'88 Trooper resto...

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Re: '88 Trooper resto...

Postby greasemonkey » Sun Jan 03, 2021 2:23 pm

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I wrapped up the exhaust today. I ran it similar to factory but altered the exit. I'm interested in seeing how it performs compared to the very restrictive exhaust that came off.
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Re: '88 Trooper resto...

Postby greasemonkey » Sun Jan 03, 2021 7:49 pm

Finally tackled the rear body mount captured nuts. At first, I cut a hole from the side of the crossmember to see if I could extract the nut and cage from the side. Nope. So then I just cut out the bottom of the piece it's attached to, cut the cage off, extracted the broken off bolt, retapped the threads, hammered the sheet metal flat, recaged the nut, and welded the cage on all 4 sides rather than just 2. Then the whole thing got welded back in. I didn't want to go this route, but it was better than drilling holes through the body from the passenger compartment.
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Re: '88 Trooper resto...

Postby paulevans76 » Mon Jan 11, 2021 10:30 am

Nice. I went wild cutting holes in the floor and then welding them back up. That undercoat is nasty stuff! Should have done it your way! :blackeye:
Scratch n Dent special 1991 Trooper S
3.4 V6 - Holley TBI, CompCams 252H, 1.6:1 roller rockers, +1mm DOHC pistons, MSD ignition, custom tune, "Ed Mc Special" 2.5" exhaust
MUA5 w/ 3.07's & fixed yoke
SAS - Waggy F D44 - 5.38's, RCV's, OX locker; Rodeo R 44 - Detroit, truss
Front Y-link radius arms, coils; Rear SOA, OME leaves, anti-wrap bar
35x12.50/17 General Grabber X3's on 17x9 Interco Birddogs
Trail armor and Warn XD9000
The White Whale - a temporary daily driver 1991 Trooper - 2.8 V6, MUA5 - stocker resto (sold)
1994 Samurai - 1.3 FI - OME suspension, 31's, 6.5:1 tcase, 5k milemarker SxS winch, more to come!
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Re: '88 Trooper resto...

Postby andy_sykes » Wed Jan 13, 2021 2:07 am

Any chance we can get an update? - Sorry, ignore that - my computer showed me I was on the last page, but was in fact still on the first page... That's a bit embarrassing

I'm thoroughly impressed with your progress!
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Re: '88 Trooper resto...

Postby greasemonkey » Fri Jan 15, 2021 8:43 pm

Sadly, I don't have a progress report. I've been working long hours 6-7 days a week and haven't had time to work on the Trooper. Maybe I'll get something done Sunday.
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Re: '88 Trooper resto...

Postby giusedtobe » Sat Jan 16, 2021 12:59 pm

You are going to have a brand new Trooper when you are done. You have to be the only one that's done a complete frame off restoration of one of these. Very impressed.
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Re: '88 Trooper resto...

Postby greasemonkey » Mon Jan 25, 2021 10:37 am

We finally got the body back on the chassis. I've been working the past few weekends but finally had one off and we got to work.
I left the well-stuck factory undercoating alone and sprayed Rusto undercoating over the top of it. In hindsight, I probably should have tried to remove all the factory stuff because it's kind of unsightly with the nice smooth black sprayed over, but it'll do the job. I also didn't want to spend a lot of time under the truck when it was on the cinder blocks and wood, but now that it's back on the chassis, I don't mind rolling around and doing a little more finish work.
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Body on but torsion bars loose-
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Torsion bars cranked to roughly ride height, and started plumbing the engine bay. Power steering, wiring, and cooling system are done. I'm working on the fuel lines in the engine bay, but my el cheapo flare kit just doesn't make good bubble flares and I don't trust my new hardlines to hold the rubber hoses without a good bead at the end of the tubing. I have a new kit ordered from Cal-Van, it's not the fancy hydraulic kit but looks like it'll work well in tight spaces.
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Ignore the disaster in the garage. I made an absolute mess with the undercoating floating all over the place, so once I get the fuel and brake systems functioning, I'll be able to get the truck out of the garage and deep clean it.
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Re: '88 Trooper resto...

Postby giusedtobe » Mon Jan 25, 2021 7:40 pm

Lol what you call a "Garage Disaster" I call a clean garage. :D
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Re: '88 Trooper resto...

Postby greasemonkey » Mon Feb 01, 2021 9:19 am

I worked 3 out of the last 4 weekends, so this is my tiny amount of progress. My freshly restored steering shaft:
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Re: '88 Trooper resto...

Postby greasemonkey » Thu Feb 18, 2021 9:44 pm

Some more progress and some more derailment. Trooper is back up and running well although I need to bleed the brakes for a 3rd time.
I stripped the interior (mostly) and found some rust. The front floor has surface rust that I'm working on wire wheeling and acid treating. The rear had what appeared to be mostly surface rust between the wheel tubs and floor. Further investigation revealed significant rust where the bed floor, wheel tub, and brackets meet. I started drilling out spot welds after stripping the factory seam sealer. I also stripped the underside of the wheel wells and found more rust.
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Re: '88 Trooper resto...

Postby greasemonkey » Thu Feb 18, 2021 9:52 pm

More pics.
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Re: '88 Trooper resto...

Postby greasemonkey » Thu Feb 18, 2021 10:09 pm

Last round.
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Re: '88 Trooper resto...

Postby greasemonkey » Fri Feb 19, 2021 8:22 pm

Tubs are out.
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Re: '88 Trooper resto...

Postby greasemonkey » Sat Feb 20, 2021 6:47 pm

Bodywork on the tubs today. I can't do much with replacing the metal for the bed floor because I haven't received my weld through primer yet, so I straightened the tubs out and added some patches to the rust holes. Not the prettiest, but these will be coated in undercoating underneath and Lizardskin up top plus carpet, so I didn't grind the welds completely flat. I left a little extra meat for strength.


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Re: '88 Trooper resto...

Postby greasemonkey » Sun Feb 21, 2021 7:42 pm

Today's body work adventures, in no particular order.
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Re: '88 Trooper resto...

Postby greasemonkey » Sun Feb 21, 2021 7:46 pm

Last for today.
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Re: '88 Trooper resto...

Postby greasemonkey » Sun Feb 28, 2021 9:46 pm

I had a whopping one day off, so I didn't get a ton done. I sprayed some weld through primer and cut out a little more rust. I got some carpet samples in the mail from stockinteriors as well.

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Re: '88 Trooper resto...

Postby BoiseTrooper » Sun Feb 28, 2021 10:02 pm

You are hardcore. I am enjoying following your build.

Great work!
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Re: '88 Trooper resto...

Postby greasemonkey » Sun Mar 07, 2021 9:10 pm

Weekly update. Metal is replaced, weld through primer sprayed, and tubs reinstalled. In hindsight, I would definitely use some panel bond to put the tubs back in rather than welding. The metal is hilariously thin. It's so thin that even on my welder's lowest setting, it blows holes in the steel without trying. I reckon I figured out why the factory undercoating is freakishly thick underneath the tubs. I have yet to seal the seams up, but maybe this week I'll leave work at a reasonable hour and get something done.
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Re: '88 Trooper resto...

Postby greasemonkey » Sun Mar 07, 2021 9:15 pm

Then I scuffed everything and sprayed Tamco DTM primer on all exposed steel. I had planned to brush it, but that didn't have the result I wanted, and I sprayed it instead.
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Re: '88 Trooper resto...

Postby hessmess » Mon Mar 08, 2021 11:29 am

Beautiful work!
86 Trooper (sold to brother) wrecked and recycled
88 Trooper (recycled)
91 Trooper, 3.1, bored .40, Cam, 4.3 TBI, roller rockers, Fiero valve covers, remote oil filter, LSD, 2.25 Cat back exhaust, BJ flip, 5 speed conversion, Round eye conversion-retired and parts donated to the new 91
91 LS Trooper, 5 speed, 3.4, bored intake, LSD, rebuilt using parts donated from the first 91
https://forum.planetisuzoo.com/viewtopi ... 15&t=81567
89 Pup LS Space Cab, 4X4, 2.25 cat back exhaust system, LSD, Jerry Cam, otherwise stock, painted Oct 2018.
https://forum.planetisuzoo.com/viewtopic.php?t=55081
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Re: '88 Trooper resto...

Postby DSUZU » Mon Mar 08, 2021 5:23 pm

Great work and thorough build. I love seeing this kind of restoration. Dennis
1991 LS Trooper 2.8 V6 5 speed conversion (Sold)
1989 LS Spacecab 2.6 5 speed 4x4 manual hubs, Rodeo torsion bars, extended shackles, 2" lift, K&N air filter (drop in), dump bed conversion, burgundy interior change, warn brush bar. Engine is bored .020 oversize and upgraded to 1994 pistons, head and EFI system.
Previously owned: 1987 Trooper II LS, 1989 Trooper (parts only), 1994 Trooper 3.2 Auto, 1997 Rodeo 2.6 5 speed, 1993 shortbed pickup 2.3 (project - sold) 1992 Rodeo 4x4 LS (parts car, devoured by Spacecab needs) plus some 70 plus other non Isuzu vehicles over the years. 1994 Amigo devoured to provide head and EFI system.
Heavily damaged by engine compartment fire while driving on March 24th 2018, condemned by insurance company and taken on March 30th 2018 :cry:.

https://forum.planetisuzoo.com/viewtopic.php?f=15&t=64060
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Re: '88 Trooper resto...

Postby greasemonkey » Sun Mar 28, 2021 7:46 pm

Weekend update. Rust is gone, floors are scrubbed and scuffed, seam sealer is applied, and Lizard Skin sprayed. I've never used the stuff but wasn't impressed after the first coat. After coats 2 and 3, I'm a fan. I'm not sure why they call it black because it's definitely not black.
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Re: '88 Trooper resto...

Postby greasemonkey » Sun Mar 28, 2021 7:52 pm

"Brushable" seam sealer is, well, not very brushable. I tried but found I got a much better result smearing it with my finger. So go easy on my sloppy application. It's all covered up anyway.
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Re: '88 Trooper resto...

Postby greasemonkey » Sun Mar 28, 2021 7:58 pm

Last round.
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