve already bought all stainless steel hardware. I’ll protect the threads with copper anti-seize. This will hopefully limit the corrosion on the hardware.
That’s about it. If the brushes arrive by next weekend I’ll be finishing the tailgate and reassembling. If no, I’ll be working on the floor again. I forgot to disconnect the battery last weekend so this weekend I was reminded I have a slow drain somewhere in the wiring OR the alternator diodes have failed again. I’ll test next week by just disconnecting the alternator.
In this post I play a chemist and use muriatic acid to de-galvanize the zinc off my Z bar. Some time ago I sourced some Z bar to rebuild the rusted ledge of the floor panel. Welding galvanized steel can make you sick. It requires a well ventilated space and likely a respirator. There are lots of videos on the YouTubes that show guys welding galvanized steel. I’ve seen enough warnings to know I don’t want anything to do with it.
So using some of the acid for the swimming pool I decided to chemically remove the zinc. This too is very dangerous. So this is fair warning, don’t try this at home kids.
I got the zinc off in short order and got the Z bar double primed and double coated with black paint. I have no fantasy that this will never rust. I just don’t want it to rust through in the next 10 years.
I also got the sunroof drain installed. This was rewarding. Getting little jobs done is great. I bought a “step drill” and am now wondering why I didn’t buy one A LONG TIME AGO. This was pretty awesome. It was expensive at $58.00(US) for one that would cut mild steel.
My next step is to dry fit the panel to confirm the Z bar and panel will fit in the place it once was. I also reached out to my biological brother’s sister (we didn’t grow up together) to see what getting the panel stripped with her metal stripping service. I really can’t go forward without that step completed.
That’s about it for this week. Like and subscribe on YouTube. Subscribe to the blog so you get notifications. I had a hit with…
Well here we go again. I decided this weekend I was going to get the Big White Bus started and move her out of the shoppe. I tried to get her started and nothing. I didn’t hear the fuel pump kick on. That’s…a bad sign.
So I asked my son to help me test. I had him turn the ignition on while I checked the voltage at the fuel pump. I had voltage.
That eliminated a LOT of testing of other components. I had a bad feeling the fuel pump was crapped out again. Turns out I was right. It was completely varnished.
What the hell right? I put 5 gallons of fresh gas in it back in December after I replaced the rubber filler hoses. I guess that wasn’t enough fresh gas. I called my friend JagGuy and asked some “chemistry” questions regarding gasoline.
Is it possible that the gas in the tank is so far gone that it varnishes? Its possible was his reply. We came to the same conclusion that all the gas needs to be removed and fresh gas added. We also talked about fuel stabilizer. I’ve never used fuel stabilizer. I guess I’m going to use it going forward.
Who knows how long the Big White Bus is going to be laid up until I can get her running regularly? Not me and I’m the project manager! So fuel stabilizer is going to be all the rage. And I’ll start running her on a regular basis.
What is odd are all these “This [insert vehicle type here] has been sitting in this field for 30 years!!! Will it start?!?!” videos on Youtube. JagGuy surmised, probably accurately that most of the truly ancient stuff has mechanical fuel pumps. Throw in a fresh battery, hope the rats haven’t eaten the wires, and if they drain the tank and use fresh gas…maybe that’s how they get them started.
Otherwise I’m calling bullshit on all these videos. There’s no way 30 year old gas is any good. My gas is five years, old give or take a year, and it’s crap.
Now I’m going to be tasked with trying to drain the tank. And then what do I do with it. Do I dare trying to mix it with good gas and burning it in my cars? What do you think?
If you watch the video you’ll see a demonstration on how simple it is to fix the fuel pump.
Ever wonder what is inside of that gigantic custom-fit subwoofer box in the back of your Range Rover Classic…well wonder no more. I had to pull all the parts of the sound system out of the Big White Bus to investigate my rust issues.
It takes a few bolts to get it out but everything is easy-ish to get to and you don’t need any special tools. Take the amplifier off the subwoofer box. Then tackle all the bolts. Once the subwoofer is out you can get to the antique CD changer. Actually in 1993 a six disc CD changer was straight up gangster. My CD changer worked for a few years. It then got a little buggy. You could get it to work if you slid it out and slammed it back in. Most of the time it started to be available at the head unit after that.
It all has to come out. I have a new head unit. I have new speakers. I don’t know if the amplifier still works. I will have to sit down at some point and try to figure out all the plugs and see if the amplifier will be part of the equation. Having a working subwoofer would be a nice addition.
Once the subwoofer is out it takes 10 screws and a little gentle encouraging and the box will come apart. It’s a relatively simple setup. There is a dual cone speaker inside and that’s it. Mine as you will see in the video is toast. the cone has disintegrated. It is at least 30 years old probably closer to 33 considering assembly line technology of the day.
So the speaker will need to be replaced. In the video I speculate about the size but it turns out to be:
Cutout Diameter 6.5 inches
Top Depth mounting 3 inches
Bottom Depth Mounting 3.25
There are a LOT of speakers to choose from online. I went to Crutchfield.com. They don’t sponsor me, I wish they did, but they don’t. They have great customer service and the spec’s for everything are easy to find on their site.
I found a speaker that looks like it will fit.
That’s not a lot of money and 4 people think it’s pretty awesome. Mounting that is still a question, but I’m not worried. I will figure it out if that is the direction I go.
There is some debate going on in my head about replacing the old one with a NEW subwoofer. I found a Kenwood on Crutchfield that was not all that expensive.
ribbed polypropylene cone, sounds naughty….
It’s pretty small too. Just a little under 18x12x6 inches. I’m certain I’d have to cover the speaker cause it would almost certainly get damaged if I didn’t. I am confident it would fit in the space. But the real question outside of would it be better is…. am I really saving enough space to matter? I’m not sure I would gain anything. The space would have to be VERY creatively designed to take advantage of a few inches more here or there.
This gives us the cheaper option of just buying the speaker and figuring out how to wire it to the old AMP and the new head unit. Another plus of this operation was the elimination of the CD player gives me 12 volt switched power line back in that corner. That might come in handy, who knows.
I like tunes as much as the next guy. I even have a playlist named, “Can’t Be Too Loud”. It’s got some songs that you turn up until your ears bleed.
Van Halen’s Eruption
AC/DC Back In Black
Living Colour’s Cult of Personality
Beastie Boys Sabotage
Black Sabbath’s Iron Man
Wagner’s Die Walküre (Ride of the Valkyrie)
Carl Orff’s O Fortuna from Carmina Burana
There are more, but you get the picture…you probably have a list of your own. Whenever I hear these songs I turn them up to maximum volume.
Mostly today…I listen to audio books. Sooooo many audio books. It’s not uncommon for me to just drive, no music, just the window down and the sound of the engine and the tires on the road. That recharges my batteries almost as just sitting in the woods next to a fire.
There is a lot left to do to get the sound system installed. I’ve got to sort out the plugs and get everything wired up. The dash is still not installed. There is an order to putting the BWB back together…and the windshield needs to be first. I’m almost certain there is water leaking in and the last thing I want is to get his all put back together and still having water coming in.
That’s it for this week. As soon as I make a decision I’ll post it up and when I starting putting the sound system together.
Your sponsorship on Patreon would be appreciated if that is in your budget. Otherwise LIKE and SUBSCRIBE to the YouTube channel. Leave me a comment…I love talking to people about Land Rovers.
In this video I’m wrapping up the quarter panel rust tasks. I got a rattle can of “bed liner” sprayed on. It took the entire can! I will probably apply another application just to be sure.
The fender install went “smoothly” until I realized later that I forgot to plug the light cluster in. So I got to do that job twice. You only get to see the excruciatingly painful initial time. I saw a funny meme. The scene is a spring install with the narrator saying something to the effect that doing a job required on both sides of the vehicle.
First time 2 days and 89 hours.
Second time 29 minutes.
Ain’t that the truth though! So it’s been a hot minute (as my kids say) since I reinstalled a fender. So it went not quite so well the first time. I did cuss some. But that’s the nature of working on cars after all, is it not?
I talk about having to remove the glass on the passenger (starboard) side to complete the welding that needs to be done on the D pillar. I also talk about how outrageously expensive new window seals will be.
I did watch a couple of videos on how to do it. One of them is listed here:
The the hell is “duck water”??
So you can see getting the window AND seal out in one piece is going to save me a LOT of money.
Lastly I tried to start the Big White Bus. After charging the batter over night, she would not start. I got one cough, but otherwise a whole lot of nothing. The relay is working, but I am not hearing the pump run. I’ll need some help with diagnosing spark and electrics at the pump. So I put this off until next weekend when I can either get my buddy Larry over, or press my son into service.
I also tried out a new camera. My son had a GoPro Hero 5 just sitting around so I
confiscated itindefinitely borrowed
asked him if I could use it. Yeah, he’s not likely to get it back. I bought a new SIM for it. The SIM I was using doesn’t work in my Hero 11 and gives me a message about that. The Hero 5 did not give me a similar message so I thought it was good to go. It was not. So you missed out on 5 minutes of riveting footage of me walking back and forth in front of the camera and using a dustbin to sweep up and spraying bedliner. I’m sure it was the difference in this week’s video being a smashing success. Que sera, sera.
Today started out “cool”. At least it was cool for an August on the southern plains. The temp was lower than I thought and clouds covered the northern sky and looked to be moving south. This usually says we are going to get a break in the hot temps. We’ve been 24 days without rain. But with all things weather in Oklahoma, a full cloud cover did not offer any relief from the heat.
Regardless I need to make some progress on the Big White Bus if I’m ever going to drive her again. So after a little bit of trimming of the hedgerow between my neighbor and our house I got to work. Sticking with the theme of welding for this summer, repairing the rust in the fender seemed like a great idea.
I had four places in the fender that needed repair before I started today. I am now down to two. I repaired a small rust spot and repaired the corner of the fender.
I fixed one spot with a simple rectangle and welded it up in short order.
The corner was a complicated piece to fix. The patch for the corner was somewhat shaped like a trough? I don’t have the tools to make that happen. I tried hammering a piece of 16 gauge into a trough but really didn’t have any luck.
I got a bit of inspiration and decided that if I put the patch in and shaped it like one of the complex sides I could perhaps hammer it to fit the other complex shape. So with a bunch of vise-grips I got the patch in place and went to work with the hammer. I worked from the back of the piece to the front and continued until it was in the right shape. To say I was surprised it worked that well was an understatement.
I tacked it into place and began attempting to weld it in place. While not a perfect job, I think it will work and will keep the water out of the truck. I welded both the inside and outside of the patch. This was mostly in a vain attempt to make it a water proof solution. I know I’m fooling myself that it is.
So the final step in the fender repair well will be to give the entire underside a healthy coat of bedliner. I will do this on all four corners once I am done with the repairs.
I am still trying to source the bed panel. There are some in England, but I haven’t found one on this side of the pond yet. I have a Facebook contact that might do a bulk purchase and have some shipped over. I am hoping this works out. I am pretty sure I could order the panel and the support pieces but the shipping is ridiculous. Like, more expensive than the parts.
There were some issues with the video. The sound decided not to record on two sections. No camera changes were made…just no sound. I did a voice over for those sections. Also the shop was too hot for the GoPro to work and after two segments it shut down. I stuck it on the portable air conditioner to get it back to operating temp twice.
There are the last two sections for this fender, the “big hole” and “the strap” as I am referring to them now. Once those are done this fender is COMPLETED! Progress will have been made!
