1985 M1009 still rolling

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scooter421

New member
4
10
3
Location
Queen Creek, Arizona
Hi all, I purchased my M1009 around June 2019 as a back up vehicle after a bad car accident. I'm getting healed up and I'm just getting started. So far, I've replaced the front end bushings, wheel bearings, brakes, seals, new tires and additional standard items (fluids, belts) from an old vehicle not driven much. From what I understand the previous owner had it several years and put a few thousand miles on it. I don't know where I'm going to go with it but I plan to stay as close to stock as possible....I think. It's hard to resist adding modern conveniences! Either way I'll have fun tinkering. I love driving it, I get a lot of looks and many thumbs up going down the road. I think I read somewhere on here someone had put a C-series air intake on the M1009 to help with the noise. Thank you, it does help! Also, someone posted the belt numbers from an M1009 out of Fort Bragg, thank you. The belts offered by computer selection at your auto parts store (Autozone, O'reilly's and Napa) are slightly off for whatever reason. I completed the relay swap and I've had no issues. I replaced the vacuum pump with Cardone select 90-1008 from Amazon and once the vacuum pod was removed ended up being a perfect match. The new pod works great, my transmission and my sanity greatly appreciate it!

Pictures of how I did the air intake are below. The tube is an irrigation drain line and irrigation offset adapter. I used a heat gun to shape the adapter to the "squarevol" air cleaner connection. I kept the heat on until the hose clamp was snug. The galvanized and aluminum bar stock I had laying around. The air intake is off an old Suburban I found at the junk yard. The drainage parts came from Home Depot. The key to making it work is the lip inside the air intake from the Suburban which matched the smaller inner diameter of the corrugated tube. I was able to trim down the corrugated tube edge to tuck inside the intake for a tight fit on the inner diameter of the tubing. I did this on my daughters C20 already, so I had scrap for a test fit. The test fit worked perfect, then I bought a new section of irrigation tubing and trimmed to fit. The tube came out of the intake too easily but the third time I got it right. If the corrugated tube edge is crinkling up too much when tucking it into the intake it will not stay and you've not trimmed enough. If you trim off too much it will tuck in easy but pull out too easy, it has to be just right. If you go this route, don't cut the corrugated tube for a perfect fit length wise, give yourself a several extra corrugations in case you have to trim to fit more than once! Hopefully, that makes sense. Whatever I do with my M1009 will be slow going but I'll try to post worthwhile tidbits when I can.
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Cheers....Scooter
 
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scooter421

New member
4
10
3
Location
Queen Creek, Arizona
I spent an insane amount of time running a wire for a dome light. That was far more of a challenge than expected! I managed to get it mounted but I still need to run power from the buss bar on the passenger side to the center console and distribute through a 6 switch panel I've yet to install. A topic for another post I'll have the 24v and 12v coming into the same buss bar, separated of course. 12v distribution for everything other than the RAK15 MRE heater. That part of the project should be way easier.

Anyway, I used two fish tapes, a bore scope and pulled several strings through once I actually got it. This took a lot of patience trial and error. I taped a bore scope to the end of one fish tape and ran it up the hole near the seat belt. I used the other fish tape to go through the civi dome light hole left covered from the factory. The cover plate is spot welded in place, once removed you have access through the existing civi model dome light mounting hole for the other fish tape. Long story short, I finally managed to get the fish tape down to the seat belt, connect some pull strings, leaving 2 for later just in case. I used a step drill to increase the hole size in the vertical pillar to 1/2 inch and installed a wire guide/protector. I then pull the wire back up through to the center light. The light started off white but that was not going to cut it. I found some camo paint which is not perfect (looks better in person) and way better than white. I got it screwed down and now I need to get the power distribution part ran another day. This particular item is at least out of the way.
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scooter421

New member
4
10
3
Location
Queen Creek, Arizona
I managed to get the 12V power ran from the front to the back buss bar. 24v on the left and 12v on the right. Although I've only gotten the dome light working at this point, the hard part is now over. I can move on to accessories! I'm debating on what to add; so far, inverter of course, air compressor, light bar, more interior lights, 12v power points, 110v outlet, a 3rd battery etc. Who knows, a disco ball and part lights, Keurig? Anyway, I'm stoked and darn happy I have a dome light.....it's the little things in life. I'm still waiting for the fuse block to connect all my wires neatly inside the "Tuffy" box. It will work until Monday.
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Cheers...
 
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scooter421

New member
4
10
3
Location
Queen Creek, Arizona
Hi all, Happy New year!

I made a little progress since the last update but the Holidays are family time. I'll take that when I can get it too! I was lucky enough to grab the Flu while off also. That slowed me down a bit.

I managed to get my Blue Seas 6 independent circuit fuse block installed for my USB/Power Points mounted into the Tuffy Box. I've got USB in the front and both sides of the cup holders in the back. To finish out the switch box, I need to find which LED light bars I want. I have 2 switches remaining in the current configuration. I imagine I'll have a front and rear LED light set of some combination. I have more power in the back with the inverter, I'll upholster or paint the wood once I'm done running wires. I need to make a support leg for the board which will mount to the tire holder bracket. The perforated angle is a piece of 3' angle at Home Depot and it lined up with the topper bolts perfectly! I used longer 5/16 bolts in order to put a nut/washer underneath to hold the angle in place with no drilling required. I used Carpentry Tee nuts to mount the board to the angle. With the power in the back I'll now be taking a serious look at space for cooking, food, coolers etc. The RAK15 is a must use item but I have to decide where I want to put it. I'm trying to decide between being portable or a fixed mount. I'll get there! As a joke, my wife did buy me a small disco ball. She thinks I'm kidding......
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