Rebuilding after 15 years of storage

[PHOENIX-GER]

When you go to mount the inner fuel neck housing you will need to modify the right side of the housing in order for the door hinge to clear. You will also need to drill a new 9/32" hole in the sheet metal in order to mount the housing to the fender. See attached. Hope this helps.

Fortunately not as much of a challenge as using sheetmetal with as little rework as possible. Thanks again for sharing your expierence. That make it for other easy to follow.
Also if the costs was high for that addtional tank it make the truck with the new drivetrain to a comfortable full daily driver with a lot of options.

 

[PHOENIX-GER]

Today we brought the old engine to the enginebilder
After talking 4.5 hour with him about the options we left the shop with a complete new solution as he had a better solution for our demands as we had ask for.
We never expected so much options and you can be really glad that you have them in your country.
In Germany we have so much restrictions in roadapproval that the tuning scene is reduced on some less brands with a small amount on options.



on our way of 250 km to the shop it was funny to notice how much stay in slow overhaul the trailer to inspect the engine on it. It seems this is a rare view on our roads

 

[Sharecropper]

Today we brought the old engine to the enginebilder
After talking 4.5 hour with him about the options we left the shop with a complete new solution as he had a better solution for our demands as we had ask for.
We never expected so much options and you can be really glad that you have them in your country.
In Germany we have so much restrictions in roadapproval that the tuning scene is reduced on some less brands with a small amount on options.

View attachment 870119

on our way of 250 km to the shop it was funny to notice how much stay in slow overhaul the trailer to inspect the engine on it. It seems this is a rare view on our roads

So I take it you gave up on the P400?

 

[PHOENIX-GER]

So I take it you gave up on the P400?

No it will be a new P400
It is up on the engineconfiguration with transmission and transfercase on our demands.
We are not used to have so much choices we found our toyshop for adults. Sure you find all also online but we are not sure about compatibility. Thats why we let do this from an enginebuilder.

We could see a P400 on the testbench from another customer like also different other engines like Optimizer and 6.2 with upgrades.
He explained a lot of details between the different blocks with the improvements and the choices we have on that enginebuild. To see it with a direct compare of the facts is impressive.

 

[PHOENIX-GER]

Another surprise gift from our Truck to us...
During reassembly the Brakesystem does I notice that we miss the gage setting No 9. After controll the pictures we made before disassembly could i see that i not lost it, it was never in











Just ordered replacement part as it is still available.
The last brake line need a bigger brakeline fitting as the other and i have of course only the smaller one ordered

 

[PHOENIX-GER]

Used the weekend to going on with Brake and steering gear







the old maincylinder said it was DOT 5.0 silicone brake fluid, didnt expect that as the complete system is new, we could use any DOT Specification we want now

 

[PHOENIX-GER]

Just saved by order the sticker for the maincylinder if we not want change and use DOT5.0

DOT5 Sticker

of course also cleaned the cover with the engraved info

 

[PHOENIX-GER]

About the new transmission was there also toughts to move the shifting to the floor.
A short shifter with benchseat will need to improve some gymnastic to shift and a "cooking stick" for shifting is ugly
We think we stay with the column shifter

Checking this weekend show the usual aging of a steering column.
Didnt expect so much dirt coming up from the lower end in it

















Time to check the rebuild Kit for that column and to make improvment on a head-light-flasher

 

[PHOENIX-GER]

Wow just a small plastic part - seems the trainees in our company got a new job to train their skills in prepare a Metalpart
they will hate me by such a lot of measurements with it
A sandwhich and a coffee will change their mind. It make more fun to train skills on things you need as just on scrapmaterial
We all went to this to become a good metalworker and machine engineer.



Edit:
I know now why this part is lost - you need to destroy it after use and it is today hard to got and at least also expensive (for me 38,36 Euro to my door with shipping, tax and fees - in USA 8,25 Dollar). Maybe the most rebuild without that gauge...



So our Trainee will rebuild in metal in two pieces that i can disconnect without destroying
Be sure i will never use it again, as now i have it saved



removed again after pictured as i am waiting for the metal-rebuild

 

[PHOENIX-GER]

What to do if the wife is not satisfied with the result? - You do it again!



After I applied a matte clear coat as a fade protection, I unfortunately done this during it was to hot. So i have a bit clouding on the surface. Most of them behind the bench, the other on the lower dashboard, so actually not so really immediately visible.
Would have accepted as a man also ... I'm not a painter after all.

On my hint that you only see it when you know it was her reply the typical answer of a woman: but I know it.
No discussion on that point with her , i know my wife long enough! She prepared again the complete Cab for new paint and i just paint first the primer.
With every job again in painting become i am more expierence in that
And of course in future i will take also more care on the temperature...

 

[Mullaney]

What to do if the wife is not satisfied with the result? - You do it again!

View attachment 872144

After I applied a matte clear coat as a fade protection, I unfortunately done this during it was to hot. So i have a bit clouding on the surface. Most of them behind the bench, the other on the lower dashboard, so actually not so really immediately visible.
Would have accepted as a man also ... I'm not a painter after all.

On my hint that you only see it when you know it was her reply the typical answer of a woman: but I know it.
No discussion on that point with her , i know my wife long enough! She prepared again the complete Cab for new paint and i just paint first the primer.
With every job again in painting become i am more expierence in that
And of course in future i will take also more care on the temperature...

.
Well, that is why you and she can work on projects like this together.
You took the hint and didn't complain - good for you!


That picture is pretty amazing.
I have never seen the inside of a truck that clean before either...
You are definitely going to to have a first class vehicle when you guys get it finished!

.

 

[PHOENIX-GER]

.
Well, that is why you and she can work on projects like this together.
You took the hint and didn't complain - good for you!


That picture is pretty amazing.
I have never seen the inside of a truck that clean before either...
You are definitely going to to have a first class vehicle when you guys get it finished!

.

I have no reason to complain as my work just painting. My wife done the complete prepare with grinding.
She was also not satisfy with her grinding as she think the result could be better if she had use finer wet sandpaper.
Also a reason for her to do the complete job again, otherwise we had just do it on the visible surfaces - my opinion
Not the paintjob alone make the job perfect - it is also the prepare work on grinding
She got also more expierence in perfect grinding with every job again

 

[Mullaney]

I have no reason to complain as my work just painting. My wife done the complete prepare with grinding.
She was also not satisfy with her grinding as she think the result could be better if she had use finer wet sandpaper.
Also a reason for her to do the complete job again, otherwise we had just do it on the visible surfaces - my opinion
Not the paintjob alone make the job perfect - it is also the prepare work on grinding
She got also more expierence in perfect grinding with every job again

.
Practice does make perfect or pretty "dog-gone "close.
I have really enjoyed following your progress!
.

 

[PHOENIX-GER]

If my wife said she was shopping .....

 

[PHOENIX-GER]

Going on with refill the Axle-Diffs - found them without leaks after rebuild , complete the Brakelines and finally prepare the box before paint again the cab


use some little helper to fill up



My wife had a lot of endurance in prepare the parts for paint.
The box is hard to clean up as there are a lot of paint layers on it
Original whatever it was as first cover really sticky and hard to remove, army green, filler from the painter 1999, red and again black as he had no order to paint the box red....
Paintstripper dont work well. She do all by metal brush with machine...
We thought more than twice about sandblasting cab as also cargobox, but we have seen how they act with the frame. We dont want have additional dents on it.

 

[PHOENIX-GER]

My wife asked me how much brakefluid to order... so i took the TM to see how much and found following statement:

"Use new DOT 5.0 Brakefluid from a sealed can as much as required"

During disassembling i doesnt measured the saved old fluid, just filled in a can for Diposal as i expected the required amount in the TMs.
So we decide to order 2 liter in 3 sealed cans - this should be finally enough to refill/bleed the complete system

 

[PHOENIX-GER]

"smooth as an android butt" so i have allow of my wife to go on



she is working still on the box - a new tailgate with chevrolet on it => Chevrolet Tailgate
Costs to our door around 1000 Euro
We thought of this in the past as the original have working traces, but we descide against as it is a part of live from the truck





and here the same sticky paint layers as in the box

i spent the whole day in customize the tankfiller on the right side - just small improvements but timeconsuming job





not 100% similar to left side but it fits - i am satisfied as for that the filler is used from left side
Both doors need still right adjustmed

 

[PHOENIX-GER]

Beside the restauration job was our hunt for the NP205 in Europe finally sucessful
We picked it up personally yesterday in NL





next will be to open and rebuild it as all we know it is used and like all used it shall have less miles

We was a long time not sure if we stay with the 208 or take better a 205.
The problem was to got one here in Europe as the shipping costs are high for it and also in the USA are these TC not often available.

 

[Mullaney]

Beside the restauration job was our hunt for the NP205 in Europe finally sucessful
We picked it up personally yesterday in NL

View attachment 873746

View attachment 873747

next will be to open and rebuild it as all we know it is used and like all used it shall have less miles

We was a long time not sure if we stay with the 208 or take better a 205.
The problem was to got one here in Europe as the shipping costs are high for it and also in the USA are these TC not often available.

.
Hopefully you can find a gasket kit and some bearings locally? Or who knows, when you crack it open it might look like brand new inside.

Happy Wrench Turning!

.

 

[PHOENIX-GER]

.
Hopefully you can find a gasket kit and some bearings locally? Or who knows, when you crack it open it might look like brand new inside.

Happy Wrench Turning!

.

Buying used without having knowledge of the previous owner is always a surprise package

Here is nothing available but you have in the USA several good shops who offer spare parts and tuning parts.
So we open this weekend to check what we need and maybe we have win the superbowl and nothing more except gaskets and bearings are necessary