Member III
Unbuilding an 80 Series
- Thread starter Dave K
- Start date
Off-Road Ranger I
No reducer. This was all shot at 50psi regulator at the gun. I played with it a bit on some cardboard before I started. Less pressure = more roughness. Pressure also dictates how fast you go through product and how fast it builds.
I did notice that consistency in distance away and angle you are spraying at are both more important that when spraying paint. Staying square to the work seemed like the best approach and delivered the best results. I also was conscious to start in the same place and work the same order on each coat but switched directions I sprayed each coat. Left to right on coat one, up and dow on coat two, etc. Not sure if this made a huge difference in the final product but it sounded like a smart thing to do to ensure a more even build.
I did notice that consistency in distance away and angle you are spraying at are both more important that when spraying paint. Staying square to the work seemed like the best approach and delivered the best results. I also was conscious to start in the same place and work the same order on each coat but switched directions I sprayed each coat. Left to right on coat one, up and dow on coat two, etc. Not sure if this made a huge difference in the final product but it sounded like a smart thing to do to ensure a more even build.
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Off-Road Ranger I
A quick fab piece today. 2” receiver in the center of the spare tire. Oh the things I will do with this.
Tomorrow we prep and shoot bumpers and sliders.
Tomorrow we prep and shoot bumpers and sliders.
Off-Road Ranger I
Well, it was decided today that the right way to do the sliders was to send them to sand blasting due to the years of Colorado and South Dakota winters this rig has lived through. We continued on the other items today.
Front bumper
Rear bumper (I highly recommend taking them OFF of your rig is possible)
Door handles
Side mirrors
Grill
Front turn signals
Upper and lower headlight trim
Rear wing/spoiler thingamajig
For anyone wondering, bumpers, sliders, grills, etc. are More work that the body. The prep time is heavy due to all of the nooks and crannies. I was spraying over old powder coat so I really wanted to make sure I prepped as good as reasonable. There are a lot of places where it is simply too tough to get into. For those areas (and really everything I sprayed today) I used Upol’s Adhesion Promoter.
Not sure what a reasonable process to spray the front bumper would have been had I not had the forklift.
As were were masking for door handles and mirrors I wished I had just sprayed it all gray.
Front bumper
Rear bumper (I highly recommend taking them OFF of your rig is possible)
Door handles
Side mirrors
Grill
Front turn signals
Upper and lower headlight trim
Rear wing/spoiler thingamajig
For anyone wondering, bumpers, sliders, grills, etc. are More work that the body. The prep time is heavy due to all of the nooks and crannies. I was spraying over old powder coat so I really wanted to make sure I prepped as good as reasonable. There are a lot of places where it is simply too tough to get into. For those areas (and really everything I sprayed today) I used Upol’s Adhesion Promoter.
Not sure what a reasonable process to spray the front bumper would have been had I not had the forklift.
As were were masking for door handles and mirrors I wished I had just sprayed it all gray.
Off-Road Ranger I
At the end of the day I am glad I went with the black mirrors and handles.
I am also very pleased with the bumpers.
Got to the shop at 6:00am and left at 11:00 pm. 2.5 hour break mid day to go do something. Fell asleep sitting at the kitchen table twice writing this update.
Tomorrow... reassembly! Got the rack to the shop today as well so I am hoping for the rack, tent and awning tomorrow as well. Time will tell.
I am also very pleased with the bumpers.
Got to the shop at 6:00am and left at 11:00 pm. 2.5 hour break mid day to go do something. Fell asleep sitting at the kitchen table twice writing this update.
Tomorrow... reassembly! Got the rack to the shop today as well so I am hoping for the rack, tent and awning tomorrow as well. Time will tell.
Off-Road Ranger I
Got the front bumper put back together. Realized that someone previously installed the marker lights in the lower end incorrectly so I addressed that. Also reinstalled the water intake and discharge. I think I will tether the caps and paint them red and blue accordingly sometime in the future.
Lots of other work completed today. Rear bumper parts, marker lights, mirrors put back in their housings, snorkel reinstalled, the whole front end reassembled and the front bumper put on.
Lots of other work completed today. Rear bumper parts, marker lights, mirrors put back in their housings, snorkel reinstalled, the whole front end reassembled and the front bumper put on.
Off-Road Ranger I
Got the old rack stripped and installed and the started in on the new tent. The Bush Company’s Alpha model has been sitting in my shop for a few weeks now. Finally started opening boxes.
Everything arrived well packaged. The guys in my shop tripped out on the stenciled and spray painted logos and words.
All of the little stuff was well Packaged and labeled. My wife asked where the directions were but who needs those when you have a hardware puzzle in front of you?
Turns out the bolts are a bit shorter that desired so I will be having to source some longer ones. I was able to get the tent installed though.
Everything arrived well packaged. The guys in my shop tripped out on the stenciled and spray painted logos and words.
All of the little stuff was well Packaged and labeled. My wife asked where the directions were but who needs those when you have a hardware puzzle in front of you?
Turns out the bolts are a bit shorter that desired so I will be having to source some longer ones. I was able to get the tent installed though.
Off-Road Ranger I
While wrestling with the new beast of a tent the wife mad a comment about how much more she liked the fact that this tent is fully on the rack. She was never comfortable with the ARB Simpson flipping over the side. She also mentioned that she liked the look of this new tent more as well. The salesman in me decided we were heading down the right path and it only made sense that she get to open the tent first. I convinced her that I wanted her to open it first rather than myself. She unbuckles the latches and I tell her give it a push up expecting to witness her be sold on this new wonder. She pushes up, struggles, pushes harder and proceeds to tell me that for what I spent and all the talking I’ve done about this tent that it should be easier to open! Of course I jump up there to show her how it’s done and low and behold, this sucker is heavy! And doesn’t stay open!! After some quick staring I realize that I can’t remember if the gas struts are inboard or outboard. The internet confirms outboard and my eyes confirm two missing gas’s struts! Perhaps they ship separate? Perhaps they ship in the tent?! My wife reminds me that direction/instructions would probably answer these questions but alas, there are none to be found. It’s late. We are tired. I have to work tomorrow. We call it a night.
Tomorrow... I put Midguard’s customer service to the test. Hopefully they tell me something easy and this boils down to me not being the sharpest tool in the shed.
Tomorrow... I put Midguard’s customer service to the test. Hopefully they tell me something easy and this boils down to me not being the sharpest tool in the shed.
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Off-Road Ranger I
Well, Rex at Midguard was top notch this morning confirming that I am indeed only about as smart as I look! Turns out the missing components are somewhere inside of the tent. I was far to busy to mess with it today so I will go on the hunt tomorrow.
If you are in the market for gear give Midguard a shot. Service was great.
If you are in the market for gear give Midguard a shot. Service was great.
Off-Road Ranger I
Decided to load up parts for tomorrow, tonight. I forget I no longer have a pickup and have to purposely schedule taking one from the shop. I did however find out the Audi is close enough. Lights, antennas, spare tire, high lift, various other crap. My son always looks at me like I’m crazy when I do this stuff. If it had load bars I’d have pipe or lumber strapped to them!
Off-Road Ranger I
So I ended the day pretty much where I started plus the struts on the tent. After struggling with struts for a few minutes I texted Rex over at Midguard. Impatience got the best of me and I went to working and missed his call back to me. I got the struts pretty well figured then called Rex back. After a pretty good conversation, Rex decided to mess up my entire day by telling me how to get rid of my rack.... which meant taking the tent and the rack back off.
So, working by myself today was just going to make it that much harder but loosing 1.5” of height and the weight of that rack are an absolute must if it can be done.
My assistant for the day. A Toyota to work on my Toyota.
For some reason everything comes apart easier than it goes together the first time. I also seem to get wiser through trial and error so I decided this time I should use to forklift to elevate my work and make life a bit easier.
Had to remove all of the original mounting hardware. One of the things I had an issue with was the placement of the hardware. I ended up on the weld a bit and that made the bracket a bit wonky. I installed these brackets with the tent on the rack. Would have been much easier had I installed them prior. Lesson learned.
Next was remove the rack. My son was working today so like a good boss, I made him stop doing productive work that makes the company money and help me pull the rack off since my Toyota Assistant was preoccupied. Aluminum and being on the tall side saves the day and we just lifted the rack off. I then removed all of the gutter mount feet from the rack.
The feet are missing a second center hole but that is nothing a drill press can’t fix.
Prior to ordering the tent I didn’t have a full understanding of what the bottom extrusion rails looked like. I had in my mind that I wanted to build a gutter mount bracket to bolt to the side extrusions of the tent. After a few emails back and forth with Dean at The Bush Co. I got that idea out of my head. Once I had the tent it was go time just get it installed on the rack. I never looked at it like this and it makes so much sense.
Such a no brainer but it just never click in my head. I got the rest done and on the tent. Not knowing exactly where these all had to go made life a bit tougher. I got them all on loose and set the tent over the truck.
This configuration lowered the tent to the point where I coul not set it on the tuck and pull the forks out without being on the roof. Had to call in help again. We got it set down through some creative work arounds. It’s a good the my Toyota Assistant can drive itself! I’ll let you imagine how that helped.
After lots of loosening, tightening, shifting and redoing I got the tent positioned to a point where I was satisfied and final tightened everything. At the end of the day the tent is 1.5” lower that it was at the start and I am guessing about 60lbs lighter as well. I am SO much happier with this setup and grateful to have had my conversation with Rex now rather than after the awning, etc was already installed. I do need to buy a fourth foot and get that installed. Ordering this week.
So, working by myself today was just going to make it that much harder but loosing 1.5” of height and the weight of that rack are an absolute must if it can be done.
My assistant for the day. A Toyota to work on my Toyota.
For some reason everything comes apart easier than it goes together the first time. I also seem to get wiser through trial and error so I decided this time I should use to forklift to elevate my work and make life a bit easier.
Had to remove all of the original mounting hardware. One of the things I had an issue with was the placement of the hardware. I ended up on the weld a bit and that made the bracket a bit wonky. I installed these brackets with the tent on the rack. Would have been much easier had I installed them prior. Lesson learned.
Next was remove the rack. My son was working today so like a good boss, I made him stop doing productive work that makes the company money and help me pull the rack off since my Toyota Assistant was preoccupied. Aluminum and being on the tall side saves the day and we just lifted the rack off. I then removed all of the gutter mount feet from the rack.
The feet are missing a second center hole but that is nothing a drill press can’t fix.
Prior to ordering the tent I didn’t have a full understanding of what the bottom extrusion rails looked like. I had in my mind that I wanted to build a gutter mount bracket to bolt to the side extrusions of the tent. After a few emails back and forth with Dean at The Bush Co. I got that idea out of my head. Once I had the tent it was go time just get it installed on the rack. I never looked at it like this and it makes so much sense.
Such a no brainer but it just never click in my head. I got the rest done and on the tent. Not knowing exactly where these all had to go made life a bit tougher. I got them all on loose and set the tent over the truck.
This configuration lowered the tent to the point where I coul not set it on the tuck and pull the forks out without being on the roof. Had to call in help again. We got it set down through some creative work arounds. It’s a good the my Toyota Assistant can drive itself! I’ll let you imagine how that helped.
After lots of loosening, tightening, shifting and redoing I got the tent positioned to a point where I was satisfied and final tightened everything. At the end of the day the tent is 1.5” lower that it was at the start and I am guessing about 60lbs lighter as well. I am SO much happier with this setup and grateful to have had my conversation with Rex now rather than after the awning, etc was already installed. I do need to buy a fourth foot and get that installed. Ordering this week.
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Off-Road Ranger I
Today, I attempt to conquer this plus all the stuff in
the Audi that never got unloaded yesterday.
the Audi that never got unloaded yesterday.
Member III
Isn't it funny how, we build things over time and never realize how much we changed until we have to remove and reinstall everything at once.
Looking good.
Looking good.
Off-Road Ranger I
Thanks, Scott.
I can’t believe how much stuff has been done to this rig over the years. I have never really thought of it as “super built out”. There are many far beyond this one. It’s also crazy how much work we will do to make things marginally “better”. I spent an entire day to end up at basically square one. But so worth it.
I was fairly happy with this rig in the first place. All I wanted was a new tent!
I can’t believe how much stuff has been done to this rig over the years. I have never really thought of it as “super built out”. There are many far beyond this one. It’s also crazy how much work we will do to make things marginally “better”. I spent an entire day to end up at basically square one. But so worth it.
I was fairly happy with this rig in the first place. All I wanted was a new tent!
Off-Road Ranger I
Progress today was not quite as much as I wanted it to be but all major components are back on.
The Audi pickup did get emptied today even if everything didn’t get installed. Not pictured is the hi lift, shovel and various other stuff on the floor in the back seat. Also added the wife and the dog to the crew today.
The spare was reinstalled. The reciever that was added last week ended up fitting like a glove. Exactly as planned.
Hi Lift reinstalled. This bad boy needs a bit o lovin’ with some paint. Perhaps a mid week project when I bring it back home.
Also got the awning installed. I am very impressed with the quality. I previously had a cheapo Chinese awning on this rig and when it was up it was cool but was a pain to set up. As a result I didn’t use it near as much as I wanted to. This awning could not be easier to use. Literally one minutes setup, one minute to put away. Sorry for the weird light glare in the pics today. Had the shop door down because the dog was on the crew and he likes to sneak off once you really get preoccupied.
The Audi pickup did get emptied today even if everything didn’t get installed. Not pictured is the hi lift, shovel and various other stuff on the floor in the back seat. Also added the wife and the dog to the crew today.
The spare was reinstalled. The reciever that was added last week ended up fitting like a glove. Exactly as planned.
Hi Lift reinstalled. This bad boy needs a bit o lovin’ with some paint. Perhaps a mid week project when I bring it back home.
Also got the awning installed. I am very impressed with the quality. I previously had a cheapo Chinese awning on this rig and when it was up it was cool but was a pain to set up. As a result I didn’t use it near as much as I wanted to. This awning could not be easier to use. Literally one minutes setup, one minute to put away. Sorry for the weird light glare in the pics today. Had the shop door down because the dog was on the crew and he likes to sneak off once you really get preoccupied.
Off-Road Ranger I
Got these cool load bars installed on top of the tent. Not sure what I am hauling up here but I am sure they will get used at some point. 
Several things went a bit sideways on me today. First was light bars. The two curved bars I have are wider than the tent really wants. The light bracket from The Bush Co is GIANT. Way bigger than I’d like.there is one configuration is which it would work but the bracket makes the light stick out way further than I’d like. If I set the light back further on the bracket the bracket sticks out further than the light. Short story, it isn’t going to work. I’ll have to work something up. Sorry, no pics.
Was able to install my 2 meter antenna but couldn’t mount the CB antenna. I had previously used a Rugged Ridge X Clamp which worked quite well. Turns out after spraying the bumpers they no longer fit the bar it was mounted on. I temped it up on a tab on the bumper just so it stays safe for the moment but a new clamps will be ordered tonight and it will be mounted back on the passenger side of the bumper.
I was also fully and completely dumbfounded by the shovel bracket. For the life of me I could not get this figured out. I was pretty dang close but not enough to throw it on
Again I resort to texting Rex at Midguard. Ended up packing up early and heading home. Just got settled in and Rex called. A quick convo and a few pics via text later and these brackets make sense. I really can not speak highly enough about Rex at Midguard and the top notch customer service this guy throws down. Do you buy parts from anyone else that you can text direct. That you can call direct? That will help you out on a Sunday?! I can’t say it enough, if you are in the market for anything fromThe Bush Company or any of the other brands that Midguard carries, give these guys a shot. Absolutely top notch service! No affiliation, just a very satisfied customer.
midguardadventure.com
Several things went a bit sideways on me today. First was light bars. The two curved bars I have are wider than the tent really wants. The light bracket from The Bush Co is GIANT. Way bigger than I’d like.there is one configuration is which it would work but the bracket makes the light stick out way further than I’d like. If I set the light back further on the bracket the bracket sticks out further than the light. Short story, it isn’t going to work. I’ll have to work something up. Sorry, no pics.
Was able to install my 2 meter antenna but couldn’t mount the CB antenna. I had previously used a Rugged Ridge X Clamp which worked quite well. Turns out after spraying the bumpers they no longer fit the bar it was mounted on. I temped it up on a tab on the bumper just so it stays safe for the moment but a new clamps will be ordered tonight and it will be mounted back on the passenger side of the bumper.
I was also fully and completely dumbfounded by the shovel bracket. For the life of me I could not get this figured out. I was pretty dang close but not enough to throw it on
Again I resort to texting Rex at Midguard. Ended up packing up early and heading home. Just got settled in and Rex called. A quick convo and a few pics via text later and these brackets make sense. I really can not speak highly enough about Rex at Midguard and the top notch customer service this guy throws down. Do you buy parts from anyone else that you can text direct. That you can call direct? That will help you out on a Sunday?! I can’t say it enough, if you are in the market for anything fromThe Bush Company or any of the other brands that Midguard carries, give these guys a shot. Absolutely top notch service! No affiliation, just a very satisfied customer.
Midguard Adventure – Everything you need for the perfect adventure
midguardadventure.com
Off-Road Ranger I
Well, it was a short weekend of work. I had to finally get this thing out of the shop so my guys do not have to move it in and out every day. Took care of a few small things and drove it home.
At the urging of my wife I finally decided to install a license plate. Seven years ago I broke a bolt swapping plates and just left it. Haven’t ran a plate since which has always bugged her. I drilled the broken bolt before spraying. Ran a tap through the holes and we’re right as rain!
Was also able to make heads of the shovel brackets from The Bush Co. They are actually pretty cool. Decided to use the old Quick Fist Clamps for my axe. I like the location for now. We’ll see how it works out moving forward.
And yes,it opens with both on there.
Because of the way the different elevations worked out and because I decided to keep the rear spoiler thingamajig, I decided to flip the awning to tent mounting brackets. Doing so made all of my problems go away but created one new problem. The awning itself was now in conflict with the drivers side spring rod that supports the tent rain fly. I knew this problem would exist thanks to consulting with Rex (thanks dude) so it came as no shock that I would have to bend a dog leg into the spring rod. A bit of simple chimp math and a bench vice later I have a workable dog leg that gets the job done. I didn’t get pics of this fine piece of craftsmanship for some reason but you can use your imagination.
Got it home and setup for review. All of the major components on the exterior except for the sliders are good to go for the time being. Lots of little stuff to play with still on the exterior. The interior... well, that’s a different story. Tons to do in there.
At the urging of my wife I finally decided to install a license plate. Seven years ago I broke a bolt swapping plates and just left it. Haven’t ran a plate since which has always bugged her. I drilled the broken bolt before spraying. Ran a tap through the holes and we’re right as rain!
Was also able to make heads of the shovel brackets from The Bush Co. They are actually pretty cool. Decided to use the old Quick Fist Clamps for my axe. I like the location for now. We’ll see how it works out moving forward.
And yes,it opens with both on there.
Because of the way the different elevations worked out and because I decided to keep the rear spoiler thingamajig, I decided to flip the awning to tent mounting brackets. Doing so made all of my problems go away but created one new problem. The awning itself was now in conflict with the drivers side spring rod that supports the tent rain fly. I knew this problem would exist thanks to consulting with Rex (thanks dude) so it came as no shock that I would have to bend a dog leg into the spring rod. A bit of simple chimp math and a bench vice later I have a workable dog leg that gets the job done. I didn’t get pics of this fine piece of craftsmanship for some reason but you can use your imagination.
Got it home and setup for review. All of the major components on the exterior except for the sliders are good to go for the time being. Lots of little stuff to play with still on the exterior. The interior... well, that’s a different story. Tons to do in there.
Influencer I
Nicely done. Love the color. By the way, how much weight you have on the rain gutters? I found that putting a long channel along the gutter under the roof rack or RTT supports, saves the gutters. They dug into the metal on one of my rigs.
Off-Road Ranger I
Did that issue happen on an 80 Series? To be honest I am not at all sure on the answer to your question. I do however know that I will be redoing the entire tent installation again due to some new things that have come to light. I will be going from four to six gutter mounts and a custom made load bar tying the feet together side to side. Should be the same height with added tent center load support along with two more feet to spread the load. Your channel idea is interest as well as it would spread load a bit more even laterally along the gutter.
I have stalled a bit on additional work as I am in the middle of a move of about 50 miles. Shop tear down and set up, etc., etc. I will be slapping the interior back together here soon to get a trip going in the next couple weeks and go from there.
Appreciate the compliment. Thank you.
I have stalled a bit on additional work as I am in the middle of a move of about 50 miles. Shop tear down and set up, etc., etc. I will be slapping the interior back together here soon to get a trip going in the next couple weeks and go from there.
Appreciate the compliment. Thank you.
Influencer I
It happened on my 60 series, but I am a bit paranoid about this. On my 80 build, I used the Prinsu rack and put 1/2” webbing inside the gutter before mounting the rack. I wrote a blog on the build on this forum. Took about a year (for the build not the blog)
