GRIZZ’s English 2001 S10 Extra Cab 4.3 V6 Truck

[Grizz1963]

Looks like I got sorted for these 3 point harnesses too.

Hope to have a pair, in black bought and paid for in the next week, as soon as the seller has them boxed up.

Currently fitted to an Anglia.



Black is a good option for me.




Back to the garage for making the second seat mounting points and plinths today.

Time consuming job, but needs doing. Chilly outside at 0’C this morning.

[Grizz1963]

Another day where there was little progress yesterday, had a new lodger to interview, that took two hours.

Cultural and language differences slow stuff down.

Anyway, back to important things……

Rummaged in my steel (scrap) pile and found an old seat support from a mobility scooter…..



Cut down, drilled and welded, ready to be fitted.



The scrap post gave me two post/riser/supports for the front of the passenger (formerly drivers) seat.

I also used some very thick walled pipe to make a pair of rear supports.

You will notice the supports are all different…….

Because the underside and mounting points all differ.

Plates to the supports should spread the load more effectively as well.

Original plan was to use a wooden brace for the drivers side, but I changed my mind, thanks to a good friend (Mr Sparkplug) pointing out the possible failings of wood.

And no hinges.



So today will be a revisit to that section copying it in Box section and then bolting the seats into place as @nickwheeler pointed out to me, it allows me to get the steering column, pedals etc into position with me sitting comfortably.

The drivers seat will also be fully adjustable for other potential drivers.

Currently frosty outside and temperature at 0’C

So not headed out yet, but it looks lovely.

[Grizz1963]

Bloody cold out yesterday.

But 5 layers, a wooly hat, and. Thermal underpants helped till it warmed up.



Plan for the day was to remake the drivers seat support in steel, and get the new front shock absorbers fitted.

Found some steel for the seat support, then got distracted by the thought of the new shocks, fitted.

Contemplating painting them red, I decided against it.

Tried to fit one with the wheels on. That was not happening.

Removed the wheel, and a load of struggling to get the mounting points lined up later, the drivers side was fitted and bolted down.

Then had a visitor for coffee for an hour and returned to part 2 on the passenger side.

Got going, and progress was faster than the guessing game of part 1.



Fitted shock.

Tightened top tower bolt and proceeded to the bottom pair that fit through a pair of tines.

Tightened first one, then the second one.

At the point of stopping the torque it went “ping”

Bu66er ! !

Resulting in this.




And looking up.




I guess the next job now will be to remove the shock again and grind back what is left of the bolt, and then drill it out in position, carefully, UPSIDE DOWN.


Not looking forward to this. Seriously.


But I have other distractions today, need to go look for a car for Sally before she goes to look over the weekend with me.

Wish me luck, on both aspects.

[Grizz1963]

11.00 already on Sunday.

Slow start after two or three days wasted with randoms stuff like finding a car for Sally.

Bought a one year old, water dispenser in door fridge that has a RRP of £336.00 for £50.00 yesterday, did not realise it was 45 miles from home, so 90 mile trip at 5.00pm yesterday, but still worth having for the lodgers, as I have a second guy from next week, and freezer space is always an issue in the double door American in the kitchen. Removed the undercounter fridge one lodger uses and replaced with this one this morning.

FREE MONEY……… GOTTA LOVE IT.

My last day off work, back on Monday, then the honeymoon is over.

Today I need to lift the front end again, remove that shock, grind back the broken stud, and use these special drill bits to make a space for a new bolt and nut to hold the shock in place.

I went to my new best friend, nuts n bolts guy and mentioned what I needed.

He suggested a “Dormer Tin coated drill bit” so I got a 4mm and 9mm that should do the job.

Bought about 2 38mm Penny washers to use when fixing the seats onto the floor.



And just looking at this, take when I disassembled and cleaned the front end, it seems lucky-ish that it is a rivet, rather than a bolt, as Bob Heine observed.



Without getting our collective moral knickers in a twist, I found a MAC Tools 8mm deep reach and driver deep in a cars engine bay this week.

It has obviously been there a while, rusty and very dirty, so cleaned it up and added to my tools.




Headed out to go drill out that stud.

Wish me luck.

[Grizz1963]

Soooooooo


Out the house only at 12.30 to start working….//

Felt like I was on the set of Magnum PI

Helicopter over my garage……



Procrastinating

It was possibly the prospect of trying to remove that broken bolt.

@pauly told me that when he worked in the trade they saw a fair amount of these broken.

So they drilled them out and fitted new bolts and nuts.

What could go wrong.

So I jacked the front up, removed the wheel, unbolted the new shock, and put some axle stands in place.

Plan was to grind the broken stud flush, use a punch, mark a centre and then start with the 4mm drill and then hopefully follow up with the 9mm drill.

Laying there, I thought about it and then fetched the BFH

What was to be lost.

Wallop

Wallop

Wallop

WALLOP !!

Felt the riveted head and thought it felt like a small gap had developed.

Two more whacks and PING !



Burger !



What a pleasure, having then put a 9mm drill through the hole, I threaded a new bolt in there, refitted the shock absorber and using a spring washer and a long necked ring spanner, I managed to get it all tightened down.

10 minutes later.

Job done.



While reassembling the front end, I looked back toward the rear wheel and found myself talking to the car, saying to it that I really liked it and enjoyed what was happening.

The 195 width is actually wider than the photo shows, and the way it sits in the wheel arch as well as the steel rim, made my heart pretty happy.

The planned 215 will be just a bit wider, a bit better.



In life we need to celebrate the little wins.

Today the BFH ensured that I celebrate.


.

[Grizz1963]

So…….

That license plate placement chestnut.

Trying to somehow camouflage the front suspension a bit.



Placement options.

Straight cover of the view



Or offset below…. Not my choice.



Standard, conservative look.

Maybe just tucked under, canted rearward.



Looking at it again……….

Makes me wonder.


While working down at the garage, I went up to the house to sort selling the small fridge.

Walking back, I saw this pic and realised my privilege, thankful that I built the carport last year, and also previous planning and changes previously set up for the future, which is now, what I am missing is actually………

Gas station forecourt boards hanging down from the top of the carport roof.

Need to give this a bit of thought I think.


Imagine a 450mm to 750mm high frontal facade with some gas station advertising.

[Grizz1963]

Making the drivers seat main support as a copy of the wooden one I had done.

Cut steel.



Measure, drill, fit up, flapwheel and prep.



Paint up.



Trial fit to seat.



Bolt to body.



Result was a very adjustable seat.

@nickwheeler hopefully this will mean getting the steering column set up just right.

Mounted and set right back.



And forward all the way.



Followed by a nice sunrise today to start my year back at work.



Next job, mount and fix the passenger seat, followed by mocking up the new roll bar.

.

[Grizz1963]

Because the BFH negated the need to use those special drill bit, I decided to see if they would refund or credit me.

Any option was acceptable to the shop, so I traded them for some shiny stuff that will get used.

From M12 downward in size.





I worked in hospital today, so after work a few hours spent getting the passenger seat lined up and bolted dowm.

Followed by another little job.

[Grizz1963]

Being back at work means my days run effectively from 07.00 to 17.30 again.

So it leaves weekends to fit Sally who works at least every second Sunday and other important housekeeping jobs into.

So the only way to get on is to start playing after work and dinner on days/eveningsmwhen Sally does not stop here for dinner and a snooze on the couch.

Night Shift working will keep things moving forward slowly.

Last night I went to the garage just after 5.00pm and closed by 8.30pm

It included a 30 minute chat and show around to my new lodger who may be here for a month or three, not sure yet.

The job I wanted to get done was to drill the mounting holes on the floor and get the height and position of the passenger seat right.

I also adjusted the drivers seat with an added 5mm shim.

Due to the lay out of the seat mounts, the legs all differ.



Eventually giving me this result, all the fitting, and adjusting took a while.

Drivers seat is fully adjustable, which is why I was looking for a spare passenger seat all the time.

Passenger seat is fitted in a fixed position.



And enough space to fit a new roll bar, it will lean back as planned, and new mounting points will be welded to the chassis as @nickwheeler had suggested for the move.



I also started to mock up the new roll bar that will be canted back, and then bend in at shoulder height.

A horizontal bar for safety harness mounting at shoulder height gets added, and a pair of diagonal rearward supports anchored to the chassis in the rear corners.



So there you go.

Nightshift is a real thing now.

[Grizz1963]

Free is good ehhhh…?

We all need a wagon, don’t we.





Clean up and reassemble should help.





More when it is cleaned up and dried.

[Grizz1963]

Another random entry.

Based on a comment elsewhere, I went up into the loft and took photos of 41 year old photos of my first car after school.

This was my 1979 140Y SDX (still no idea what it really meant as an SDX other than matt black bumpers which I stripped the week I got it in 1981)





This little car used to go like hell and was driven like that too at times.

RWD ruled.

[Grizz1963]

One more thought on the roll bar design.

I am thinking that the rearward supports should be quite low, at the same shoulder level as the safety harness mounting points, and tucking into the rear corners, thus leaving a bit of space for beers and BBQ in the rear.

Still need to create some kind of cover and mounting point for the battery in there too, as the MX5 wiring loom and positioning was in the trunk/boot.



Another crazy thought was to use box section, repeatedly pie cut and shaped to form the bends needed and welding all the cuts, shaping with flap wheel and painting up.

Crazy yes, a load of work, yes…… BUT.

[Grizz1963]

Another useful bit of free cash collected last night.

1780mm tall, 800mm wide, 400mm deep.

Will replace a cabinet half that size and allow me to collect more junk and display it to collect dust.



Free cash guys, remember that.

[Palf70Step]

[Grizz1963]

Originally Posted by Palf70Step

Absolutely Bill.






Got home today from getting the Focus serviced.

Mickey shouted over the fence…… “Got a parcel for you”

So he hoiked a 19 pound box over the hedge.

It had a Home Office pass tape on it, so I guess inspected and passed.



Dennis had sent me a parcel with some treasures.

I actually only got to unpacking it at about 8.00pm and it made me laugh out loudly, tears in my eyes.

Generous yes, and crazy for sure.

Just reminded me that family is a lot more than blood.

Karma is a strange mistress, but I love her and know she balances the books at all times.

Unpacked the parcel, T-shirts for me and Craig and Sally from Clem in Arkansas and Dennis in St Louis.

I sent some cash to Clem’s Tuba Trucks Toy Drive via Dennis’ daughter in law Hanna on Paypal (you see we can all be kind and contribute to worthwhile charities) and in return I got a T-shirt.

Also included was some Oatmeal cream cookies, an all time favourite, and what had me laughing loudly was some of Roger Orf’s hunted smoked deer sausage.

The sausage was wrapped in bodyshop panel paper and masking tape to keep the wrapping together.

Just perfect.



Then parcel no 2 in a Rural King bag delivered a hoody for Sally and I each.

Way too generous.



And then, for the Rezin Rockit a pair of high end, 5 point racing harnesses.

Simpson.



And one for the passenger.



So there you go.



Karma bucket overflowing.


Life is good.

Roll on the weekend.

[Grizz1963]

[quote author="@glenanderson" source="/post/2715104/thread" timestamp="1642164024"]At or slightly above. [/quote]

What I thought.

But it seems downward is recommended.

[quote author="@nickwheeler" source="/post/2715105/thread" timestamp="1642164315"]I expect the manufacturers' websites will provide definitive information[/quote]

Spot on.

[quote author="@jimil" source="/post/2715125/thread" timestamp="1642170062"][a href="https://simpson-europe.com/en/content/harness-geometry.html"]Simpson[/a][/quote]


Thank you Jimi, that is great, I would not have found it that quickly.





A. Crotch belt must be split at about 20 degrees to create the stabilization of the pelvis bone (hip area).
B. Crotch belt routed through seat vertical or slightly backwards. Try to avoid that the belt pivot on edge of hole through the seat.
C. Shoulder belts must be angled 10 to max 20 degrees down behind the neck. Belts should never pivot or touch the edge of hole through seat.
D. Lap belt is where we want to remove as much energy as possible in a crash. The pelvis (hip area) is the strongest bone in the body. Therefore, it is paramount the lap belt is mounted with correct geometry and height so it can work properly. Install backwards 20-45 degrees from vertical line, make sure lap belt can hook and secure the pelvis bone. The harness lock-mechanism should be placed as low as possible to avoid submarining and damaged to stomach and lower back.
E. Shoulder belts should be mounted as close as possible behind seat back (20-50cm). If HANS is used it can be wisely to angle the belts 20 degrees towards center to avoid belts sliding off the HANS.

[Grizz1963]

Friday…..

WEEEEEEKKKEND ! !

So today I took my lunch break and grabbed a coffee and headed down to the garage.

I had started on the mock up of the roll bar the other day, so continued with that.

Also a few other little jobs.

Do note, the drivers seat has been mounted lower because in the fully back position it needs to slide back and downward on the rails.

So if you move it forward for shortarsess if will raise it vertically.

Make sense?



And finally, drawn for copying, the cross bar for the harness mounts are at shoulder height.



I think I am liking this so far.


Remember 28 August 2020 ?

First pic or is that PIG entry on this thread.



When I came in today there were a few letters and a recycled padded envelope (my kinda thinking) addressed to me……..

First thought was that I had not ordered anything off Ebay, nobody had said they were sending a small envelope.

So I opened it………..

@peteh1969 had gone and created a 3D printing programme for the Rocket Pig and printed me some logos for the Rezin Rockit to use once it is ready to be on the road.

I will need to try paint them in chrome, and then hopefully get some clear resin to fill them in as badges for the sides.



I was chuffed as a chuffed thing can be.



These little details make a big difference.

I have another plan.

Small triangular side plates to add to the outsides of the seats, just to prevent sliding out, more as a visual detail.

In the style that @dez put on his Transit, recovery.

With dimple die holes in three sizes. Or just step drilled in different sizes and finished off.

Or something like that.

Picture lifted from Dez’ thread.



Using the seatbelt bolt and securing pin to keep it in place.




Adding more and more little details, hmmmmmmm….?

maybe tomorrow will see some real work again.

[Grizz1963]

Foggy and cold till midday today.

Remember the rescued scrap wagon.

Cleaned it all up, disassembled the cushions, washed them, reassembled.

Of course one panel missing…….



So I made a replacement rear panel up after getting all four wheels pumped up. What a pita when you cannot get to the valves.



Painted it white, then added some “distressed” blue stripes.

An inverse “Stars n Stripes” design due to the red wagon and white stars.



Then selected from my collection of motorcycle license plates, a plate to add to the rear.



Not really the plate I wanted to use but I had three AZ plates.

Have to wait for the enamel paint to dry fully as 4’C is not the optimal temperature for paint to dry.




So not much Rezin Rockit time, but a nice change of pace.

[Grizz1963]

[quote author="@westbay"]"A Change is as Good as a Rest"[/quote]


Thanks Tony.

Absolutely agree, and change on my terms, means not Christmas or shopping or yard work.

So woodwork in stead of metalwork is quite therapeutic too.

I did spend some time clearing a load of epoxy or whatever from inside the Rezin Rockit body in preparation for taking on the A-pillars and steering or dash support today.

This morning after a night indoors, the paint was fully dried on themrear panel of the wagon.

Reinstalled it does look a bit weird, but I am leaving it like that, good enough to be a wagon for carting around treasures or work.

Garden wagon for Sally maybe.



Now off to the garage to get going with measurements, cutting, and tacking the flat bar and angle iron to create a strong carrier for the dash supports.

[Grizz1963]

The headlights on the RR will need replacing.

I have seen a few designs I like, or that have grown on me.

Now I give you: 24 volt, LED, ex-Humvee and from Afghanistan headlights.



Closer up.




So tonight, or tomorrow mornings question of the clever electrical types……

These lamps are 24V

Can one simplistically convert a regular 12V system to deliver 24 volts to these headlights?

Thanks for the input.

[Grizz1963]

Yesterday i started out with some yard work, and by 11.00 started on the RR.

Plan was to start creating a strong, supportive frame to support the Land Rover screen @glenanderson donated to the build and also make a place to attach the dash and steering column etc.

Space to lay the foundation.



First lengths of angle iron cut, drilled and bolted down to create a starting point, also drilled for eventual kick panel fixing.

Awkward reach, stretch, tighten.



Walked up to grab a coffee at the house and also go check up on Mickey next door, as I came back from looking through Micks front room window (he was asleep in his chair) @nickwheeler pulled in over the street.

He had come over to add to my limited hands, skills and planning. Perfect,

It is amazing how long some awkward jobs take,

Nothing is exact in this body tub, so every bit of steel has to be custom cut, shaped and made to fit, assembling, disassembling repeatedly takes time to get a decent fit before tacking and welding.

Upright tacked and welded to the bottom, and then top angle iron inside scuttle return clamped, welded in place, and then cross braced from sides upward.

Also pre drilled the holes for the door hinges.

Currently Land Rover items fitted, but liable to change if I cannot get them to open and shut easily.



Another slow but nice job was cleaning all the old silicon, epoxy, resin and paint from the top of the screen mounting surface.

But needed to be done to generate a decent fit.

Interestingly there is a 10mm deep dip between the sides and centre which will need some rectification later.

Also need to figure simple small, bottom mounted windscreen wipers and motors to be externally fitted on the screen.



Door frame and hinges looking good.

Holes above the top hinge, ready to fit the mirrors.



Mock up of door, panels and netting, along with Nick holding the screen frame in the position it will probably be fitted in.



Happy with that so far.



Followed by more welding and swearing as there is not space for a welding helmet under the dash, so open eye tacking before removing and doing a full stick weld.



Next job was to add in the scuttle brace for the screen and its 375mm diagonal braces.

Some G-clamps,muupside down tacking and a lot of swearing when I welded all the upside down contact points, amazing how welding splatter burns through 3 layers of synthetic fibers and continues to burn, a bit like getting a wasp up your trouser leg.



Amazing how many hands you need for some of the jobs, at times three G-clamps and four hands just got the jobs done.

MX5 dash and steering support being trimmed back while I was welding.



I really enjoy the company, but what it also great between Nick and I is actually getting on with other jobs if one of us is busy doing a one man job.

Looking back, we had little to show for the time spent, but in fact it was a huge step forward.

Tons of planning, proposing and visualisation went into yesterday as well.

Next jobs include cutting the old dash out, well, quite a bit as a new one will be created.

I also need to make a template for the screen support for the studs to be welded into the screen, holes marked and drilled for mounting and a good long look at the original fuel tank which may be completely FUBAR or reusable in order to create space for the exhaust to be mounted as a rear exit.

Dinner at Sally’s tonight, her treat for my birthday.

Later gang.

[Grizz1963]

Found this pic of the originals I saw in 2015.


Loved the headlights.

[Grizz1963]

Remember the stables I went to help mate Craig pull down along with Fil from Cambridge.

That came down to allow for “redevelopment” as a residence.

In the mean time groundwork and foundations have been done.

Yesterday at 09.00 the new homes stud walls came onto site.

Pics from Craig.





We all need a strong long arm.





By 3.30 pm this was the status.



And this morning the chilly sunrise brought this view.






Not sure when exactly I or we will get the call to go help Craig raise the walls on the stables and get the roof on top of them.

Hopefully the weather will be kind when the time comes.

[Grizz1963]

I had planned on making the template for the front screen tonight and possibly drilling the scuttle.

But this cold, wet fog and along, hard day decided it was not a clever idea. Wusss?

Ordered these tonight.

£40.00 delivered.

Lets hope I do not see a pair for half the price.



Fitting as soon as it lands.

[Grizz1963]

So when rebuilding the front end I missed out on he track rod ends.

No real reason, but I did.

So……….



Now, on Ebay these items are available, but they do look different to what is fitted to the car.

Typically I cannot figure whether it will be the right fit for the car.



Described:

Ford Cortina Mk3,4 & 5

All Models 1970 to 1982

Pair Track/Tie Rod Ends

Top quality Delphi Steering Parts


Would this be the right fit, but just looking a bit different.