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No longer rusting... Driver's side floor plan is solid. I wire brushed it thoroughly, sprayed it with Rust Reformer, and then with Rustoleum Trim & Bumper paint. I figure bumper paint might stand up to boots a little better than others. This is not cosmetically ideal, but it is no longer...

Thanks! The M1010 definitely comes with an SS account. It's an essential part of the package for any operating MV, IMHO. Membership in the local 4WD club is also part of the plan, in case she ever needs a tow out to the road and SS isn't available. (We have tow bars and a pintle hitch that...

Thanks. We put all this energy into fixing and preventing rust underneath, and inside places like rocker panels. I wasn't expecting to find it inside a truck that never saw salt. Once I found it, I'm feeling driven to eliminate it to the extent possible.

I'll add a point. Running the wire brush, I accidentally nicked my door seal. Rookie mistake, I know. A stream of water shot out 6-8" into the air! I was using a wire cup on a 4.5" grinder, and suddenly the back of my hand was getting wet!?!? So there's another contributing factor to the...

The places where I have rust are in the compound curves. I don't know how I'd bend 12G diamond plate to match those compound curves. How would you do that??

M1010 pics Pics of the mechanically-refreshed M1010, under its shade tree. It runs great. Working on the interior, electrical connections/grounds, and secondary systems like A/C and heat.

Ground off the radio mount welded to the passenger side floor. Rust underneath that was only cosmetic. Wire brushing revealed that rust over by the transmission hump is fatal, for the floor pan. Bummer. Unfortunately, it seems the rusted-through area is just above the replacement floor pans I...

I got great deal on a Warn 18,000 lb winch. I need to fab a mount for it, since Warn doesn't sell one. I'm thinking an appropriate sized angle iron between the frame rails. I need to work out the engineering details...

The transfer case shift level rides in a slot in a rusty plate visible in my first picture above. Is there any reason not to remove it, clean it, and paint it? It seems straightforward and safe enough. Or will I open a can of worms if I remove it? I would like to be able to reassemble this...

Cab floor rust and related mysteries The rubber floor mat had holes through which we could see rust. As recommended by cucvsrus and others, I removed the rubber and the underlying jute. We definitely have some rust, but I suppose it could be worse. We haven't started grinding yet...

Understood, but to remove all the rust stain would involve grinding away much of the aluminum around the rivet holes. would it work to make a thorough cleaning with a mild abrasive like a Scotch pad, followd by RustOleum Rust Reformer to chelate any remaining ferrous oxide? I have little...

Rear passenger compartment heater issues I tried firing up the rear passenger compartment heater. No luck. The fuel valve below the heater is open. I'll try bleeding the fuel lines and the TM troubleshooting next. This truck lived in the South, so the heater has probably never run since it...

Tiny Tach directions say to power it from a circuit that is turned off while starting, to protect it from voltage surges. I've been poking around with a meter and reading wiring diagrams. Is there a CUCV circuit that powers off during starting? (Radio circuits do this...)

That's a steel rivet securing aluminum sheet. I'd need to drill them all out in order to isolate the metals. At that point, I could just replace them with aluminum rivets. Perhaps that's the best approach...

Yes. I was told that the mount and power feed at the passenger's feet of my M1010 were for NBC detection gear, sensors that were supposed to alert the occupants if there were dangerous chemicals, biological agents, or radiation in their environment. I thought NBC stood for...

M1010 A/C troubleshooting I was running the A/C and the fan quit. The 30A fuse below the dash is intact. I'm digging through the troubleshooting docs. If anyone is familiar with troubleshooting the M1010 A/C system. I'd appreciate any words of wisdom.

Litter support arm clips The supports for the upper litters fold into the ceiling. Clips hold them in place. Several of those clips have a broken arm, picture below. If anyone knows a source of replacements, I'd appreciate any pointers.

galvanic corrosion prevention? The litter carriers have steel rivets holding sheet aluminum to a steel frame. I presume this corrosion is at least partly due to dissimilar metals. What's the best way to stop this kind of corrosion, and to prevent it from recurring? Naval jelly followed by...

Stair Latch Problem The stair latch seems ineffective. If someone knows how this should be, I'd appreciate some guidance. The plate that the hook engages is too far forward to engage the hook, so someone bent it back. Now it engages the hook, but it's at such an angle now that the hook slips...

NBC Cable insulation failed. Scary. The M1010 is finally in the driveway. John at Hillbilly Wizards replaced the rubber, fluids, filters, batteries and a fried alternator. He checked out all the systems, particularly brakes, steering, etc. I wanted a pro to go over the truck before I hand...