Rebuilding after 15 years of storage

[PHOENIX-GER]

Unfortunately the batts are now complete dead.
With a full charging could we just test Dacota, but its not enough for start the Engine anymore.
Dacota was offline of a fuse which was broken. A sensor cable of the tank switch unit was disabled and touched the frame.
It must happen unnoticed by removing all cover from the underbodyprotection.
Another reason why we have all additional devices always saved by fuses.

I have order today new batts, the size is uncommon and not on the shelf of local shops.

So not much progress now. We used the time in rearranged the wiring with the fuse boxes.
It was the 3rd time where we need to check on it and it was always heavely annoying about the difficult and tight space by access.

We build up now the fuse and distributor boxes behind the bench. We doesn't want first this location as it needed to bring a wiring hose along the transmission hump behind the bench. Remember we have no insulation or carpet in the truck. Now we have a different opinion. The cable hose will be less annoying than having to dismantle the speaker every time there's a problem, and then having so little space because all the cables are bundled together there. We are not car electricians and therefore have not thought far enough. But that's okay, you can change it and learn from your mistakes. This won't happen again with the next vehicle.

 

[PHOENIX-GER]

What a difference with new batts,
One try and it fired up immedeatly.



Still no rpm



Still no correct signal on the Tanksensor.
Switch on the other tank have the same result.
Tank 1 is filled on 20 liter
Tank 2 is empty
Wiring problem...



24V voltmeter shown full operational, but Gen 1 is not charging - typical problem, we will check it
Still no rpm
We choose rpm signal from the TCM Compushift. Need to check out what wrong with it.
Otherwise we have also a RPM sensor for the Reluctorring in the Adapter.

6th September start our annual holidays and we hope to finish all for roadregistration



Still also need to clean up this new electrical wiring behind the bench with cable hoses

 

[PHOENIX-GER]

Failing Gen-1 Light: We figured out the generator plug is defect and we ordered a new one
Directly with the Pulse wiringe so that we can take RPM from the generator.
We have to use also an additional Dacota Module to got the Diesel RPM. As we learned now it is not just to pick up from the TCM.
For roadregistration is it not relevant so that we not need it immediatly. I dont know the delivery time by dacota but we wait on the RTX and the BIMS we need more than 6 Months....

About the Wait Light: well the Glowplugmodule have a defect on it and dont work. I guess starting was possible as we had summertime, no need to glow a lot.
Fortunately we have a second Module where it work well, of course found out after we had open already the complete dashboard.
Thinking to buy a spare new card from Hilbilly Wizard.... just for the case it broke

Figured out to make the setup on Dacota.
Noticed the Fuelsensor have a learning routine before working correct. It need 2 complete Filling/Empty circles.
Fortunately our Device have the APP Setup, thats nice and easy to do all settings rather than with a pushbotton-Switch

We descide to go with the blue setup Theme - picture is from the Demo-Mode



Also finshed the wiring behind the bench



The appointment with professional shop for setting track, emissiontest, adjusting lights and finally the Roadregistration test can be scheduled as far the new plug for the generator is here (ETA Thursday 10th.)

 

[Guyfang]

Will not be long and you will be rolling down the road!

 

[PHOENIX-GER]

Will not be long and you will be rolling down the road!

Can't wait for it and still there are enough possibilities to fail.
Most does i fear the emissiontest. It was all the years in the past difficult to pass.
The braketest can be fail also if the brakesystem is complete new.
With a difference in the brakepower will we not pass. We check it before going through the roadregistration in the professional shop.
At least i hope they do not check the noise another issue to fail if we be louder now than the value in the papers.
Should not be as all is original .... and its not regular testet only after tuning, changing stock exhaust or if the truck is obvisiously to loud.

 

[vanaisa]

If you have problems with your anally strict MOT, register your truck here, in Estonia. Without new TI gauges, you probably get our historic black plates also without worries.

 

[PHOENIX-GER]

The new gen plug arrived today and we can go on tommorow with a testride.



Not the cheapest but fullfill all our demands
Rockauto delivered reliabel within 3 days

The shop appointment is schedulded for next wednesday, also earlier if the truck is ready.
Ordered today the new registrationplate.
About the additional info for history condition and saisional registration become the plate 8 cm longer and will not more fit. there is no space for a longer plateholder



We will solve it with smaller platelights. Ordered today.
I really missed our small local partshop which have all on the shelf. Time gone for this shops.
Had there the best motortalks.

To use the "free" time as for all other we need a running engine, does we prepare the Trailer also for roadregistration.
It make sense as pintle hitch and toeeye need both a special test and Roadregistration, can be done in one appointment. The restoration can be done after this. It will costs insurance and tax but as also going with saisional registration will it be not that big ammount.

We will do only demanded adjustments. First we need to remove the round reflectors on tailside to triangel reflectors.
In Germany triangel reflectors are only on trailers so its directly to recognize as trailer.



The preowner in the netherlands already customize for the roadregistration in NL the taillights. He break out the blacklights and use this as yellow turnsignals. Also customize the wiring.
Its a possible solution we will go with it for our roadregistration.
By restoration will we go back to original condition include the wiring and use the "lightbridge" to fullfill the german law.

We also need to customize a plateholder. The plate we use in this pic is an old one from our horsetrailer in 1992. It have the same size like our actually plate.
No matter where we place it, it will be always a superfluous pimple

 

[PHOENIX-GER]

Here we go - this was hard 18 days with a lot of minor steps back.... before finally have our shop appointment





i followed the truck



He is very fast on 50 km/h which is the speedlimit in the city.
The new drivetrain is a hugh difference and worth the money/work with it.

The trailer was gone with a tractor to the Shop as we couldnt find a trailer which was big enough (wide 2.18m, the most flatbed cartrailers have just 2,10m and use a rail on the sides... no chance to have a safe drive with this).
So we used the old dutch toeeye which fit in the tractor hitch. The military toeeye dont fit in any truck or tractor hitch here and change it in front of the shop again on the stock toeeye



Of course with a second set "special plate" like use on the chevy (called here red number with restriction using) had we go trailer and truck together, but we could got only one set plates from the shop.

Now we waiting our destiny ...

First check up was:
We had to remove the parking lights out of the turnsignals in the front turnlights.
Never was this a problem before. We had new headlights in which already have a parkinglight. So we slip off just the plug from the bulb
Than he morned about registration number: Papers are different from the vehicle ID. And in fact in 2021 with our first roadregistration after longtime storage before restauration the roadregistration had made a typing mistake. One letter different. The one in the first line which said its a chevrolet truck
1GD instead of 1CD
Thats not a minor failure and can result in a complete stop of all.
In Fact today i have no papers for the truck.
Fortunately i am the only owner since the truck left military service and i have all papers from this time until today an can show that it is just a typing mistake of roadregistration office. But it make annoying trouble.
He had could pass but its delay of that missing "legal paper"
I must confess i never checked if papers of roadregistration was ever correct in more than 40years with several vehicles in my life.
How ever we are now in that situation.

The Trailer will not pass without mounted additional turnsignals. To use a yellow buld in the tarnlight section will not be accepted.



So we had ordered LED Turnlights from Hella and will bolt them just on the plastic cover of the taillights in the blacklight area. The taillights are already "destroy" from the preowner by brake out Blacklight. It will look ugly but fullfill the law here.. For now its just to fullfill the rules. We will do this tomorow in the parking lot of the shop as bring him home and back again is more work than just change it there.

Another change was to stick over the red reflectors a yellow one, changing the yellow sidemarker from the front to the side and tape red sidemarkers in the front as red in front visibility is not allow here





Also necessary a fog taillight, so this is also added
Papers are prepared for the trailer but as this is the first registration in Germany... a lot of can be still prevent roadregistration.
Friday will be finally check up on TÜV/Roadregistration. Than we know more.

Also if we got our roadregistration is the truck still not finished.
The compushift need an adjustment as it shifted very hard.
We need for the tachometer another Dacota Device to display it on the cluster. Didnt know it, was also not informed from Dacota by purchasing the cluster include Diesel tachometer with all additional devices. A good customer service had mention this.
As the truck have not a locked trunk should be a locked Military box on the bed.
We have 3 big boxes, where we want one use as stationary box on the bed. So we will customize a save mount for it beside using just strapes.

I think it will never finished as there is always something to find you can improve.

Couldnt resist to use this patch inside

 

[PHOENIX-GER]

Time to clean up our shop for the next challenge

 

[PHOENIX-GER]

A big step forward.
We passed the technical test and the examination for historical vehicle.
Finally we also got the dixon bates pintle hitch for roaduse approved.

The biggest problem was the rearbrake. For us occur only a not sufficient adjustable parkbrake. We had all new in the brake.
The shop find out the brakeshoe had to much space and coudn't be push enough against the drum. Left arrow in the picture. For this parkbrake wasn't also adjustable.

Parts bought for a K30 build 1984.

We didnt compare the shoe design with the old one...

They solve be weld the slot in the bracket to shorten the slotspace. Right arrow in the picture. Work now perfect.



The trailer doesnt go to technical test as the engineer advice not to do it with him as he need to search on all details which result in high costs. He dont accept to follow the datasheet from the top technical office TÜV Nord. He work for another technical office which got also the goverment approve for this tests.
I contacted the technical office TÜV Nord which tested the trailer for sotaparts, (german vendor for Humvee and Military Trailer) and signed the technical datasheet for roadapproval here.
I have now an appointment with this technical office for the test on 22 October.

For the Chevy does i have on 15th October appointment for roadregistration. This time i will be control all papers on correct data and vin!

 

[Guyfang]

Going to TÜV is like going to the hair dressers, for a tooth ache. BS is their job.