LD`s Custom Scout II

[ihojeff]

This build-up is for one of our best customers. We are performing this build from the ground up starting with a new frame and will be swapping the body over to it once the body is done getting painted. Some quick specifications on this build are as follow:

Engine - Balanced 345 w/ ported heads, MPFI w/ RPT Aluminum Intake, custom serpentine belt set-up, Camcraft custom ground camshaft, custom CPT oilpan, Stans Tri-Y headers.

Transmission - Custom built NV4500 5 speed manual w/overdrive. 11" clutch w/ hydraulic release.

Transfer Case/Drivelines - Advance Adapters Atlas 3.8 transfer case. Highangle 1 ton CV driveshafts.

Axles - Custom built Dana 44 front and Dana 60 rear axles w/5.13 gears, Tru-Trac differentials, Dutchman 4340 Alloy shafts with the rear being 35 spline 1.5" semifloat. 63" wide front/rear WMS to WMS. Stock GM front brakes w/ drilled/slotted rotors and Wilwood Engineering 12" rear disc brakes w/ aluminum 4 piston calipers and internal parking brake. PartsMike knuckle/hysteer kit.

Suspension - Custom SOA with reverse shackle. Custom made Alcan springs front/rear. Front springs made very similiar to front GM truck springs(2.5" wide, 48" long) while the rear are same length as Scout II rear springs except they are 2.5". Bilstein 5100 shocks - dual front, single rear.

Other notables - Custom dash, custom roll cage, custom wiring, dual Optima batteries, Vanco Hydroboost brakes, custom hydraulic clutch setup, Flaming River steering column, 37x12.5x15 Goodyear MTR's, Vintage Air heating/cooling system, FSR custom Aluminum radiator.

I will edit this post as I remember/add new parts to this build-up.

And now for the build-up.

[ihojeff]

When the vehicle arrived to us it was already a project started elsewhere with almost all the body work completed. A fresh 345 engine with a built 727 and Atlas transfer case was sitting in it as well. The suspension was SOA but the quality of work was lacking so we started with a new(used) frame/axles and began by grinding off all unwanted brackets - which was just about everything. The drivetrain was removed as the engine was getting a bunch more work, the 727 was getting replaced with a NV4500, and the Atlas transfer case was being replaced with another newer Atlas transfer case.

[ihojeff]

With the custom Alcan springs delivered we were able to start building the suspension. Body mounts were replaced with much beefier ones(look for these soon as a regular CPT product). The rear frame/body mount area was beefed up as well. A CPT reverse shackle kit was modified for the wider leafs. We also changed the normal r/s fang support bar to two seperate 90* ones for a more custom look.

[ihojeff]

More pictures of the fabrication of the suspension. Custom hangers were fabricated for the rear springs and were outboarded slightly more than stock for a more stable ride. Hangers are tack welded until we know for sure that we are happy with their location.

[ihojeff]

We started building the custom front and rear axles. All axles we use are custom built in house. We stripped down a GM Dana 44 front housing, narrowed it to our customer's specs, set the castor and camber angles, and welded it up. We took a rear Dana 60 semi-float housing, again narrowed it to our customer's specs, and welded on new billet ends that allow for a much beefier SET20 bearing while allowing the Wilwood brakes to be directly bolted on. The chassis was set perfectly level for all critical measurements. The steering box portion of the frame was plated as well for extra strength.

[ihojeff]

A couple more pics of the finished axle housings. We also tore down the core NV4500 transmission and prepared to rebuild it. Same as our axles all manual transmissions and transfer cases are rebuilt in house. Next we assembled a mock-up drivetrain assy and set it up in the Scout frame. We then fabricated new prototype motor mounts(another new item coming soon) and a custom crossmember.

[ihojeff]

Once the NV4500 transmission rebuild was complete we then tore down the 345 for both inspection and modification. The dampner was sent off to the machine shop so that the dual groove pulley could be machined into a serpentine belt type pulley. Once we got it back and reinstalled mock up of a prototype serpentine belt set-up began(another new product coming soon).

[ihojeff]

Work on the custom dash was started before we received the Scout. The holes for the a/c vents were already cut in as well as the custom dash panel was welded in. Darren finished it up by cutting in the holes for the gauges, heater-a/c control head, and switch's.

Darren then fabricated the mounts for the Vintage Air evap/heater core box, installed the Flaming River steering column, mounted the hydroboost setup from Vanco and then fab'd up a way to change the mechanical clutch linkage over to hydraulic. Custom battery tray mounts were made for the dual Optima batteries.

[ihojeff]

More work was done on the frame while we waited for some other parts. Darren loaded the chassis so to speak with a dozen cylinder heads in the back in order to verify axle location was within specs with the suspension at ride heigth. With a little adjustment made to the rear spring hangers final welding and gusseting was performed. Also, mockup of the FSR custom aluminum radiator began. We decided to send the new radiator over to our radiator shop for modification since it came to us with the wrong lower neck.

[ihojeff]

We are now caught up showing you this build up. As we continue to work on this project this writeup will be updated as time goes by. You'll also notice that Darren(one of my best friends, a master fabricator and mechanic) is starting to do a lot of the fabrication work on this project. The shop has been real busy so in order for this project to be completed in a timely manner we found it best for Darren to perform the majority of the work while I concetrate on the design and procurement of parts for the project. You'll find Darren's fabrication skills to be among the best.

So stay tuned..........

[Joe V]

I can't believe how orderly and organized your shop looks. My garage looks like a tornando hit after a simple oil change. Selling prefabbed body mounts is a good idea, the rears always tend to bend more so than the others, if you can come up with something for the rear that would be great.

Looking forward to see this thread develop.

[ihojeff]

Originally Posted by Joe V

I can't believe how orderly and organized your shop looks. My garage looks like a tornando hit after a simple oil change. Selling prefabbed body mounts is a good idea, the rears always tend to bend more so than the others, if you can come up with something for the rear that would be great.

Looking forward to see this thread develop.

Thanks Joe. We really take pride in keeping a clean shop.

As for the build-up there unfortunately hasn't been much to add this past week. Both Darren and I came down with some crud so it took the motivation out of us but we did manage to work on the rear spring hangers some more, started fabbing the rear bumpstop mounts, started the roll cage, and continued developing the serpentine belt set-up.

[ihojeff]

I had Darren start fabbing up the exhaust system. Since the Atlas transfer case is right next to the framerail on the passenger side we had to run the passenger pipe under the bell housing and then back around.