Pacific Northwest Four Wheel Drive Association

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warrpath4x4 01-02-2010 08:30 PM

WARR-WAGON trail cleanup truck
SINCE THERES NO DODGE SECTION LOL i guess ill post this here.

(from the beginning)

i bought this from an old co-worker. its a 1980 dodge W200 4x4, the last of the powerwagons. 360 (runs) 4speed 205 transfercase, HD44 front, 60 rear, warn 8274 winch, it used to be a DOT truck.

crate motor
rear winch
tool box
rear bumper (with swing out tire carrier)
dual batteries
new seat
extra rack over canopy
inner airlock double beadlocks
OBA (york)

onto the pics:

when i brought it home

put a set of 35"s on the rear but they wouldnt mount up on the front cause they are 15" rims and it takes 16" rims to clear the calipers. but this can be worked around.

old skool outside temp guage

the PO told me there was some rust in the driver side floor board but he took care of the rust and fiberglassed it. yah his fiber glass was a piece of plastic shower wall screwed down.

so i fixed it the other night

the seat belts were broke so i threw in some spares till i get the new seat

i thought about putting a set of these in since i have them but they arent the easiest to ride in all the way to the coast.

id like to put something like this in, 40/20/40 with flip down center console and built in seat belts.

yesterday i started on the rear bumper, but i have a cold so i only worked for like 10 minutes.

my rats nest of a wiring mess to straighten out.

warrpath4x4 01-02-2010 08:31 PM

ok got the truck into the shop this afternoon. pulled the hood, grill, and pipes off the bumper and my camera batteries died. then i painted the grill, pulled the radiator reservoir, fan shroud and drained the radiator. when i pulled the pipes off the bumper there was rust and crap behind them, luckily only surface rust.

did some more work on the truck today, pulled the radiator, winch, fenders. my **** camera runs through batteries like crazy so i ended up using my camera phone.

apparently they used this spot for storage lol

warrpath4x4 01-02-2010 08:32 PM

friday the old man came out and helped me pull the core support and the engine.

then sunday i helped put a leveling kit on another guys newer ford, and yesterday was my first day at my new job. hopefully today i can drag my butt to the shop for a bit but its cold outside lol.

an expensive day, i ordered ALOT for the powerwagon.

crate motor
6AL MSD ignition
edelbrock intake
edlebrock carb
3 core radiator
power steering pump
upper/lower rad hoses
100 amp alt
white face gauges (speedo, volt, water, oil pressure, 5" tach)
spark plugs
new starter
water pump
motor mounts
dist cap
plug wires

which all ran me $3268 with about $300 in core deposits.

warrpath4x4 01-02-2010 08:33 PM

i picked up my parts, took some pics of some of the goodies but my camera batteries died so they re recharging right now.

oh yah

thats sexy right there (with rev limiter)

color changing

they had just got freight in when i was there so i couldnt get my engine (it was blocked in). so i went back in the afternoon and got it and my new 3 core radiator. now the fun will begin. i will have to get a comparison picture of the 60 amp alt. and the 100 amp alt, lol its almost comical lol.

heres is a pic of the stock alt compared to the 100 amp alt.

spent today building a new welding cart to hold the welder and my new plasma. :wings:

carts still not done yet, i was test fitting everything

warrpath4x4 01-02-2010 08:34 PM

new engine still wrapped up till i get the sheetmetal all cleaned up and ready to put on.

here you can see how flat the old springs were
and with the helper spring

not sure why all these holes were drilled in the frame but i am going to weld them up

got my BFG's mounted on a different set of wheels with less back spacing, mounted them on the truck and without the engine in its almost level on the bed.

got the old heater core out, didnt come out as simple as i had planned, im going to weld in a piece of sheetmetal to fill the hole. then i have a summit brand mojeve heater to mount inside.

it sits at 23 3/4" t the pinch seam.

warrpath4x4 01-02-2010 08:35 PM

went out today for a few hours after i got off work, doesnt really feel like i did much cause i kinda just bounced around. i pulled the motor mounts off the cross member, the driver side was fun. painted some of the front frame section. pulled the front diff cover and cleaned it up and painted it, inside the diff didnt look bad, a ittle bit of metal grind in there but no chunks or anything like that and the fluid looked fairly new. also started to sand the hood down, i dont know about anyone else but MOPAR to me just screams blacked out hood ;D

thats a 2 foot pipe wrench and a 3 foot pipe on my half inch drive

installed the front diff cover today

found the diff tag on the rear when i pulled the diff cover. the fluid in the front axle wasnt too bad but the rear diff must have been the red headed stepchild, 3.54 gears (not what id hoped for but oh well)

and the first coat of semi gloss on the hood

kinda splurged a little this morning. i tried to clean up the valve cover but there is so much crap baked onto the inside and i couldnt get it all out of there and i didnt want to chance any of it getting into the new motor so here we go

Fabricated Small Block Mopar Aluminum Valve Covers

These are a fully TIG welded aluminum cover. Thick 1/4" billet rail. 1 1/4" baffled breather holes. 3.5" tall. Includes bolts.

warrpath4x4 01-02-2010 08:36 PM

in between the coats of herculiner i put on the floor boards of my XJ i painted the engine with high heat 500 degree paint. i prefer the color of grey just because it is easier to see any leaks that arise.

so after we put the interior back into the XJ, i cut out my first piece with my plasma cutter

but i didnt make some of my corners right and i cought my hose on my clamp and took a bigger slice out of one spot, plus i decided i wanted the diamond tread on the inside of the engine bay so i cut a ew piece. it turned out alot better, here it is fitting in place.

half way welded in and with the two holes drilled in it for the hose fittings for the new heater

fully welded, then after this picture i finished welding the old mounting holes but dont have a pic of that yet.

warrpath4x4 01-02-2010 08:37 PM

instead of using a rubber grommet and just pushing the heater hose through the firewall i came up with this. just a coupler and two barbed fittings that will smash the firewall between the big washers.

i think i found an orange that closely matches

and here is the piece i am going to use for my new dash (rough cut of course)

other than that it was a day to clean the shop after i got off work.

warrpath4x4 01-02-2010 08:38 PM

did lots of little things today, or atleast it felt like little things. bolted on the flywheel, clutch, harmonic balancer, mouts for the motor mounts and the motor mounts, then dropped the motor in but we had to clearence the bellhousing. you could see where the flywheel made marks inside the bellhousing when we took it out and it would not fit back in. then i we put the valve covers on but only sealed the passenger side since i still ned to mess with TDC on the drivers side, and put in the thermostat and housing.

we pulled the tub off of my dads jeep yesterday so he brought it out today so i can cut out the rust and weld in new metal.

warrpath4x4 01-02-2010 08:38 PM

today seemed like one step forward and two steps back. put the headers on to find out i couldnt get the starter on. one of the carb studs had messed up threads so i bought new ones only to get back to the shop and see they are too long. unhooked the power steering pump to put the new one on and broke the high pressure line.

i ended up just taking the headers back and cleaning and installing the stock manifolds. painted them with high temp exhaust paint, yah it probably will just burn off but it looks nice now lol.

my paint booth lol

cleaned up


used some aircraft paint stripper on the stock air cleaner housing, this stuff really takes the paint off.

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