1963 Scout 80 resto-mod

[BK2LIFE]

Pics will be slow at first, as there are customer projects in the shop that need more attention than personal toys.

Plans are:
-Slammed to the ground
-4 corner double adjustable coil overs, bags or ridetech shockwaves
-stock appearing interior/exterior
-custom doors ( no windows, solid top, possibly with later model door jambs and hinges )
-chopped top
-4 corner Wilwood big brakes
-fuel fill behind rear taillight
-Dakota Digital gauges
-full LED lighting
-custom paint, possibly silver on sides and red on top
-both full sized top and small 'truck' style top
-vintage air heat/ac
-LS powered

I'm thinking all red interior, red with painted sides and bed liner on the floors all red, same matched colors.

My seats are already covered in greyish leather. So, I'll match the leather color to the paint, and then spray the outside in that color. The outside, the seats, and the leather on the billet steering wheel will all match.

I don't want anything that sticks out or doesn't look right inside of the scout. Want to keep it looking like it came that way.

Here is a potential rending I drew up to get a visual..

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[BK2LIFE]

UPS man delivered:

brakes
4 link
steering parts
coil overs

- - - Updated - - -

went and got a carpet sample.

now will go to the paint store and have it matched so we can start painting interior pieces.

The carpet is darker than GMs red

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[David Sloan]

Sweet
Looking forward to updates

[BK2LIFE]

went and got some paint matched to the seat leather and the red carpet.
Going to spray out some panels to see the color better.

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- - - Updated - - -

parts have been coming in for this as well.

4 link, coil overs, although i think it will need airride, as itll be too low to steer, gauges, AC parts.. etc

I think by the end of july we should be able to spend some time on this and make it roller

[BK2LIFE]

Might be settled on this 1956 GM color called India Ivory for the body paint color.

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[BK2LIFE]

WE have settled on a single turbo, Gen IV 4.8, 4l80e, quick-change rear axle to move this one around.

[BK2LIFE]

waiting on some parts from sandblasting

[BK2LIFE]

thinking all the suspension/chassis will be red as well.
a mix of powder coating and paint, but I think the red will work well for this build

[BK2LIFE]

had to adjust the rendering to better match the color of the leather on the seats

much darker, but it a better representation.

The more i look at it, the darker is sexy.

Now need to figure out a pearl to mix in with it. I think itll need a little pop to sparkle in the sun..

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[BK2LIFE]

The ididit steering column arrived
The gauges are here
The hydroboost unit is here
The wire harness is here

-possibly going to run an aluminum driveshaft, but need to see the specs if it'll hold up to what we are planning

[BK2LIFE]

Started working on the chassis and the body modifications needed to get this thing on Terra Firma..
The trans am wheel is just sitting there to get an idea how small 16s look :)

Monday ill pick up some 3x3 tubing to build the rear frame section to allow the axle to travel that high up into the wheel well.
Once that is tacked in, we'll move to the fitting the S10 suspension to the front frame rails.

Already ordered up the air ride parts needed be able to make the chassis 'lift' so in a week or two we should be able to get this chassis on the frame rack to ensure square/straightness/level etc.


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[SShep71]

Glad to see another Scout project. I have a 79 Scout 2 that I have heavy plans for, I want to put my Scout body on a HMMWV chassis. I have everything to do it, except for the space and time. Good luck with the progress on this project.

[BK2LIFE]

Redid the rendering this morning, and added the Company logos for some of the parts being used on this build.

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[cornfedbill]

That body looks very clean. Good find.

[BK2LIFE]

That body looks very clean. Good find.


Thank you. was a near perfect rust free body with minimal body work needed

[BK2LIFE]

the new frame material is here

the main components for the air ride is here

waiting on a few replies for double adjustable shocks for front and rear

Have the general idea of the rear back half designed, just need to start cutting metal now.

Depending on Mother Nature, might have the chassis tacked together this weekend.

[BK2LIFE]

I prepped my "CAD" table and started building to scale, my rear back-half.

Using a 1:1 scale my chassis is 3x3 and I laid it out how to best be used for the bag on bars suspension and the rest of the parts that need to be inside of it.
IE fuel tank, air tank, compressors, floor bracing ect.

Once I got everything lined up to where and how it should look, fit and work, I made some templates for some CNC cut brackets for the lower 4 link bars, and the upper air bag mounts. Hopefully these are done this week. I used oval holes instead of the normal circles for ‘speed holes’.. I might use this oval theme throughout the build.
I’ll start piecing together the back half and get them all tacked together.

The front ‘s10’ suspension portion/clip/frontend needs to be clearance for the air bags, and then it can be mocked up under the front fenders to see where the frame splicing will occur. I will install the front wheels, upper/lower control arms onto the frame piece to make sure the wheels are centered in the wells. I build them so when they are aired out the wheels are centered. I don’t really care if they’re not centered when driving down the road. It’s sitting, aired out, that matters to me.

Enjoy the pics…

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[BK2LIFE]

I prepped my "CAD" table and started building to scale, my rear back-half.

Using a 1:1 scale my chassis is 3x3 and I laid it out how to best be used for the bag on bars suspension and the rest of the parts that need to be inside of it.
IE fuel tank, air tank, compressors, floor bracing ect.

Once I got everything lined up to where and how it should look, fit and work, I made some templates for some CNC cut brackets for the lower 4 link bars, and the upper air bag mounts. Hopefully these are done this week. I used oval holes instead of the normal circles for ‘speed holes’.. I might use this oval theme throughout the build.
I’ll start piecing together the back half and get them all tacked together.

The front ‘s10’ suspension portion/clip/frontend needs to be clearance for the air bags, and then it can be mocked up under the front fenders to see where the frame splicing will occur. I will install the front wheels, upper/lower control arms onto the frame piece to make sure the wheels are centered in the wells. I build them so when they are aired out the wheels are centered. I don’t really care if they’re not centered when driving down the road. It’s sitting, aired out, that matters to me.

Enjoy the pics…

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[ryeguy2006a]

Looks like a fun project! I'm planning a 4 link project for one of my next upgrades. Are you buying a kit for your rear suspension, or are you scratch building it? If scratch, what calculators did you use to come up with the bar lengths, and etc.

[BK2LIFE]

what calculators did you use to come up with the bar lengths, and etc.


i build all my own since like 2004.

bottom bars figure out a good length that fits your chassis.
top bars are about 70% the length of the lower

Thats the easy part.

The rest is your pinion angle, and if youre going triangulated, parallel, pan hard bar, watts link etc.

And then coil over, air ride, hydraulics.

there is so much info on the net, it just takes a bit or research

[BK2LIFE]

got my brackets

time to weld up some rails..

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[BK2LIFE]

new rails built, and tacked into place into the S10 suspension

need to make a few crossmembers and get them tacked in
and then the entire chassis can be moved to the welding table for finish work.

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[BK2LIFE]

.....few update pics

frame is a solid chassis now from front bumper mounts to rear bumper mounts.

The frame needs to be removed and finish being welded, but that is after building the 4 link.

Waiting on a few parts i had to order for the air ride...once these arrive i can make the rear 4 link.

not much else at this point.

I wonder how many scouts have a quick-change rear axle?

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[BK2LIFE]

got out the windshield frame last night, and wanted to get an idea how much of a 'chop' it needed to match the rendering.

turns out about 5 inches needs to come out to match.

im going to round the edges of the new glass, since early scouts are square.
and will be doing 'oversized' glass so they can be glued in and 'flush' mounted.
No more big rubber seal to hold the glass in..


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[BK2LIFE]

Lower link bar 'ends' came in..

now I can set up the rear 4 link and finish the air bag mounts.

should be able to make the vehicle go up and down here real soon...

Exciting!!

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[BK2LIFE]

been a little slow on updates this past week.
but the BBq has been good !!

hope you are all doing well...thanks for lookin

[BK2LIFE]

New LCAs arrived yesterday.
maybe this coming weekend i can get them on and see how they fit.
then modify them for the lower airbag mount.

They will be red powder coated with everything else once fitted and modified

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[BK2LIFE]

Removed the windshield frame and drilled out a bunch of spot welds on the side portion. These spot welds hold the ‘brackets’ which mount the door seals.

Since I wont have door windows, no door seals are needed, so off came the brackets.

Then I cut the window frame into 4 pieces and decided that a 4-inch chop was going to be the best for what I'm building.

Some measuring, a few templates to make sure left and right match, and voila’

It’s welded back together, and next is rounding the corners of the windshield frame.

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[BK2LIFE]

So today I was working on my 4 link tabs, and a buddy came over.
So shootin the sh*t we started talking about the windshield, and a few hours later, the metal work is nearly done.
Some sanding, some bondo and primer and itll be ready for paint.
Then ill drop the frame off at the window guy and let the take it from there.
I want to paint it body color before dropping it off for the window to be made and glued in. This way I will know it is got epoxy, primer, paint and plenty of rust and corrosion resistance before the flush mount glass is mounted.
I'm not sure if the ‘red triangle’ needs to be made or not. Currently it is a not so 90 degree corner. I'm guessing the black around the glass will hide the corner. But, it’s something I got to figure out.
Hope you all like the chop, and the rounded window ‘corner’s

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[BK2LIFE]

So as some of you might remember from my rendering, the door lines aren’t ‘scout’ lines. The scout doors have that inward angled portion on the back.

One of the modifications I wanted to do was suicide doors, and I don’t like how the rear B pillar is on the scout bodies.

Not anytime soon, but my plan is to use my old truck, ‘Alice’ door jambs and flip them side to side and shorten to fit. Peel off the door skins from the scout and modify them to attach to the 2001 doors frame.

This way, itll have inner hinges that are factory reversed for a reverse or suicide opening, just like it came from the factory.

I put the ‘drivers/left side’ door jamb next to the passenger side of Allison to see how much work it will take. I think I need to narrow the door jamb about 4 maybe 5 inches to fit, but, it appears to be a relatively easy modification. I think in a weekend or so I could have the ‘new’ doors hung and functioning. Not fully completed, nor body worked, but able to be opened and closed.

No I won’t be putting the angled lower portion of the door as the scout had, it will be a normal ‘square’ door with rounded lower corners.

Here is a picture for reference.

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[BK2LIFE]

This evening, I had about 2 hours to spare, so I grabbed the new lower control arms and hacked off the bump stops from them.

Pulled off the front suspension and stuck on the new lowers.

I found it they 'went' up higher than the dehumped stockers I had previously, but they still hit part of the frame.

The sun was getting pretty low and visibility was very low, so I pulled the suspension, jacked up the front of the frame and slid in an airbag for a picture.

The opening. cut out for the airbag is very rough at this point. I am just trying to get everything to fit and operate correctly before it all gets torn apart for the frame rack, final fabrication and welding.

My S22 phone still amazes me at the pictures it takes. This below pic was nearly pitch black out. I couldn't walk without my flashlight, but yet, the phone can take pics like its 5 pm in the afternoon.. crazy

Tomorrow morning ill finish cutting the frame section that is hitting the lower control arm and do a bit more clearancing for the air bag. The object here is to get the suspension going up and down, steering, engine/trans mounts made etc..

Then tear down for final fab work, powder coating etc..

-oh, and no I do not know if I am keeping that sway bar mount there or if I’ll cut it off and move it.

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[BK2LIFE]

So yes I removed the sway bar mount..

Did some more hacking on the frame to get the airbags to fit and not rub.



Hooked up some airline and gave it a few up down tests. (down is the fittings leaking at the airbags, theyre only hand tightened..)



The new bushings squeak, but at least it goes up and down in the front, and I can grease them after powder coating.



Next is to tackle the rear air ride and 4 link bars.



-----> small video https://www.youtube.com/watch?v=xEP62aCrY-E



....one step closer

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[BK2LIFE]

Today, slightly hung over, i wet sanded the window frame and sprayed the base/clear onto it.
Tomorrow I'll drop it off for the flush mounted glass to get cut and installed.

The color is a tri-stage, grey base, violet pearl and then clear.

I had planned on gold pearl, but i didnt have any when i thought i did. So i grabbed the violet to see how it looks.

Now that this window frame is completed, i can get back to fabrication...214984214983214982214981

[BK2LIFE]

I picked up a 1964 ford car front bumper I think im going to section and cut down to fit my lowered scout front end. It's nearly 18 inches too wide 😆 lol

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[BK2LIFE]

Here is the bumper shortened to fit the scout. I have not shortened the sides of the bumper asi can't really do that until i assemble the front end to see how far I want it to go onto the fender..



I had to 'strgihten' out the bumper as it was more V shaped then it looked.



Came out pretty good though.



I am not sure if i am going to weld up the bolt holes, or use them..

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[BK2LIFE]

decided to weld the front solid and make a 1 piece front end

sat the frotn end onto the body and propped up the bumper to see how much i have to cut out of the sides of the bumper.

Thought this pic looked cool with the scout between the other cars.

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[BK2LIFE]

Little more trimming to the bumper..

i need to fab up brackets now to hold the bumper to the frame so i can make final cuts and adjustments on the bumper to fit the fender well openings and body lines better


215177

[BK2LIFE]

Well the show I want to take the scout to for the first time is coming up.
December 7th. So much to do before that date, but, if I can get it on and off the trailer then I'm happy. I really wanted to drive it there, but there is still so much needing done.

My goal is to get it there to the show, lay it out, and enjoy some margaritas and tacos..

The windshield is supposed to be done ‘by the weekend’..not sure what that means, but fingers crossed.

Ugh still so much more to do..

[ryeguy2006a]

You may want to call the Overhaulin' crew! Looks like a lot of work to get a running/driving car in 3 weeks haha.

[BK2LIFE]

You may want to call the Overhaulin' crew! Looks like a lot of work to get a running/driving car in 3 weeks haha.
not driving, only rolling to get on and off a trailer.
i wanted to have it driving, but, just running out of time, and not enough help.

- - - Updated - - -

Had this beautiful 1941 rear cadillac bumper dropped off.
So with some measuring, i cut, chopped and got it ready to be mounted to the scout...


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[BK2LIFE]

Was able to get a few hours on the rear suspension.
Got the 4-link all tacked in place.
I lifted it 8 inches and had 2 degrees of movement on the pinion, which is more than fine, as ride height will be about 3 inches off the ground.
Started looking at cross bracing, fuel cell and the other final components that need to go back there -such as air tanks and compressors.

Need to make the mid and front body/core support mounts and then remove the body for final fit and welding.

I think the last thing I'm going to tackle before the show is the gauges in the dash and steering.

I'm not stressed, but I'm trying to get it to the show as a motivator. If people, see it now it'll get me going to push harder.
I have already 'failed' as it's not running and driving, but that is how life goes.

I ran the upper bars on the outside of the frame rails to not have them visible once the inner sheet metal work is done. I wanted to keep a non-cluttered section visible. I think I'm going to run the spintech mufflers as well, as I like their square small boxy appearance, and they have such a unique sound to them.

-oh and windshield wasn’t done. Maybe today I’ll get it back…

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[BK2LIFE]

Laid out some 3 inch tubing to visualize an exhaust system...

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[BK2LIFE]

motor/trans mounts fabbed


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[BK2LIFE]

Got the front bumper somewhat mounted. I got a few real good ideas on how I will be permanently attaching it after the show. But for now it won’t fall off and I can get some good eyes on to see where I need to adjust it. Not trying to be perfect, but, wanting to make it look like it is supposed to be there.

I think this is the 1st Scout with a car type bumper, and I want people who see it to not know that. Unless you’re a scout fan, you probably wouldn’t know anyways.

Started workin on the steering column mounts. The lower is done, just need to fab up a column drop for the upper.

Also started the dash panel. I’m going to not use the stock scout panel and just start fresh with a piece of sheet metal as it will save time of me trying to weld up all those spots for no real reason. Also, I might mount the gauges in the middle of the dash.

I had an old GM truck billet grill laying around so I butchered it to fit, not sure how I feel about it yet, but, we will see.

I think I'm not posting any more pictures until after the show. Sort of want a bit of a surprise for y'all..

-james

[BK2LIFE]

few pics from the past weekend...

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[ryeguy2006a]

It's got a killer look man. Can't wait to see more.

[BK2LIFE]

It's got a killer look man. Can't wait to see more.

thank you for the kind words...

and me too!! i cant wait to get time to get back on it.
customers vehicles first.... :(

[BK2LIFE]

Started fabbin up the new tailgate.
I'm waiting on the hinges to arrive, but, it will swing open to the side, not down like a normal gate would.

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[BK2LIFE]

sat the gate on the truck to get an idea of looks...

[BK2LIFE]

new tailgate hinges arrived...

[BK2LIFE]

Been working the side swinging hinge for my tailgate. It’s not 100% where I like it, but its opening and closing. The hinges are made for a thick door, not a thin tailgate. OS I have to work some sheet metal to cover it and make it look good.

Not sure if I said it above but I'm trying a new powder coater. I sent off oil pan, transmission case, trans pan and front cover to be coated. If they look good, ill send more parts to the shop. Eventually all chassis and parts will be powder coated red.

I dropped off my lower control arms to my buddy and had him press out the ‘stock’ lower ball joints and installed ‘tall’ style ball joints to help with alignment and getting another ½ inch drop out of the suspension.

I order some new upper control arms that will allow more lift from the air bags. I might use them and make a jig to modify them to work more with this type of suspension, and not the ‘drag race’ set up they are made for.

[BK2LIFE]

today mr UPS man dropped off a few boxes.

I promptly took the new holley intake and ground off the 'holley EFI' logo and ran a DA with 80 grit over the top surfaces to smooth out the rough casting and bead blasting they did.

Then I put the parts in my truck and dropped them off for powder coating...

-intake manifold
-fuel rails
-valve covers
-front engine cover
-valley plate / knock sensor cover
-engine oil pan
-4l80e transmission case
-aluminum trans pan

I also dropped my cell off for new glass as it has had some nasty cracks for awhile now.
And since my phone is linked to my computer, i cant upload any full res pics, so youll have to enjoy this tiny one for now..


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[BK2LIFE]

....and now they are all red


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[BK2LIFE]

Getting the parts bolted up and readied for transportation to the exhaust shop for the custom up and rear twin turbo manifolds to be built..

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[BK2LIFE]

Took the trans out to vegas to have a rebuild done on it for the power levels im planning on putting through it..



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[BK2LIFE]

The March accessory kit arrived...
took all the parts out, inventoried, and dropped off to the powder coater to be stripped and coated red..

The alternator, PS pump and AC compressor will all stay black.

Only waiting on the turbos now.

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[BK2LIFE]

Trans is cleaned, parts have arrived, and it should be assembled in day or two...


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[BK2LIFE]

....some more red for the ole gurl



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[BK2LIFE]

time for exhaust....


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[BK2LIFE]

...the stainless pieces and parts have arrived for the turbo manifolds and the first few tack welds have been started.

when i get some pics i will post them up.

[BK2LIFE]

few pics

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[jaybee]

I love this project, and I very much approve of the use of International Harvester red under the hood.