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1991 Trooper Restoration
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jeremy_worden
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PostPosted: Thu Sep 24, 2009 11:42 pm    Post subject: Reply with quote

wow, that looks great. i cant wait to see what you are going to do with it...
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1995.5 isuzu rodeo LSD and snowflakes
1988 isuzu trooperII []OlllllllllllllO[] 245-75-R16, yakima load warrior basket, custom rear bumper, and an AUSSIE locker, and AISIN hubs
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Ruination
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Location: Greenville, SC

PostPosted: Fri Sep 25, 2009 8:55 am    Post subject: Reply with quote

btw1549 wrote:
I graduated from Tunkhannock but I started school at Wyoming Valley West. You weren't to far from my area though. The have started to really destroy the beauty that the Pocono's once had however. Having no neighbors up there is becoming very hard to achieve with everyone from NY moving in to PA and building houses there. It's a sad thing to see happen.


I know the feeling, although we moved from NY to PA in 2000, we owned the property for some time.. my parents moved from The Wallenpaupack area to Factoryville, on Lithia Valley Road right by Lake Winola. I dreamed of buying their Log Cabin from them, but they had to sell it when the economy tanked. Ah well.. Beautiful country up there.

Sorry for the offtopic- I'm liking these pictures though!
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btw1549
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Joined: 04 Aug 2009
Posts: 585
Location: PA

PostPosted: Mon Sep 28, 2009 1:27 pm    Post subject: Frame's Painted. Reply with quote

Sorry I haven't updated since Friday but I went on vacation so i didn't have much time. Anyway, on to the next update. I got the whole frame painted and ready to start installing parts.



I just have to get my brake and fuel line and my suspension components on the frame.



Then once it's on wheels again I can throw the power train and exhaust on.



I'm very impressed with the way the paint turned out. It shines good and after letting it sit and dry for a week it got super hard. I think it should have superior rust protection.
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BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
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btw1549
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Joined: 04 Aug 2009
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PostPosted: Tue Sep 29, 2009 3:38 pm    Post subject: My C4C grab! Reply with quote

So the dealership I work at is right next to the local pick-a-part. I mean close to, I can walk there; so the trucks that tow the scrapers to the yard drive right in front of my garage. They've been out full force with Cash for Clunkers and the other day I saw a newer body style trooper on one of the role backs first thing in the morning. That afternoon on my lunch I went down for an awesome score.



25 dollars for the whole thing. Backing plates, calipers, mounts, hubs, rotors, all the hardware, pads, and the rubber lines!! It was a 96 and it was in really good shape which was rather disappointing.



The rotors were like new and so were the pads! Unfortunately, the truck had 4 new tires as well so someone took those before I could get there and scraped the nice wheels. Of course they left the spare on the back with the bad tire though. Thanks to this site for informing me about the bigger brake upgrade for my truck!!
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Last edited by btw1549 on Tue Sep 29, 2009 7:47 pm; edited 1 time in total
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stusvend
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PostPosted: Tue Sep 29, 2009 4:02 pm    Post subject: Reply with quote

^Yep. The brake upgrade is one of the best things you can do to a first gen. Nice find. Excellent price too.
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Matt

88' Trooper LS 2.6L manual "Smokey" & 69' Toyota FJ40 Land Cruiser "Sherman"

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btw1549
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Joined: 04 Aug 2009
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PostPosted: Wed Sep 30, 2009 3:35 pm    Post subject: Junk yard score part 2 Not C4C Reply with quote

So after I went down and got my bigger front brakes the next day the yard hauled in a first gen trooper. It wasn't cash for clunkers but it was a good find. It was a 1988 4 cyl 5 spd black. It had the front brush guard on it but I was to lazy to take that. What I did take was the wind deflector for the back, The rain guards for the windows, and the cross bars for the roof racks.





The rain guards. They were all in good shape and all the hardware was there!



The wing. It was the first one I've seen in a while and I've been looking for one since I bought my other truck.



These cross bars are a different style from the ones I have now and the bolts are 1/8'' off but with a little fab they should fit nicely.

That's my latest find. I might go back down and see what else I can take later in the week only because I've been really short on time lately.
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stusvend
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PostPosted: Wed Sep 30, 2009 3:41 pm    Post subject: Reply with quote

You should seriously get that brush guard. It's a little hard to find them for these first gens for any kind of a deal. Good finds though.
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Matt

88' Trooper LS 2.6L manual "Smokey" & 69' Toyota FJ40 Land Cruiser "Sherman"

Smokey's story and build: http://forum.planetisuzoo.com/viewtopic.php?p=304331#304331

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btw1549
Mud King


Joined: 04 Aug 2009
Posts: 585
Location: PA

PostPosted: Fri Oct 02, 2009 1:05 pm    Post subject: Parts Truck!! Reply with quote

I'm gonna run down in about an hour to the yard and see if I can't grab that brush guard. I did recently buy a parts truck for my project. I bought an 89 LS 2.8l 5 speed for several reasons. 1st, I wanted the stock alloy wheels even since mine had steelies. 2nd, My truck isn't an LS so it has no power options or cruise; so I plan on switching the power windows, locks and cruise control to mine. 3rd, I want the 5-spd manual for my truck. I already had the auto rebuilt since I was planning on using that again originally not having a 5-spd truck to swap from; but now that I have it I'm going to do the swap while it's apart. I just recently did a swap on my 88 S-10 from an auto to a 5-spd man without it apart so I know how much easier it is gonna be to do it now. 4th, it will be nice just to have as a reference since my truck has been apart a while and even though all my parts are in separate labeled cans I still can't remember everything. And lastly, before I rip it apart I'm gonna be driving it around the farm and stuff a little bit. Reminds me of how much fun these trucks are and how much I want to get mine down!! Here's a few shots...



O and It has all the chrome trim that I may end up using on mine (the window trim, bumpers, grill, etc.)



It also has the nicer seats with the armrests. The fabric is really dirty and the passengers side has a burn hole in it, but I'm still not sure if I'm gonna use these seats and reupholster them or get a set of 08-09 Passat sport front seats (They are so nice ad they're full power and heated, see image below). I got spoiled from driving my 09 Audi A4 with the heated seats!!



I have to find some in my travels first. Back to the parts truck.




The frame's pretty rusty. The DS shackle is right through the frame and the body is much worse than my body that's why I'm not just using this body on my frame.

Hopefully I have some luck at the yard now and the guard comes right off!
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btw1549
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Joined: 04 Aug 2009
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Location: PA

PostPosted: Tue Oct 06, 2009 4:12 pm    Post subject: Trailer Hitch, Front and Rear Bump Stops. Reply with quote

Sorry I haven't posted in a couple days but it's been pretty hectic lately and my Grandfather just past away so I've been super busy. It also hasn't been very nice weather wise lately so finally the rain stopped and I got some parts installed on the truck. I'm currently waiting for some more parts to arrive so I didn't do much, but I got the Trailer Hitch and the Front and Rear Bump Stops on. Here's some pics.



Obviously the frame is still upside down because I have to put the front suspension back in and I found it easier to do it this way. The Hitch mounted up nice though.





All stainless hardware. All the nuts and bolt's I'm going to use are going to be stainless. I want this thing to last me a long time!!
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BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
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btw1549
Mud King


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PostPosted: Fri Oct 09, 2009 9:39 am    Post subject: Front brakes Reply with quote

With the change of horrible weather to sunny and semi warm weather for the weekend I also got to clean up the Bigger brakes I recently got from the 96 for the front of my 91.



I used a special caliper paint from VHT. The color was real red and I have used it before with great results.



You are supposed to bake the paint when you are done but I found if I just really clean the parts good and then take a heat gun and heat up the metal for like 5 minutes and then paint it followed by another heating with the heat gun it seams to work really good.



I paint my backing plates gray because I like to repaint my rotors hat and outer edge when I do a rotation to keep them from rusting bad and I use a gray color to match the alloy wheel. This way I don't have to worry about getting paint the backing plate when I do that. Plus I just think it looks cleaner.

Here's pictures of the same paint on my Audi Before and After about 10,000 miles. Holds up good.

Before:



After:


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BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
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btw1549
Mud King


Joined: 04 Aug 2009
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PostPosted: Fri Oct 09, 2009 9:42 am    Post subject: Reply with quote

Oh and I just wanted to add that when I did my Audi brakes it was the middle of winter and I did them at work 2 hours before I had to drive home in a snow storm. Just mentioning that because the paint impressed me even more by holding up so well with such short dry time and surviving my 45 minute drive home and through the rest of the winter.
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BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
http://forum.planetisuzoo.com/viewtopic.php?t=33157
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btw1549
Mud King


Joined: 04 Aug 2009
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Location: PA

PostPosted: Tue Oct 13, 2009 9:50 am    Post subject: LSD Reply with quote

I went down to the yard on Wednesday to grab a set of snowflakes they had down there and decided to look at the 1996 Trooper I took my bigger front brakes from to see how much it's been stripped. Well it wasn't to stripped down, most of the interior was there but that's not what I was interested in. I went for the build code label under the hood and what I was looking for was there. G80!! So I closed the hood and went on my way to get my wheels. I got my wheels and the next day went down to the yard with my cordless saws all and four extra batteries to tear out the rear. After two batteries, a half hour of my time, and a lift of the truck from the yard fork lift I had the whole rear assembly out. Here's a few pics of the rear.



This tag was nice because you never know if the previous owner had to put in a different rear at some point.

This weekend I only had Sunday to work on the truck so Sunday I took it in the garage and started ripping the third member out. The only problem I had was the one long bolt in the third member was frozen to the housing and took me a while to get it out but it's out, cleaned, inspected and ready to go into my rear!



I put it in a bucket with a towel to keep it clean until I could get my rear apart and ready for it to go in. That's this weekends project along with getting the snow blowers and plow truck ready for winter.

Then I started taking my rear apart. First off come the old springs that will be replaced by some OME springs when they finally get to my house.



Then to save myself the hour or two of struggling with that stupid bolt that wouldn't come out I drilled two tiny holes in the housing around the bolt and kept filling them with PB-Blaster.


It worked good too. After I continued on with losing the axle bolts and stuff up this bolt came out no problem thankfully enough. Now all the bolts are loose and ready to come out next weekend; so I will update again after I get the LSD into my rear. I also have to finish my shackles this weekend too so I should have good updates for next week!
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btw1549
Mud King


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PostPosted: Tue Oct 13, 2009 9:57 am    Post subject: Reply with quote

Almost forgot to add that the limited slip is only a temporary thing. I am hoping eventually to get air lockers but just do not have the money to spend on those right now with what I'm spending on the rest of the build.
My though is LSD is better than open and for $30.00 it can't be beat. Not to mention Take a look in this pic and you can see how bad my pinion seal was leaking...



The whole underside is wet from the pinion seal leaking. The rear is almost out of fluid. I would have had to take the rear apart and do the seal anyway.
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BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
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stusvend
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PostPosted: Tue Oct 13, 2009 10:00 am    Post subject: Reply with quote

Wow. Nice find. That's a golden nugget right there.
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Matt

88' Trooper LS 2.6L manual "Smokey" & 69' Toyota FJ40 Land Cruiser "Sherman"

Smokey's story and build: http://forum.planetisuzoo.com/viewtopic.php?p=304331#304331

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nfpgasmask
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PostPosted: Tue Oct 13, 2009 11:33 am    Post subject: Reply with quote

So 2nd gen G80 LSD rears work with the 1st gens?

Bart
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Tad
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PostPosted: Tue Oct 13, 2009 12:13 pm    Post subject: Reply with quote

92-97 12-bolts share the same 3rd member design. VXs also seem to have the non-modified 12-bolt so a VX 3rd could swap if you wanted 4.30s.

-Tad
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nfpgasmask
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PostPosted: Tue Oct 13, 2009 12:34 pm    Post subject: Reply with quote

Tad wrote:
92-97 12-bolts share the same 3rd member design. VXs also seem to have the non-modified 12-bolt so a VX 3rd could swap if you wanted 4.30s.

-Tad


OK, so it's the ratio. I guess my best bet would be finding some 4.77s and then add a rear locker. That should be my goal I think...

Bart
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btw1549
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Joined: 04 Aug 2009
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PostPosted: Tue Oct 13, 2009 10:20 pm    Post subject: Reply with quote

nfpgasmask wrote:
So 2nd gen G80 LSD rears work with the 1st gens?

Bart


Yea the only difference I have seen is that the 2nd gens have a wheel speed sensor built into the third member for the ABS which I kind of like because it leaves me with the option of installing ABS if I ever decided to.
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reran
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PostPosted: Tue Oct 13, 2009 11:18 pm    Post subject: Reply with quote

btw1549 wrote:
nfpgasmask wrote:
So 2nd gen G80 LSD rears work with the 1st gens?

Bart


Yea the only difference I have seen is that the 2nd gens have a wheel speed sensor built into the third member for the ABS which I kind of like because it leaves me with the option of installing ABS if I ever decided to.


I believe only the ones with the rear ABS have the sensor in the third member. The trucks with 4 wheel ABS do not have the sensor.
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btw1549
Mud King


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PostPosted: Wed Oct 14, 2009 10:30 am    Post subject: Reply with quote

reran wrote:
I believe only the ones with the rear ABS have the sensor in the third member. The trucks with 4 wheel ABS do not have the sensor.


Well that's a good thing to know because when I get a ABS module I will have to make sure it wasn't from a truck with 4 wheel ABS and one with the sensor in the third member.
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btw1549
Mud King


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PostPosted: Mon Oct 19, 2009 11:34 am    Post subject: Rear End Parts Reply with quote

Well it rained/snowed all day saturday so I was stuck in the garage for the day. I started ripping apart the rear and got the open diff out. I stripped down the front DS spindal and got that ready for paint. I also Took the rotors of the hubs and cleaned them up so I could paint them and cut them. My ball joints arrived saturday morning so I got a quick coat of paint on those. I don't understand why new parts come unpainted. I understand that the material are so thick they will never rust through but they will show surface rust which I really can't stand.

Then Sunday it was sunny out so I went to sandblast the rear and some other components but it ended up being one of those days when nothing goes right. By blaster broke and took a while to fix so by the time I got everything cleaned I almost wasted a whole day. Then when I was baking the rear caliper mounts on my furnace one of the mounts fell down inside the furnace so I had to take the Furnace apart to get that out. I did end up getting everything except for the rear primed and ready to go and the ball joints and the spindal got a 2nd coat and the calipers and mounts got painted.

Here are some pics...



The rear calipers and mounts with the first coat, I'll get a second one on next weekend.



Here is the ball joints and the spindal. I used Rust-Oleum Hammered Black. That's what I'm going to do all of the suspension components with including the rear. I'm also going to put new seal in everything.



My ball joints. I went with MOOG because they were the only one's I could find with the lowers with grease fitting and they come with a lifetime warranty.



The rear cleaned up. You'll see probably next weekend why there is a spot of red there!! And that's my 2002 on the side there. That's the project after the s-10 diesel project after this one is done!!

That's what I got accomplished this weekend. Like I said not as much as I wanted to get done but pretty close. I might work on it some during the week after my midterms tonight and tomorrow night.
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btw1549
Mud King


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PostPosted: Mon Oct 26, 2009 12:21 pm    Post subject: Finished Rear and Other Things Reply with quote

This weekend I got a few more things done. I'm running hard lines through the garage for the air because I'm moving the compressor out back of the garage in a enclosed area so it's quieter in the garage.

I really wanted to get the rear end painted and reassembled this weekend so that was the first thing I tackled. Now's when you get to see why I painted the back part red. I took and masked of the whole area and as pictured below made 3'' letters saying LSD for the limited slip diff.



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stusvend
Donor
Donor


Joined: 08 Jul 2009
Posts: 2427
Location: Nashville, TN

PostPosted: Mon Oct 26, 2009 12:33 pm    Post subject: Reply with quote

^ thats gonna look cool. Cool
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Matt

88' Trooper LS 2.6L manual "Smokey" & 69' Toyota FJ40 Land Cruiser "Sherman"

Smokey's story and build: http://forum.planetisuzoo.com/viewtopic.php?p=304331#304331

my music: www.myspace.com/mattgreermusic
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btw1549
Mud King


Joined: 04 Aug 2009
Posts: 585
Location: PA

PostPosted: Mon Oct 26, 2009 12:47 pm    Post subject: ERRRGH Reply with quote

I hit the Submit button rather than the Preview.

Anyway back to the rear.

I then took and welded new brackets on the rear for the brake line since the old ones had rotted off. A little bigger than the original but my hope is it will take longer for them to rust off.




Then I started to paint. I painted it with the Rust-Oleum Hammered black and it turned out pretty good.





As you can see I made a bracket to hold the sensors wire in place because I'm still not sure if I want to get involved in ABS or not.

Then I had to fix my backing plate problem with the rear. The one sides was rotted through bad and I couldn't find new ones so here's what I did.

I took and cut the center mounting part out of the old rears



Then I took and used the backing plates from the smaller front brakes and did the same. Here's the old centers of the fronts.



Then I welded my new plates and cleaned up the welds, gave them a paint job, put the axle together and installed them in the rear!





Next step for the rear is to put on the OME leaf springs. Then I had a little time in the day left so I got the new rebuilt my front axles with new boots and gave them a paint job. Then put the new seals on the knuckle and axle. I put the new knuckle bearing in and then put the axle in the knuckle. I was gonna keep going and put the backing plate, rotor and hub on but I need to get new wheel bearings first so possibly next weekend.



I have a question now. The front axle mounting plate lying next to the axle shaft, Does anyone know where to get the bushings for in there??? One of them was stuck to the mounting bolt and it ripped in half on the way out.
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BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
http://forum.planetisuzoo.com/viewtopic.php?t=33157
http://www.facebook.com/album.php?aid=2028368&id=211501242&l=ee54b89a09
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RED DRAGONS!
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btw1549
Mud King


Joined: 04 Aug 2009
Posts: 585
Location: PA

PostPosted: Mon Oct 26, 2009 12:49 pm    Post subject: Reply with quote

Almost forgot to add. I am going to clear around the LSD to keep it from getting destroyed.
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BtW - 1991 LS Trooper In Progress, Complete Restoration with 3.4L Swap! (The Tank)
http://forum.planetisuzoo.com/viewtopic.php?t=33157
http://www.facebook.com/album.php?aid=2028368&id=211501242&l=ee54b89a09
http://www.facebook.com/album.php?aid=2028932&id=211501242&l=5df63efdaa
http://www.facebook.com/album.php?aid=2030921&id=211501242&l=d0b01a4d37
RED DRAGONS!
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