Recovery Mission

Last week, while considering the two trucks I’d learned about in New York, I got a text from Bennett:

The owner is a friend’s family and they wanted it gone before it collected more tickets from the local constabulary; I told Bennett I wanted it and asked for his help in going to get it. He got in touch with his brother for the towing rig and a plan was hatched.

Sunday morning I met Bennett over at his storage yard so that we could pull the Hudson off the trailer, park it, and use that for hauling. Before we could leave, we had to replace the hot lead to his trailer winch, which took some surgery and delicate tinkering. Moving the Hudson was pretty easy (we’re used to this procedure by now) so we were on the road north by 9:30.

The truck was at the bottom of a tricky driveway at the end of a fast curve, so I stood outside and stopped traffic while Bennett expertly backed the trailer up the hill (digging the bottom lip all the way up) on his first try. He backed it down the lane to stop at the rear bumper of the Travelall.

She looked worse in person than in the photos (big surprise!) Like she’d been at sea for years and had been beached in a storm. The owners of the house came outside and watched as we busied ourselves setting up the ramps and unloading tools.

The first issue was that it was on four flat tires: two of which were questionable and two of which looked like a dinosaur had been snacking on them. I put my compressor on the “good” ones and got the passenger’s front to fill and hold, while the driver’s side rear would fill and empty at almost the same rate. So: it was up to the winch. We aligned the ramps and yanked the truck backwards up to their edges, and realized the trailer hitch would never clear the deck of the trailer. But we’re pros at this: we stacked up some scrap wood and propped them with 2×4’s to lengthen the ramps and make the angle work better. I put a long board between the hitch and the trailer, levered it over the edge, and we were quickly up on the deck. Turned out the one good tire was bolted to a drum which had frozen, so it was effectively useless.

We pulled it back as far as possible but knew having the engine over the rear axles was dangerous, so we made a plan to flip it around as soon as we found a good-sized parking lot. After strapping it down tightly, we said our thank-yous and I went back out to the street to cover traffic. Bennett got up a head of steam and came down out of the driveway at an angle to avoid getting high-centered, and we were soon on our way.

Down the road we found an empty restaurant parking lot with a couple of steel posts that would be perfect for our next trick: pulling the truck off the trailer, then loading it on facing front. He backed it up to a post which we fastened a strap around, and he gently pulled forward to pull the trailer out from underneath the truck. The front tire—the one with air—still wouldn’t budge. We used the strap to pull the truck backwards to clear the post, and Bennett turned the trailer around to meet the front of the truck.

When we’d gotten the Travelall about 1/2 of the way up the trailer he remarked that he was impressed with how well the battery was holding up on the winch; fifteen seconds later the winch began to sputter as the power dimmed. We dicked around with ratchet straps and a come-along that was definitely not strong enough, and finally unhitched the Ford, pulled it up to the front of the trailer, and used jumper cables to juice the battery enough to get the truck winched all the way forward.

From there it was easy to strap the truck down and get on the road. After a quick lunch at the diner up the street, we drove back to Maryland through howling wind and snow showers to my house, where I’d moved the red Travelall backwards to make room.

Here we used a similar method to get the truck off the trailer: we hooked my tow strap to the telephone pole and the tow hitch on the truck and Bennett simply pulled the Ford forward. We quickly threw a tarp over the carcass to hide its beauty from my neighbor, who is coincidentally trying to sell his house—sorry!—and packed things up. Then we drove back to his storage lot to help get the Hudson back up on the trailer. We got everything covered and strapped down, and took off for home.

I haven’t had a ton of time to look the truck over, but here’s what I see so far:

The outside sheet metal is all Pennsylvania-good. Meaning it has rust in many of the same places the red truck does: in the front fenders at the bottom and over the eyebrows, in the front grille below the marker lights, behind the rear wheels at the bottom of the arches, and in the bottom corners under the taillights (mine is solid here). There’s good chrome trim around the outside which looks like it might all be intact. There’s one good chrome rocker trim on the passenger side—the driver’s side was ripped off at some point. Both bumpers are in excellent shape, and the rear bumper has a set of inset reverse lights. There’s a beautiful roof rack and luggage rail setup on the roof. It’s a single-tailgate model but we can’t figure out how to open it—there’s no handle anywhere, and this truck came without a key. The drip rail is in excellent shape given how long this truck had been sitting. There’s a lovely patina of the original IH green, buffed down to red primer, splashed with yellow lichen across the whole truck.

Inside, it’s a 4-speed stick, and the furnishings are all Custom—it says this on the dashboard. Fabric door cards, fancy steering wheel, padded dashboard, and deluxe headliner. The front bench is shot, and the rear bench had been folded forward, so I can’t see what shape that’s in. Water has gotten into the truck from the driver’s door seal so the front floors and seat are wet. In the far back, there’s what looks like a heat or A/C unit sunk into the wheelwell on the passenger side, and a square toolbox on the driver’s side. The chrome trim for the headliner inside is all intact, and there are two visible dome lights.

A quick look under the hood revealed a V8 with power steering, and a large brake booster, as well as a mount for an A/C compressor. It’s IFS up front, which means there’s no leaf springs for me to grab, but I can definitely pull the rears to have them re-arched.

So, the next steps are to do an inventory of what’s good and what’s not, and start pulling parts off the truck. I have no title and no bill of sale, although the owner said he’d look for the former. Our cursory inspection showed a lot of rust and I’m sure it’s deeper than it looks, so stripping this truck down to the shell won’t bother me too much. Jen doesn’t want it lingering in the driveway, and neither do I, so I think I’ll sell some Scout parts to make room for Travelall parts. I’ve already dug two spare fenders out of storage, and I can sell one set of spare doors to free up a lot more space—Bennett said he might be interested in them, in which case they are his for the asking.

Posted on   |     |   Leave a Comment on Recovery Mission  |  Posted in Friends, Travelall, Trip Logs

New York Crispy

Two weeks ago, an ad popped up on Marketplace for a Travelette about 20 miles from my sister’s house in New York, and the only picture provided showed a very tired old truck lost amongst a stand of trees. I contacted the seller and he told me a little bit about it, then mentioned he had a Travelall further back in the field, and was vague on pricing. Later in the week, my brother-in-law generously offered to go bushwhacking to check it out, and he called me from the field to tell me what he was seeing. As I suspected, both rigs were New York-tired, meaning they’d lived a hard life on road salt and were well corroded on the bottom.

He sent me a number of pictures of rusted panels and cabins full of leaves and junk. The Travelette would offer a good grille surround as far as I can tell, and perhaps some glass, but there isn’t a lot of good stuff there to go with. The Travelall was a panel van, meaning the rear area where the glass lives is solid metal. But it was a barn door model, and there were some good parts left here and there from the pictures he sent; the ’62 grille and headlight surrounds might be worth some money, and the front clip looked like it was in good shape.

So, if I can make it up there this spring before the whole thing gets overtaken with weeds, wasps and water, I’ll stop in and pick up some of the remaining good stuff before it all oxidizes into the ground.

On Sunday I spent the majority of the day out in the driveway prepping the rear bench seat for upholstery with Jeff. They were still covered with foam and burlap after I’d removed the covers, and they needed to be separated, stripped down, wire wheeled, and covered in Rust Encapsulator. These two seats were an order of magnitude more disgusting than the fronts. Critters had made nests inside long ago (when I took the covers off, it covered the driveway in nuts and bedding) and the foam and burlap had been damp for a long time, so the springs were all covered in surface rust. I took them apart, soaked those bolts in Evaporust, and wire wheeled the outside of the frames. Then I brushed on Rust Enapsulator over all of the exposed metal, and when that had dried, sprayed the rest with black Rust Stop.


May 2023


March 2024

Meanwhile, I sanded the high points off the driver’s fender, skimmed some new mud over top, sanded it again, and skimmed a light amount on top to build up the body line for feathering out. It’s really close—it might take one or two light layers of filler to nail the ridge perfectly, but I can see how it’s a million times better than my original attempt to fix the problem.

Posted on   |     |   Leave a Comment on New York Crispy  |  Posted in Travelall  |  Tagged

That’s Expensive

Following a request for help on a Travelall-specific FB page, I filled out a general inquiry form on an auto glass supplier’s website for new production of curved rear glass. I got an email back yesterday with the following quote and a note at the end (emphasis mine):

Dear Customers:

1 side then $1,495 + Fr 400 = $1,895 delivered cost lower 48
Both sides $2,595 + Fr 600 = $3,195 delivered cost lower 48
50% deposit and 50% due when it ships – under 12 weeks.

These #’s are based on 20 lefts & 20 rights being made.
If more PO’s come in b/ we make – cost decreases.

This will be last time we look at making these.

This roughly squares with a separate estimate I’d been given last year before I found the Holy Grail in Ohio, minus freight.

Posted on   |     |   Leave a Comment on That’s Expensive  |  Posted in Travelall

Weekly Update, 2.26

From what little UPS has told me, my seat covers are gone. I had to go to the location I mailed them from and ask, and the guy went into the back of the office and looked and claimed they cut me a check at some point for $100 plus the amount I paid for shipping. Which also hasn’t arrived. So I have to organize a meetup with Jeff somewhere between here and Pittsburgh to hand over the seats.

My spare fuse block made it out to the Scout Connection on Wednesday, and Dave called me to let me know it’s actually not the right fuse block for my truck. I asked if we could swap it for a correct used spare and call it even, and he was happy to do that. So that process should be underway, and hopefully I’ll get a harness in the mail sometime soon. I can’t wait to open that Pandora’s box get that process started; having a working electrical system is one of the three biggest obstacles to getting this girl on the road.

I bought a basic hammer and dolly set from Harbor Freight on Saturday morning and got to work hammering out the dents in the driver’s fender. It took a bit of time to understand how the tools worked; there’s a hammer with a small contact area on either side and a flat spoon for wider areas, as well as two solid steel dollies for the backside. I started with the hammer and quickly realized it was too small a contact patch, and switched over to the spoon almost exclusively. In a couple of hours I had the edge shaped correctly and most of the valleys flattened out, as well as the overall curve of the fender re-formed. Hanging it on the truck I was pleased to see it matching up with the body line really closely, and the panel gap looked really close. After a few more adjustments I re-hung it to confirm everything aligned, and then got things ready to skim some filler over top.

Sunday morning I had a little free time so I used the orbital sander to knock off the high spots in the filler and then skimmed a second coat over the fist; the filler portion of things is going to take a lot of time (as the other fender did) to flatten the large areas and also match the curve over the fender.

 

February Update

I’ve had a bunch of shorter clips in the hopper for a while, and figured I’d collect them into something resembling an update.

On the project side of things, I used a heat gun to remove all of the old bondo on the driver’s side fender, then cut off the pop rivets used to hold a crappy patch in place installed Back in The Day.

When I had that out, I cut a larger square out to get things ready for a proper butt-welded patch. The other thing I had to do was to try and bend the rear edge of the fender outward and back into original position. At some point somebody really bashed it inwards so it never looked correct when it was hung on the truck. I was able to get it mostly back into place, and used my everyday hammer to do some dent removal. At this point I want to get an actual bodywork hammer and bag to pound out the larger dents instead of trying to hide sins with filler.

Once I had that cleaned up, I cut down a section of metal and tacked it into place. I’m going to have to finesse the bottom edge a little bit—or grind this off and re-orient it further down—but it looks like it’ll go in pretty easily.

Posted on   |     |   Leave a Comment on February Update  |  Posted in Travelall, Video, Welding

Weekly Roundup, 2.19.24

I spent a couple hours last weekend looking at the spare C-series wiring harness I’ve got tacked to a board vs. the diagrams in the service manuals, with a goal of trying to identify what I’ve got and to possibly refurbish it for the truck. In the manual there are two model years provided, those for the C100 series and those for the D1000+ series. With a lot of studying and some magnification I was able to track down some of the cable runs from the fuse block to their endpoint at the bulkhead connectors.

The easiest ones to follow were for the headlights: two green wires marked 18A and 18B, which didn’t change between the two model years. I put a multimeter lead at either end and tested for continuity, and was please to see things worked. I found and tested a couple more but got stalled when I was trying to compare what I found at the end of some of the bulkhead connectors to what the diagrams said, and stepped back to have a beer and a think. This wiring harness is in decent shape and is about 90% complete, but there are several runs that end in clipped wires before they get to a connector, which means I don’t know where they lead or how they connect to the truck.

I decided to do some product research. My first call was to Super Scout Specialists, who sadly told me the guy they had building their wiring harnesses is no longer with the company. Next I (gulp) called Travelallparts.com, who have harnesses listed on their site for $2-300 more than SSS does. They confirmed the price and told me I should consider a blade fuse upgrade to the kit for an additional $300. Then, on a hunch, I called the Scout Connection, with whom I had excellent luck finding the brake part nobody else was able to identify. Dave took my information and when he called back gave me a great price for a bench-tested used harness, minus the fuse panel. I told him I’d send him the spare fuse panel I have on my workbench, and we set up the deal.

Having a mostly working electrical system will be a huge upgrade to the truck; right now it starts and runs without any fusible links at all, which is still a bit mystifying to me, as are the working fuel and amperage gauges and the single brake light that worked before I disconnected the leads to the aftermarket trailer brake.

In other news, the box of dilapidated seat covers I sent Jeff last week have gone completely missing via UPS. On my visit to mail off the fuse panel (which was insured), I asked them to help me track it down, but they still don’t have any information.

Right In The Feels

This old girl showed up on Barnfinds.com today and it hit me right in all the sensitive spots. This rig is an exact copy of Chewbacca back in the day, except for the Diesel badges on the fenders and the license plate arrangement on the tailgate. Like this truck Chewbacca was a 1978 painted Siam Yellow with no exterior trim, had all four stock hubcaps, a color-matched traveltop with no roof rack, and inside was the same Tanbark high-back bucket seats, rubber floor mats, green accents, and 4-speed stick. Chewbacca had regular side mirrors and BFG Mud-Terrains. The example for sale has some serious rust in the rockers and quarter panels, some road rash and there’s a Nissan diesel under the hood, but if I squint just a little bit I can see ol’ Chewbacca parked out in front of my house waiting for another trip to the beach.

Posted on   |     |   Leave a Comment on Right In The Feels  |  Posted in Chewbacca

Shiny Red

Jeff gave me a ring early in the week and asked me to send him the existing overs off the seats I have because he’s worried what he has might not fit correctly. So I went out at lunchtime on Tuesday and quickly pulled the covers off the rear bench and front vertical section, wrote where they came from, and boxed them up to be UPS’d up to him. I would like to have spent more time taking pictures of how they were assembled, but I was up against the clock and weather, and wanted to keep the process moving.

Jeff said I’m welcome to come up to his place and he’d show me how they go together when he’s got them completed, and it’s looking more and more like I might take him up on that offer. I’m sure I could figure out a lot of things on my own but I’d rather have an expert show me the right way first before I ruin anything.

The other thing I did on Saturday was to cut and fit two sections of steel to the corners before welding them into place. I have no idea why they would have kept these parts separate, and I figured sturdier is better in any case. A spray can of Rust-Stop helped me reach all the sections the brush missed, and with that the front bench is ready for upholstery. Next I’ve got to clean off the rear.

On the fender I got all of the low spots mudded out and sanded down, then used fill & sanding primer to identify any last trouble spots. When I was satisfied with the way things looked I used some 1000 grit to polish it up and then sprayed on two coats of rattle-can IH Implement Red to cover things. Overall it looks very good, and there’s only a drip around the fuel inlet port I have to smooth out. The next step will be to scrape all the old undercoating off the back, wire wheel any remaining rust, cover it with Encapsulator, and then spray on some undercoating.

I took the driver’s side off and started knocking off all the Bondo I’d applied in the summer as well as the stuff it came to me with; I’m going to take it back down to bare metal and start over again. This time I’m going to cut out the bad metal and riveted patch and try to get it as close to the original as I can while I keep looking for replacements. This one is going to take a lot more time to fix.

Posted on   |     |   1 Comment on Shiny Red  |  Posted in Seats, Travelall

Compression

Saturday morning broke with the first good sunshine we’ve had in a long time, so I decided that I would take advantage of as much of it as I could. After a mile-long walk with the dog and a cup of coffee with Jen, I put on my coveralls and headed out to the garage. The first thing I wanted to tackle was pulling and inspecting each spark plug I’d installed last year to ensure they were gapped correctly and to do a compression test. I pulled the coil wire, started with the #1 cylinder and worked my way backwards on the driver’s side, then finished on the passenger side.

All of the gaps looked right at spec, and the tips were all covered in gassy-smelling oil—which I expected, considering that I haven’t been able to get her running consistently for a long period of time. The most important information was good information: all of the cylinders had excellent compression, with the lowest of any of them at 125psi. This means the rings are in great shape and have hopefully reseated themselves after their long slumber.

When that was done I pulled the passenger fender out into the sun and hit it with sanding blocks for the second time, working the high spots down and smoothing out the second skim coat. It’s really shaping up on the outside, and I’m having great luck with the new filler.

One drawback was that the inner metal collar I’d welded on to the backside of the fuel port came off as I was sanding it down; when I welded the inside edges and then sanded off the excess metal apparently I was a little too zealous and weakened those welds. So this time I predrilled a bunch of pilot holes along the outer circumference and used those to tack the collar back in place from the back side—something I should have done in the first place. I’ll fill the inside edge with seam sealer to hide the welds, which are mostly hidden anyway. Then I skimmed filler on the low spots, which are (thankfully) decreasing in number.

Sunday morning I ran up the Scout for the first time in two weeks and let it warm up in the driveway. After attaching my ghetto exhaust extender (a 5′ length of HVAC pipe attached to the tailpipe, with 20′ of PVC reaching past the side of the garage) I turned both idle mixture screws all the way back into the carb and then backed them out 1/4 turn. Adding a little starting fluid to the carb, she fired right up and idled much smoother than she had two weeks ago, but then I saw the giant clouds of white smoke coming from the end of the exhaust and figured I’d better shut her down. So the rough idle issue is mostly sorted out, but I need a good windy day to run it up and clean the Berrymans out of the fuel system.

Next, I got to work tearing the front bench seat base down to the metal. I set up a GoPro and took a bunch of pictures, then started tearing the old vinyl off the frame. Removing the foam, burlap, and reed padding, I cut the old hog rings off and wire wheeled the outside elements, and then looked it over. There were three sections that needed to be welded back together, so I set up the MIG, dialed it in for thinner metal, and put them back together. Then I brushed encapsulator on the whole thing, which was a tedious job.

There are two sections on the back side that look like they could have been welded originally, but also maybe they weren’t. I texted Jeff to see what he thought and he told me his seat is from a ’68 and doesn’t look like mine. I’m mulling over whether I should weld in a set of supports there just to keep the whole thing sturdy.

While that was drying I pulled the fender out and continued sanding the high points down. It’s getting very close. There are only about five small areas that needed to be skimmed—hopefully for the last time—so I put some filler on to cure while the weather was still warm.

Posted on   |     |   Leave a Comment on Compression  |  Posted in Seats, Travelall, Welding