🔧 BUILD Reviving The Cherry Popper - 1980 Scout

[Jon01]

Need to update this some.
Still waiting for the heads to get done at the machine shop.
Advance adapters got me the kit to adapt the D300 to my 6l80e.
I also ordered the engine harness from BPAutomotive but it got stuck in the blizzard so won't be here till Tuesday.
Today father in law and I went and snagged the tires that finally came in.

Definitely gonna need that lift to fit these under it.

 

[Shawn1112]

?

 

[Jon01]

I did some more thinking on this motor, I have been going back and forth on running a hone down it and throwing some rings and bearings at it while it's down to a short block. It does have 170k on it...
I stopped by the machine shop and talked to them about it, I'll have about 350 in machine work - tank/surface/hone block, polish crank and install cam bearings. Then another 350 additional in bearings and rings.
I already have a bunch of the shit I'd have to replace again if it does have issues - oil pump, gaskets, lifters...basically half of what this will cost to just do.

I'm thinking I may just pull the trigger, then it'll probably last damn near for the rest of my life with as much as this thing is going to get driven.
They can turn it in a week or so if I assembly myself, months if I want them to do it.
I've put together a couple of bottom ends so the assembly doesn't intimidate me too much.

Next thing would be to rebuild the 6L80E while it's out. I'm really torn on that one.

 

[OffshoreDrilling]

I did some more thinking on this motor, I have been going back and forth on running a hone down it and throwing some rings and bearings at it while it's down to a short block. It does have 170k on it...
I stopped by the machine shop and talked to them about it, I'll have about 350 in machine work - tank/surface/hone block, polish crank and install cam bearings. Then another 350 additional in bearings and rings.
I already have a bunch of the shit I'd have to replace again if it does have issues - oil pump, gaskets, lifters...basically half of what this will cost to just do.

I'm thinking I may just pull the trigger, then it'll probably last damn near for the rest of my life with as much as this thing is going to get driven.
They can turn it in a week or so if I assembly myself, months if I want them to do it.
I've put together a couple of bottom ends so the assembly doesn't intimidate me too much.

Next thing would be to rebuild the 6L80E while it's out. I'm really torn on that one.

Have I got the thread for you! And holy shit I can’t believe this was 7 years and three cars ago already

OffshoreDrilling's DIY 6L80 transmission rebuild

The transmission in my 07.5' Sierra Denali has been on the fritz for over a year now. I bought the truck used with 80k miles on it two years ago and have put almost another 40k on it in that time. There's evidence the truck had done a lot of towing in its previous life given that it had been...

www.thechicagogarage.com

 

[Jon01]

Need to get an update rolling here.
Our doggo was given a terminal diagnosis end of January so I put this on the back burner to spend what little time he had left doing all of the best things. We had to let him go last weekend so it's time to refocus and get moving forward.

I brought the Scout home yesterday so I could poke away at the wiring in the evenings after work.

Today besides working on stuff around the house and being hungover I got the original dash harness pulled, stripped and started laying out the AAW replacement - they're really on their game, this harness is really nice.

Also got the box of goodies from TSP for the valve train in the engine.

My hope is that this week I can get most of the wiring wrapped up and hopefully by the end of the week have the block and heads home so I can start reassembly of the engine over the next couple of weeks.
The machine shop is wayyyy backed up but this'll be week 2 of the 2 they asked for so we'll see how much progress they've made.

 

[Jon01]

Had some time today to get back on this.
First I tackled swapping out the clutch pedal/brake pedal assembly for an automatic setup. It didn't suck too bad.

Next I started stringing the dash harness until I was held up by my lack of decent quality zip ties. I got about 40% of it strung out and ordered ties to be here tomorrow.

Once I hit the wall there I went to the rear of the truck and pulled out all the stock chopped to shit wiring, installed the new taillights and marker lights I bought along with their new pigtail harnesses.

Overall I've very happy with this AAW system. They put a ton of thought into it and build lots of flexibility into things for swaps/future growth. Expensive but would definitely buy again.

My hope is that I can get out of work at a decent time this week and continue to move forward on this part of the build now that DST is in effect and the weather has warmed up.
I'm also gonna harass the machine shop, they've had my shit 4 weeks now. It's time to get it done.

 

[Mr_Roboto]

It blows my mind that there is a good aftermarket for this truck. You don't see a lot of them.

 

[Jon01]

It blows my mind that there is a good aftermarket for this truck. You don't see a lot of them.

The core stuff is pretty readily available through light line dealers.
There is a very strong focused following of them, seems that once people get their first they end up with 7.

 

[Jon01]

More progress tonight.
I stopped by the machine shop tonight on my way home. The heads are done but they haven't touched my block or crank after 3+ weeks. They said 1 more week so we'll see if they can get shit done.
Got the dash harness loom pulled apart and things spread out where they will end up.
Connected up the headlight, wiper and ignition/turn signal switches.
Waiting on some crimpers to arrive and I'll get to work on finishing off the connectors to the stock instruments.

I know it looks like a disaster but I had to chop open their looming so I could route things nicely as this is a sorta universal fit across all years of Scout 2's.
Crimpers should be here tomorrow so I hope to get back after the adapter harnesses for the stock cluster. Once I get those built I'll be able to stick the dash frame in loosely and move to the front and rear lamp harnesses.v

 

[Mr_Roboto]

It's a few pages back but I think you said 6L80E? What are you doing to drive the dash?

 

[Jon01]

It's a few pages back but I think you said 6L80E? What are you doing to drive the dash?

Yeah, 6L80E. I'll adapt stock senders to the 6.2 for oil pressure and water temp then plan to use a Cable-X to drive the speedo.

 

[Mr_Roboto]

That was the part I was wondering about, trying to figure out my own speedometer if I do a 4L80E in the Lemons.

 

[quikturbo]

Great build! A man after my own heart
Bought it Jan 2021

Current state (5.3, 4l60e, Dana 300 w/advance adapter)

Almost done at the bodyshop and then on to final assembly.

Sorry, didn't mean to hijack, just excited to see another International owner on here If I can help out on anything just let me know.

 

[Intel]

What are you going to use to wrap those harnesses once it is all routed?

Looks like a really fun project!

 

[Jon01]

Great build! A man after my own heart
Bought it Jan 2021
View attachment 114543

Current state (5.3, 4l60e, Dana 300 w/advance adapter)
View attachment 114544
View attachment 114545

Almost done at the bodyshop and then on to final assembly.

Sorry, didn't mean to hijack, just excited to see another International owner on here If I can help out on anything just let me know.

Fuck yeah man! Looks like you're doing about what I am, except you're really making yours nice!
Questions offhand:
What did you do for fuel tank? Stock or aftermarket? How about pump?
Are you gonna run a/c?
I see you went with the Wizard radiator, how happy are you with it?

What are you going to use to wrap those harnesses once it is all routed?

Looks like a really fun project!

I'll be using braided sleeve throughout, same stuff I used on my C10. It's pretty easy to work with. The harnesses that aren't terminated I've been using unsplit sleeve, those that are terminated are getting split.

 

[Jon01]

Tonight's progress:
Built the connectors to plug the AAW harness into the stock dash components.
Not earth shattering but tedious as fuck cutting the harness up and figuring out the routing on the mirrored images.

I went ahead and spent the bucks on the AAW crimpers and they really were worth it.

Tomorrow night, now that these are terminated I will get back after the dash, hopefully I'll be able to loosely hang the dash frame, final route the harnesses and start looming/organizing things up.

 

[Mr_Roboto]

Gotta love old school looks with new school movement.

 

[quikturbo]

Fuck yeah man! Looks like you're doing about what I am, except you're really making yours nice!
Questions offhand:
What did you do for fuel tank? Stock or aftermarket? How about pump?
Are you gonna run a/c?
I see you went with the Wizard radiator, how happy are you with it?

I'll be using braided sleeve throughout, same stuff I used on my C10. It's pretty easy to work with. The harnesses that aren't terminated I've been using unsplit sleeve, those that are terminated are getting split.

Haha, well I wasn't going to at first but we all know how projects spin out of control sometimes.

For fuel I went with a new poly tank and an external Bosch fuel pump & inline filter. I re-purposed one of the evap ports on the tank as the return. So far using good rubber isolators on the pump mount its not too loud. I do wish there was a better option for tanks and in-tank setups. I looked at doing something with that Holley hydramat but didn't go too far down that path.

I'm planning on running A/C and likely using the aftermarket setup which would not use the factory wiring/pcm logic. I'm slightly concerned with that setup and how the truck will respond when the load from the compressor kicks on and runs, since the pcm won't automatically adjust like it would integrated.
What are you thinking for yours? A/C or no?

As for the radiator, I hated having to spend so much but in all honesty trying to find one that fit perfect with the correct location/size inlet & outlet was exhausting lol. The anything scout setup fan & wizard radiator were a good investment.

I used ScoutCo motor mounts and trans mount, only issue I had was finding a set of headers/manifolds that cleared, which it took 3 tries

 

[Jon01]

Haha, well I wasn't going to at first but we all know how projects spin out of control sometimes.

For fuel I went with a new poly tank and an external Bosch fuel pump & inline filter. I re-purposed one of the evap ports on the tank as the return. So far using good rubber isolators on the pump mount its not too loud. I do wish there was a better option for tanks and in-tank setups. I looked at doing something with that Holley hydramat but didn't go too far down that path.

I'm planning on running A/C and likely using the aftermarket setup which would not use the factory wiring/pcm logic. I'm slightly concerned with that setup and how the truck will respond when the load from the compressor kicks on and runs, since the pcm won't automatically adjust like it would integrated.
What are you thinking for yours? A/C or no?

As for the radiator, I hated having to spend so much but in all honesty trying to find one that fit perfect with the correct location/size inlet & outlet was exhausting lol. The anything scout setup fan & wizard radiator were a good investment.

I used ScoutCo motor mounts and trans mount, only issue I had was finding a set of headers/manifolds that cleared, which it took 3 tries
View attachment 114571

Yeah I can totally relate to scope creep. That's how a dash swap in my C10 turned into a frame off rebuild.
Also a big part of why I'm not tearing into this thing further. I want to enjoy it this year, not in 4. And once it's perfect I'll struggle wheeling it like I want to.

Did you just use a stock sender/pickup tube for your fuel pump?
I had my stock tank all boiled and ready to go then discovered Binder Boneyard makes a sick aluminum 30 gallon tank with a nice in tank pump etc...for $1100 so I think I'll just do like you did and run an external unit and C5 filter.

For AC I plan on running one of the Anything Scout under dash systems with an SD7 compressor down in the stock location.
The load of the compressor shouldn't make much difference in idle. I don't have my C10 compensating and it doesn't dip much.

I'm glad to hear you feel the radiator and fan setup was money well spent. I'm leaning towards going that way myself. At this point easier has value vs using 40 year old stuff that leaks.

I ended up with the Anything Scout mounts and headers, the mounts seem good enough but the headers are definitely Chineseum and have small primaries. I may run them, I may not we'll see where things are at the point I'm ready for them.

Damn that truck looks good! What's it got for suspension etc?

 

[quikturbo]

Did you just use a stock sender/pickup tube for your fuel pump?

Yep, just a new one though. Also, I did VDO gauges so needed to make sure I got the right resistance rating

I had my stock tank all boiled and ready to go then discovered Binder Boneyard makes a sick aluminum 30 gallon tank with a nice in tank pump etc...for $1100 so I think I'll just do like you did and run an external unit and C5 filter.

Yeah, I liked the idea of the 30gal but at that price point, yikes! I didn't use the c5 filter with the regulator built in, just using the factory 5.3 rail regulator.

For AC I plan on running one of the Anything Scout under dash systems with an SD7 compressor down in the stock location.
The load of the compressor shouldn't make much difference in idle. I don't have my C10 compensating and it doesn't dip much.

I think that some other Light Line dealers carry that same setup slightly cheaper, like ScoutCo and SuperScoutSpecialists. AS' kit doesn't include the compressor or the relo bracket and it's $1300.

ScoutCo ProductsScout II Air Conditioner Kit

www.scoutcoproducts.com

$900 without compressor and bracket
$1200 with

Addon Air Conditioning Kit! Scout II

Kit is close to the same as the stock plastic under dash unit used from IH on the 1980 Scouts, but it is slightly different...so it is not a direct replacement. It stretches from the passenger kick panel to just about the centerline of the steering column, and has 4 outlets, to cool both front...

www.superscoutspecialists.com

$999 without
$1299 with

I'm glad to hear you feel the radiator and fan setup was money well spent. I'm leaning towards going that way myself. At this point easier has value vs using 40 year old stuff that leaks.

I ended up with the Anything Scout mounts and headers, the mounts seem good enough but the headers are definitely Chineseum and have small primaries. I may run them, I may not we'll see where things are at the point I'm ready for them.

Damn that truck looks good! What's it got for suspension etc?

Thanks much, you're is coming along and looks awesome as well. Something about leaving them period look correct just makes them even more special.
I have factory leafs, new bushings and Bilsteins . It had this old school reverse shackle setup (gives it a little bit of a lift) on there that I decided to keep since it needed something to remind us it was a cattle rancher truck out in Wyoming most of its life

 

[Jon01]

Good call on SSS, I've gotten a ton of stuff from them and you're right in that AS seems to gouge for their stuff sometimes. If AS wasn't so close and convenient I'd use others more. And they give a 5% discount for pickup orders.

I'd be real curious how yours rides with the bushings and Bilsteins. That's what I plan on running, except SOA and 35's so ride quality should be similar.
When do you think you'll have yours on the road?

 

[quikturbo]

Good call on SSS, I've gotten a ton of stuff from them and you're right in that AS seems to gouge for their stuff sometimes. If AS wasn't so close and convenient I'd use others more. And they give a 5% discount for pickup orders.

I'd be real curious how yours rides with the bushings and Bilsteins. That's what I plan on running, except SOA and 35's so ride quality should be similar.
When do you think you'll have yours on the road?

I didn't realize you were out in AS' neck of the woods, that is awesome, and convenient. SSS being in Ohio has saved me some on shipping the bigger sheet metal stuff and they are always good about true whats "in stock"

I'm hoping to have it done with paint in the next couple/few weeks. I have a local glass shop for the windshield, and then some assembly like window glass, seat belts, etc.. to make it road legal. The goal is to be able to drive it by May. Most of the remaining stuff I can do while it's driveable, carpet, rollbar, stereo, etc..

How about you, on timeline?

 

[Jon01]

I didn't realize you were out in AS' neck of the woods, that is awesome, and convenient. SSS being in Ohio has saved me some on shipping the bigger sheet metal stuff and they are always good about true whats "in stock"

I'm hoping to have it done with paint in the next couple/few weeks. I have a local glass shop for the windshield, and then some assembly like window glass, seat belts, etc.. to make it road legal. The goal is to be able to drive it by May. Most of the remaining stuff I can do while it's driveable, carpet, rollbar, stereo, etc..

How about you, on timeline?

Nice! You're a lot closer than I am!
Do you have a build thread anywhere?

My plan is to have this thing in the mountains of Wyoming and Montana sometime in August or early September.
I think it's still very doable, if I can focus on wiring this weekend and next week, pick up block to assemble the motor next week or 2, jam it in and swap axles in through April, rebuild steering box and get driveshafts in, then it's just misc stuff - install and wire/hang seats, install carpet, have bumpers built, AC install.
Sounds easy on paper. Hopefully it holds true.

 

[Jon01]

Didn't do a ton this weekend despite having big plans.
Installed the new firewall pad with wifey today. Tried to get a hummer while working but failed. Will try again.
Got the dash harness finished up, radio wired in and am pretty much to the point of needing to install the dash and gauges.
The ones I bought from Anything Scout aren't exactly like the stock ones despite their saying they were...so I got into the light line catalog and found exact repros that'll be here Wednesday.
Started tearing the front light harness out to replace it, gonna have to pull the grille to get it all apart. That intimidates me quite a bit as they're a not reproduced 1 year only unit and serious coin when a decent one comes available so decided to tap out there. It's something I can poke along at over the course of the week. I'll just leave it out until I complete the motor swap as it'd have to be out to do that.

 

[Jon01]

Got OEM style dome light switches in and finished dash wiring off with exception of taping up some of the loom joints then I'll get the dash installed and plug the radio back in.

Also got the call from the machine shop that my block, crank and heads were done so I picked them up on the way home from work.

Going to run to farm tomorrow to murder a groundhog and I'll grab a couple things while down there to hopefully finish this part of the install up tomorrow night.
Currently waiting on RockAuto to get the mains, rods and rings here so I can start the reassembly process of the long block.