Isuzu SUV Forum banner
1 - 20 of 97 Posts

·
Registered
Joined
·
612 Posts
...part 2?

Hello all. It's been a while, but I'm back with the original Trooper. It made a few cameos in my original build thread of the off road truck I built 11 years ago and chronicled on this site. My parents bought this one brand new in 1988, and it has never left the family. It criss crossed the country many times, often pulling a Uhaul, as we moved from place to place. It's been a very reliable truck, and my parents took great care of it. The interior, although slightly worn, is spotless. It has a little bit of rust around the windshield due to shoddy windshield replacements over the years, and a small amount in the rockers. I believe there is a little bit hiding in the rear doors as well that has been covered up by body filler from past repairs.
Last year, the clutch stopped working, so I towed the truck to my house and figured I'd change the hydraulics and send it back to the parents.
20190902_183751_copy_3024x2268.jpg
20190904_185133_copy_3024x2268.jpg

Crawling underneath revealed oil everywhere. It was leaking so much engine oil, it was impossible to tell where it was coming from. I did the only reasonable thing I could think of. I yanked the motor.
20190908_121512_copy_3024x2268.jpg
20191106_101048_copy_3024x2268.jpg
 

Attachments

·
Registered
Joined
·
612 Posts
While the engine was out, we scrubbed the engine bay for a few hours and cleaned up the frame rails and front end as well as we could.
20191106_162911_copy_3024x2268.jpg

Then we started teardown of the engine to see what was leaking, and assess the overall condition. The rotating assembly looked great, so we rehung everything and cleaned up the block for paint. All the bolt on parts were media blasted and painted.
20191122_143818_copy_3024x2268.jpg
20191130_084850_copy_3024x2268.jpg

20191111_160523_copy_3024x2268.jpg

20191111_161625_copy_3024x2268.jpg
 

Attachments

·
Registered
Joined
·
612 Posts
This right here is my little helper. She's a little superstar and learning quickly about cars. Just about any time I was out working on the ol Troop, she was right there with me.
20191206_144648_copy_3024x2268_1.jpg

Finished product.
20191201_180346_copy_3024x2268.jpg

20191214_183110_copy_3024x2268.jpg
 

Attachments

·
Registered
Joined
·
612 Posts
With the engine back in and running great, clutch hydraulics replaced and working properly, and Troop running around under its own power again, it was time to address the rust. With rust repair comes paint, so I figured to spray the whole truck.
20200403_191250_copy_3024x2268.jpg

20200405_133722_copy_3024x2268.jpg

Then it came time to pull the rear bumper. And the project went WAY off the rails. One bolt snapped and the other 3 just spun, meaning the captured nuts weren't secure anymore. That usually means...rust.
I'm familiar with rust. My other Trooper had rust. It had rust to the point of being a unibody truck with some rust hanging down where frame rails used to be. That one got a complete frame swap. Maybe this needed some investigating.
So I cut the bolts off and cut some holes in the crossmember to see what I could see. It wasn't good. The crossmember was full of rust flakes.
20200405_161043_copy_3024x2268.jpg

20200405_161055_copy_3024x2268.jpg

20200405_163314_copy_3024x2268.jpg
 

Attachments

·
Registered
Joined
·
612 Posts
You know what's next. It's time to yank the body. This went way farther than I ever intended, but I've always been a fan of overdoing something and not having to mess with it again.
The tub looks great, but of course the captured nuts on the rear body mounts spun and I had to cut the bolts off. I'm getting good at cutting body bolts.
20200614_105456_copy_3024x2268.jpg

Off she goes.
20200614_132935_copy_3024x2268.jpg

Upon inspection, the crossmember is really the worst piece. The frame is solid still. It has some rust flakes in it, but no cancer and no soft spots. If I found a completely rust free frame, I would probably swap it; but for now, I'm going to strip it down.
After a week or two of thrashing on it whenever I could, I stripped the frame down and got it to a good state to blast.
20200704_171026_copy_3024x2268.jpg

20200705_153146_copy_3024x2268.jpg

I think these were bump stops at some point in time. They're long gone.
20200705_153500_copy_3024x2268.jpg

That's where it sits today. I'd love to dedicate all my time to it like the old days, but I'm working 12 hour nights due to the Covid stuff. My one or two days off are usually spent catching up on house and family stuff. I'll update as I go along.
 

Attachments

·
Registered
Joined
·
2,969 Posts
That is looking great, I wish my kids would do something like that, but they just think I am nuts. Keep up the fantastic work!
 

·
Registered
Joined
·
1,453 Posts
Awesome. So glad there is still a troop in your life! Looking forward to watching this progress.
 

·
Registered
Joined
·
2,087 Posts
Diggin' it. Just finished my first and hopefully last foray into body mount nuts, bolts, and bushings. That trooper is going to come out the other end as good as it was fresh off the factory floor. Good luck!
 

·
Registered
Joined
·
675 Posts
So impressed with your work! Especially the speed in which you are doing this!

I also think your little assistant probably has more mechanical skill than I do. :oops:
 

·
Registered
Joined
·
612 Posts
It's been a few weeks, here is where we stand now. Frame is back from galvanizer, washed with degreaser.
20200829_162957_copy_3024x2268.jpg


To get paint to stick to zinc, you have to etch it. I used vinegar to wash it down, then a thorough rinse and into the garage for drying.
20200829_171613_copy_3024x2268.jpg


And finally, a good spray of epoxy. I used Summit Chassis Shield, I haven't used it before but I like the way it sprays out. It's supposed to be satin, but it came out glossy. 2 heavy coats later, she's ready to dress up.
20200830_131526_copy_3024x2268.jpg
 

Attachments

·
Registered
1989 Trooper R/S
Joined
·
4,176 Posts
Awesome, what a complete build. Don't remember following along before, but will now. Gotta see the end result.
 

·
Registered
Joined
·
452 Posts
Beauty work!
 

·
Registered
Joined
·
1,664 Posts
Your first build was literally one of my favorites. I'm subscribing to this one! Looking great so far!
 

·
Registered
Joined
·
612 Posts
Lower control arms have been blasted, but they had some flaky rust inside. They got a bath in some Ospho.
20200902_192747_copy_3024x2268.jpg

I used to be able to take parts to work and use their industrial blast cabinet. Due to changing jobs and not working nights anymore, I bought my own to use at home. Highly recommend. My compressor is slightly undersized for the air consumption of the cabinet, but as long as I go slowly it works great.
20200902_192803_copy_3024x2268.jpg

20200902_192824_copy_3024x2268.jpg
 

Attachments

·
Registered
Joined
·
612 Posts
Pics of progress over past few months. I spend most of my spare time wrenching on this thing. It has fought me every step of the way, but I think I've turned a corner.

20200905_162214_copy_2268x3024.jpg


20200905_163701_copy_3024x2268.jpg


20200906_140530_copy_3024x2268.jpg


20200906_182649_copy_3024x2268.jpg


20201010_091135_copy_3024x2268.jpg
 

Attachments

1 - 20 of 97 Posts
Top