Ripped the Band Aid off! Build Thread and Advice Sought.

[SafeAirOne]

The one great thing is I have a brand new 109 tub NOS still in the original wooden packing crate painted bronze green with all the fitments. Hence the reason I am breaking it down to restore. All still in wrap.

Hmm. Your existing tub is looking pretty nice in that pic.

[stonefox]

He he he....ask Stonefox how that went for him! We all remember the clutch replacement incident.

What.....? All I did was read the manual.It said in order to replace the clutch you need to take every nut and bolt off the truck, replace them and spend wayyy more money than you actually tell your wife you did. I was just following the manual!!!!

[PH4]

Hmm. Your existing tub is looking pretty nice in that pic.

It is in good condition. The reason I am replacing is that the 109 was originally a hardtop and the PO cut the bulkhead behind the front seats to add a third fuel tank. I sold the full length hard top and purchased a pick-up top. The bed is fine for full length hard top or canvas top or no top at all. It is for sale I just have not listed yet. I may have an original tail gate to go with it.

[Revtor]

if youre gonna be launching boats then galvanizing would not be a waste of time or money.

Id sell the NOS tub to pay for the galvanizing.

[PH4]

if youre gonna be launching boats then galvanizing would not be a waste of time or money.

Id sell the NOS tub to pay for the galvanizing.

That was one of only a few times I launched a boat with it. I always pressure wash and spray with waxoxyl after I go on muddy roads or launch a boat.

[PH4]

Any secrets or tips for getting the front fenders and wheel wells off? Bulkhead off?

[l.a. rover]

ditto

well ph4.... i ripped the "band aid" too this week end.... am replacing the rear cross member due to rust.... nice 109 u gots!

[PH4]

well ph4.... i ripped the "band aid" too this week end.... am replacing the rear cross member due to rust.... nice 109 u gots!

Good luck. I am going to try and remove the bulkhead tomorrow.

[o2batsea]

Any secrets or tips for getting the front fenders and wheel wells off? Bulkhead off?

Yah, undo all the nut plates, nuts and bolts. They come right off after that. You will learn new body positions that you weren't aware that you are capable of, especially when getting after the mud shield upper fixings.
If you are working alone, a pair of vise grips on the other side is the best approach to nuts that you can't reach around for. Don't worry about snapping off anything, it is all still available.

[PH4]

Pressure washed and went all over it with a hammer and screw driver. Only surface rust except where the rear portion of the area where the rear shock absorber attaches and very little there. I was able to get the flakes off with hammer and chisel and it was only minor on the top. Please see photos below and would like to hear thoughts and comment from the forum. Best regards,

[bkreutz]

One of the main reasons these frames rust from the inside out is that the outside, being more exposed to the air, dries quicker than the inside. Since these frames are mostly sealed it's hard to tell, maybe you could borrow a borescope and look inside.

[73series88]

looks great
aaron

[PH4]

Progress today. The Bulkhead was a tough one. I still have not decided on the whether to replace the chassis. Part of me thinks to do so since everything is apart, however, the original chassis seems to be in very good condition at least on the outside. Miles to go before I sleep.

[PH4]

Best use for the 109 Tub you just removed from your Series. Part of "The Fort".

[o2batsea]

Gad, those wings have me drooling even with the effed up looking diamond tread stuff on them. You just cannot get them any where.

Just buy a new galvanized chassis. Fooling with the old one, no matter what you do to it, you'll always wonder if it is bad inside.
I went with new on mine for this exact reason. Originality is of absolutely no consequence as far as value is concerned.