Project Brusier (Trooper-UP)

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Project Brusier (Trooper-UP)

Postby VX1032 » Tue Nov 24, 2009 4:26 pm

So here she is as she sits now, except for the broken tranny pan bolts, and the piece of exhaust missing, she is ready to start the body work, or finish, since the top has already been chopped. I will keep everything in this thread so you can all stare in wonder at my trials of learning to weld.

Image

Have to lose about two inches in the rear window area for my tastes, but that's my baby!
Last edited by VX1032 on Sun Jul 18, 2010 9:49 pm, edited 1 time in total.
Ryan Christiansen
(sold) 99 Vehicross 1032 OME 912's, Stric9 Sliders, Definity Dakota MT 285/75 R16, Aussie Lockers Front and Rear, 4.77 gears and Warn Premium Manual Hubs.

(sold and purchased Back) 88 Trooper 2.6 Auto with Snowflakes and 235/85's, and a pickup bed! In progress
https://photos.app.goo.gl/aonWS8uuo8cRZMzJ8 Album 1
https://photos.app.goo.gl/3BMo6pGyUy9Mee7DA Album2
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Postby TonkaToy » Wed Nov 25, 2009 5:24 am

That is one hell of a project. So what is the vision for this machine?

For your comfort I would try to pick up a set of used Jeep softtop windows and cut them down to size and install snaps so you can try to keep some of the heat in in the winter. Besttop sells a kit just for repairing or replacing softtop snaps. I still have mine from my Jeep days.

Good Luck!!
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Postby VX1032 » Wed Nov 25, 2009 11:46 am

Once the rear section gets welded on, I need to build a rear wall to seperate the cab from the bed. I have a rear pickup window from a 91 pickup that will go in as the rear window, and the side windows will be glass, cut down from the existing windows I took from the trooper, well I hope. If I can't I might just sheet metal over it and make it a big B pillar, that would be easier.
Ryan Christiansen
(sold) 99 Vehicross 1032 OME 912's, Stric9 Sliders, Definity Dakota MT 285/75 R16, Aussie Lockers Front and Rear, 4.77 gears and Warn Premium Manual Hubs.

(sold and purchased Back) 88 Trooper 2.6 Auto with Snowflakes and 235/85's, and a pickup bed! In progress
https://photos.app.goo.gl/aonWS8uuo8cRZMzJ8 Album 1
https://photos.app.goo.gl/3BMo6pGyUy9Mee7DA Album2
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Postby TonkaToy » Wed Nov 25, 2009 12:13 pm

Very cool!
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Postby ZOMGtrooper » Wed Nov 25, 2009 1:47 pm

looks nice. Are you going to weld up the rear doors?
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Postby Sabre07 » Wed Nov 25, 2009 7:38 pm

VX1032 wrote: If I can't I might just sheet metal over it and make it a big B pillar, that would be easier.


Think of the sticker space you would have...
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Postby Cronk » Thu Nov 26, 2009 12:55 am

Looks cool! Can't wait to see the progress.
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Postby Metal88 » Sat Nov 28, 2009 12:04 pm

thats awesome! this one looks more original than other troopers ive seen with the roof chopped off. it looks clean also.

im guessing your thinking on a roll bar?
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Postby VX1032 » Mon Nov 30, 2009 9:42 am

Sticker space would be pretty big!!

Actually, at the moment I am not thinking of a roll bar, but I won
t rule it out. there is a lot of beef in the D pillar and it is close to the B pillar, though it does rest on the door that isn't all that reinforced, so that might be the solution instead. Not sure yet.

Yes, doors are getting welded shut and eventually you won't know they were there, or that is the plan.
Last edited by VX1032 on Mon Jan 18, 2010 4:23 pm, edited 1 time in total.
Ryan Christiansen
(sold) 99 Vehicross 1032 OME 912's, Stric9 Sliders, Definity Dakota MT 285/75 R16, Aussie Lockers Front and Rear, 4.77 gears and Warn Premium Manual Hubs.

(sold and purchased Back) 88 Trooper 2.6 Auto with Snowflakes and 235/85's, and a pickup bed! In progress
https://photos.app.goo.gl/aonWS8uuo8cRZMzJ8 Album 1
https://photos.app.goo.gl/3BMo6pGyUy9Mee7DA Album2
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Postby jl8088 » Wed Dec 02, 2009 11:20 pm

awesome, keep us updated. Wish i could help!
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Postby IsuzuGeek » Thu Dec 03, 2009 3:27 pm

That chop looks awesome. I like the way it kinda retains a stock look.

Bart
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Postby VX1032 » Sat Jan 02, 2010 5:18 pm

Been spending a little time working on the truck. I needed to buy a welder and all the other toys since I have never welded anything prior to this project. Yeah, I picked sheetmetal to learn to weld on. I like living on the edge.

Image

Here is the roof welded together, lapped with the rear going under the front. Gonna need some bondo to level the gaps and make the transition smoother, but overall, it is serviceable I think.

Image

Here is the drip rail, lined up, needs a little push up at the joint, but not too bad. Nice how the body barely changes from the front to the back on the early troopers.

Image
Image

Drivers side is all I have worked on so far, tying the rails together with a piece of 1/8" steel and then the door to the rear tub. Tomorrow I tie more of the 'C' pillar to the rail.

Image

The door is mostly welded shut now. I took a small piece of steel stock into the gap and welded it over. Bondo should take care of the dimples as the door was not flush with the rear quarter anyways.

I need to tidy up the drivers side then move to the passengers side. I also need to make a rail for the entire tub area to cap the bedrails and pinch weld, that way the 1/8" steel will never be seen.

A friend suggested I leave it open, Bronco style, but I an still going to put the wall up and make a true pickup.
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(sold) 99 Vehicross 1032 OME 912's, Stric9 Sliders, Definity Dakota MT 285/75 R16, Aussie Lockers Front and Rear, 4.77 gears and Warn Premium Manual Hubs.

(sold and purchased Back) 88 Trooper 2.6 Auto with Snowflakes and 235/85's, and a pickup bed! In progress
https://photos.app.goo.gl/aonWS8uuo8cRZMzJ8 Album 1
https://photos.app.goo.gl/3BMo6pGyUy9Mee7DA Album2
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Postby Ditchdoc » Sat Jan 02, 2010 10:31 pm

Looking gooooooooddddd Git-R-Done......
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Postby IsuzuGeek » Sat Jan 02, 2010 11:16 pm

x2 looking cool. What is your "final" plan? Are you just gonna leave it be as a trail banger or spif it up with some paint? Fill in the rear door handle area maybe?

Fill us in.

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Postby VX1032 » Sat Jan 02, 2010 11:48 pm

Mostly trails, but used as a pickup around town on the needed occasion. It will have paint, black and blue, hence the name, but it will also have some body dents and the paint will be done by me probably, so far from perfect.

Haven't gotten to the rear door handle yet. I have a couple rust spots to fix too. Need to figure out the best way to cut sheet metal, and to buy some. Been using the scraps from the roof chop for the current patches, but the rear wall is going to use most of the roof so I need to find a local supplier.

Measured the pickup bed and it comes out to 52", 3" longer than a SportTrac bed, enough room for some bark mulch and concrete!
Last edited by VX1032 on Mon Jan 18, 2010 4:25 pm, edited 1 time in total.
Ryan Christiansen
(sold) 99 Vehicross 1032 OME 912's, Stric9 Sliders, Definity Dakota MT 285/75 R16, Aussie Lockers Front and Rear, 4.77 gears and Warn Premium Manual Hubs.

(sold and purchased Back) 88 Trooper 2.6 Auto with Snowflakes and 235/85's, and a pickup bed! In progress
https://photos.app.goo.gl/aonWS8uuo8cRZMzJ8 Album 1
https://photos.app.goo.gl/3BMo6pGyUy9Mee7DA Album2
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Postby Audacity » Sun Jan 03, 2010 12:19 am

Most definitely going to be a cool ride once it's done! I'll be watching, and as far as your 'chopping' goes, how much did you take off the top? I love the first gen Troopers, just find their stance a bit.... Top heavy?
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Postby IsuzuGeek » Sun Jan 03, 2010 1:18 am

Audacity wrote:Most definitely going to be a cool ride once it's done! I'll be watching, and as far as your 'chopping' goes, how much did you take off the top? I love the first gen Troopers, just find their stance a bit.... Top heavy?


The "tallness" is EXACTLY what I like about them. SOOOO much cargo space.

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Postby VX1032 » Sun Jan 03, 2010 10:30 am

Audacity wrote:Most definitely going to be a cool ride once it's done! I'll be watching, and as far as your 'chopping' goes, how much did you take off the top? I love the first gen Troopers, just find their stance a bit.... Top heavy?


Go to the link in my signature and you can see all the pics. Sawzall and grinder.

Supposed to do more work today, but the garage is 46 degrees and the welder is just about out of gas. Might only get an hour or so in. Oh well football and beer afterwards since no one around here sells gas on Sundays!
Last edited by VX1032 on Mon Jan 18, 2010 4:25 pm, edited 1 time in total.
Ryan Christiansen
(sold) 99 Vehicross 1032 OME 912's, Stric9 Sliders, Definity Dakota MT 285/75 R16, Aussie Lockers Front and Rear, 4.77 gears and Warn Premium Manual Hubs.

(sold and purchased Back) 88 Trooper 2.6 Auto with Snowflakes and 235/85's, and a pickup bed! In progress
https://photos.app.goo.gl/aonWS8uuo8cRZMzJ8 Album 1
https://photos.app.goo.gl/3BMo6pGyUy9Mee7DA Album2
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Postby Smiley » Sun Jan 03, 2010 12:58 pm

VX1032 wrote:http://picasaweb.google.com/RyanVehiX/ProjectBruiser#


Keep those photos coming, Ryan! --- You're inspiring me to build a makeshift tarp garage and start getting something (anything!) done on the Rodeo 8)


Cheers!
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Postby Joe Darlington » Sun Jan 03, 2010 7:11 pm

looking really good, you need to learn how to weld with a torch, a little bronze would help strenthen the weld line and fill the holes/low spots. too bad you live so far away, could teach you how...
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Postby VX1032 » Sun Jan 03, 2010 11:16 pm

Well, Joe, if you want to teach, I might have an extra bed at the house here. If you got the time, I might be able to come up with the fundage!!

Kinda wishing I would have played with the welder more before I went at it, but they all look functional to me, though not pretty. It is VERY relaxing though to go and work on it after everything else, nice release.
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(sold) 99 Vehicross 1032 OME 912's, Stric9 Sliders, Definity Dakota MT 285/75 R16, Aussie Lockers Front and Rear, 4.77 gears and Warn Premium Manual Hubs.

(sold and purchased Back) 88 Trooper 2.6 Auto with Snowflakes and 235/85's, and a pickup bed! In progress
https://photos.app.goo.gl/aonWS8uuo8cRZMzJ8 Album 1
https://photos.app.goo.gl/3BMo6pGyUy9Mee7DA Album2
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Project Bruiser

Postby Cavmedic » Sun Jan 17, 2010 9:31 am

looks cool cant wait to see more
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Postby VX1032 » Mon Jan 18, 2010 4:19 pm

Pictures below of the progress this weekend (today). Seems like I am out of town every weekend, so thank god for days off. I think I got a little high from the fumes from the work this morning.

Don't pay attention to the dates on the pictures.

Left Side C pillar, old D pillar, welded in.
Image

The next two pics are the sheetmetal piece I had to cut out and weld in to seal off the rear door. Now there is no access to the rear door hinges and it will be a cleaner door jam for the driver's door. The pictures don't give the lack of room to the rear weld justice. It is tough getting the MIG torch back there. Welds on the front seam are looking better.
Image
Image

There rear portion of this rocker had a piece of silver tape, bondo, and blue spray paint that hid the hole in the rocker. I knew about it so I knew this patch was coming.
Image

What I didn't know, was that there was a hole here. While welding the bondo just kinda krinkled up and the wire brush exposed this. That will be next week. But on a nicer note, that line of spot welds is looking much better.
Image

Now I just have that hole on the rocker to fix, fill the door handle in, and then grind grind grind. Once that is done, I can flip the truck around and start work on the passengers side.

I remember some one saying use an 86 2dr to start because it would be a lot easier. I wanted the AT tranny, and axles from an 88 instead. I am beginning to think it might have been easier swapping the axles and tranny. Oh well. My first roll of welding wire is just about up, second bottle is 2/3s gone as well.
Ryan Christiansen
(sold) 99 Vehicross 1032 OME 912's, Stric9 Sliders, Definity Dakota MT 285/75 R16, Aussie Lockers Front and Rear, 4.77 gears and Warn Premium Manual Hubs.

(sold and purchased Back) 88 Trooper 2.6 Auto with Snowflakes and 235/85's, and a pickup bed! In progress
https://photos.app.goo.gl/aonWS8uuo8cRZMzJ8 Album 1
https://photos.app.goo.gl/3BMo6pGyUy9Mee7DA Album2
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Postby RustyZu » Tue Jan 26, 2010 6:39 pm

Wow! Wish I had the time and money to do projects like this! Also wish we had clean bodied Troopers here in the midwest! All the older import trucks are all rusted out. Gotta go south just to find a decent one... Great project!
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Postby VX1032 » Sun Jan 31, 2010 7:04 pm

Two more weekends, and a good deal of progress.

Drivers side has been completely welded and ground down.

Swapped the VX and Trooper in the garage for better light and started on the passagers side.

Passangers side as it is now, just needing some grinding, all welded up.
Image

Image

Image

The passangers side has the wires to the brake lights running down it. Normally this runs along the roof to the c pillar and then drops down on one side for the RR door adjar switch and then to the rear for the license plate light and brake lights, while also branching across above the c pillar to the drivers side for the LR door adjar switch.

I drilled holes in the door jam prior to welding and had to line with hose to prevent chafing. Also had to drill a hole in the 1/8 plate that goes across the top of the door prior to welding.

Image

Image

After it was al welded up I rant the harness back through, starting with a hole I had to drill in the new C pillar.

Image

Image

All to get to this little connector.

Image

As she sits now. Path the hole I took the photo of the wires in C pillar and a rust hole in the bed and then grind it all down and the passangers side is done. Another 2-3 hours.

Image

Need to learn how to make C channel out of sheet metal without a brake soon for the structure of the rear wall. I will hopefully be doing that next weekend.
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(sold) 99 Vehicross 1032 OME 912's, Stric9 Sliders, Definity Dakota MT 285/75 R16, Aussie Lockers Front and Rear, 4.77 gears and Warn Premium Manual Hubs.

(sold and purchased Back) 88 Trooper 2.6 Auto with Snowflakes and 235/85's, and a pickup bed! In progress
https://photos.app.goo.gl/aonWS8uuo8cRZMzJ8 Album 1
https://photos.app.goo.gl/3BMo6pGyUy9Mee7DA Album2
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