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The 89 2.6 trooper project

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The 89 2.6 trooper project

Postby drinksoptional » Sat Aug 25, 2012 6:07 am

Description:
Hi my names is Stuart i live in Glasgow- Scotland with my wife and 8year old son.
I own two isuzu`s lWB 1990 lotus edition 2.8td bighorn Hi -Top . 1989 2.6 petrol swb barn find. The daily drive is the bighorn and the 2.6 is a restore project and offroad toy.

Modifications and Accessories:

Suspension: standard
Body Lift:standard
Tyres/Wheels: standard
Traction Aids: LSD,
Bullbar: Frontera wrap around cut back
Spot lights and Lighting: N/A
Communications/GPS:N/A
Dual Batteries:N/A
Engine:2.6 (soon to be a 3.1td)
Exhaust:standard
Sound system:N/A
External: work in progress
Internal: work in progress
Others:


Pictures:

These are my two Isuzu

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The daily drive
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The 2.6 project
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drinksoptional
Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby drinksoptional » Sat Aug 25, 2012 6:32 am

I bought the 2.6 after a bit of humming and hawing at the time i was using a 97 2.0 frontera sport as a offroad toy it was orignally my daily drive
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As time went on i did the usual mods
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Then i added mud tyres and a cb
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Anyway fast forward to present day i have been working on this 2.6 petrol mk1 trooper

As i said it lived in a barn for two and half years after the fuel lines went on it , they were replaced but the farmer /owner lost intrest. A mate had told me about this trooper in a barn. At the time i wasnt looking for a trooper never mind an old one.
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It was grubby full of dead bugs n spider webs and wasnt even sure if it would start an i was happy and £100 quid lighter .It then sat there for 5 months till i sold the frontera,.
The the big day came it was been put on a trailer an my mate was dragging it 100 miles to my house.
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This was the beginning of my first ever project. I had bought a clarke mig welder the year before an had never did welding before so i was clueless about how and where to start.
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Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby drinksoptional » Sat Aug 25, 2012 6:35 am

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Then i gave it a wash  and put up garage tent
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Now we all caught up.  The real job and fun begins

I removed back seats the seat belts and the carpet.  I held aloft my mighty light and  an old screw driver began poking the rust bits

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the other side
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There was no going back now
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Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby drinksoptional » Sat Aug 25, 2012 6:39 am

Most the next post and picture i have copied from the itoc forum save me writing it all out i again . I will do best to edit to keep it up to date . I hope i have this in the write place and not breaking any rules apologies in advance if i have .

The progress so far
i Jacked it onto axle stands got the wheels off,
I used my trolley jack and a plank of wood jacked it up under the tank i then undid the 6 bolts?  for the fuel tank and dropped it down. i then undid the hoses as i went

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Behind the wheel the rust  looks even less appealing if rust can ever be appealing
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I had a look at the rear cross member and it is corroded at each side i ended up partly removing  the rear bumper
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I know the pictures arent that good i was using a cheapo torch.

Is there supposes to be a rubber bump stop here :lol:

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Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby drinksoptional » Sat Aug 25, 2012 6:40 am

I had issue with the repair trying to beat rust an following the shape of arches against the boot floor.

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I know patchwork but solid.
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The other side is not as bad
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Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby drinksoptional » Sat Aug 25, 2012 6:42 am

Update been back at it again this time the opposite arch

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That went ok . The next part wasnt so good found a ruddy big hole in the seat mounting.  The mount uses 2mm i have 1mm metal i can cut round the hole the rusty edge of an still have most of the mount  might be able to patch. It will be good practice for the crossmember.  Its like they used tin on that part the metal changed thickness . I had to cut it all away at one point i was twisting it round long nose pliers like openning can of tuna

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Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby drinksoptional » Sat Aug 25, 2012 6:43 am

I removed the front seats and carpet

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Off with center console
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Next job was  too deal with the rust around the windscreen
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It didnt go according to plan I cracked the screen i saw that coming as its been 10 years since i removed one.
The side i thought was bad was better than the side that looked good.
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Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby drinksoptional » Sat Aug 25, 2012 6:44 am

I started off with removing the factory fitted ?  radio/cassette. Easy. next was any screw that held the dash to the body. I am glad the window was out made it alot easier. I had to stripout the three center oil/fuel/temp dials  aswell as the speedo rev dials  and few other parts . A bit of fighting with screws and connectors i finally got the dash out

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Finally it let go
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I didnt even upset this wee guy he just sat there laughing
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Until i threatend him with a blow torch
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The next stage was check out the rust damage not as bad as i first thought , wee bit off work on drivers side is definetly needed

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passenger side
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I cracked open my can of bru and sat back for a breather
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Then i thought where am i going to put all these interior parts
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I then moved onto the front bumper one bolt bent then sheared couldnt get the last bolt off even with a blow torch and dw40  need a bigger bar
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Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby drinksoptional » Sat Aug 25, 2012 6:46 am

I managed to get the front bumper off

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The cross member is in good condition  now i could see all of it i am glad for that.  The radaitor mount is well corroded
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I had a frontera bullbar i cut down so i retro fitted that just to see how it would look
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Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby drinksoptional » Sat Aug 25, 2012 6:47 am

Busy weekend stripped the gearbox, engine, radaitor front and rear props (and rear diff flange) Part wiring loom and fuse box and fuel tank out of a 95 3.1td comercail.

First job was to get access to gearbox .  With some help from Jack and his special GET ACCESS TO GEARBOX TOOL this was surprisly easy

Click image for video

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This what a swb trooper looks like underneath now dont try this at home this is a specialy trained to play dead Trooper.

The wiring loom was a nightmare as i didnt know what to keep and take i just cut off what i know i didnt need an kept what i didnt know  :lol:
There was a load of connectors under the dash i split them and dragged the loom out of the gromit on drivers side .  

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The engine lifted out nicely in one go bar one wire for egr just a wee socket to unclip.i took home the gearbox and other bits i had to leave engine it wouldnt go in the back with the forklift  the there wasnt enough  height , will get that  at a diffrent date on a trailer .


Now the fun begins getting the one out of mine with no forklifts  and getting that one in with no clue what i am doing i feel this is going to be a nightmare getting it into a 2.6 petrol mk1. The good thing is from what everyone said there is very little wiring . When i compared the engine mount to my 2.8 td there was not much diffrence . I move house at the end of the month getting out this crap hole . I wont be doing anything till after i move
drinksoptional
Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby drinksoptional » Sat Aug 25, 2012 6:49 am

Sorry if its a big read anyway this is where i am to date. I move house next week so this project will have to wait plus the engines is 210 miles away as it wouldnt fit in the back of the bighorn on a pallet i will use a box trailer to get it home
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Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby geeves » Sat Aug 25, 2012 7:29 am

the joys of salted roads

thats a biiiiig project
good luck
Sanding your knuckles before starting work can help. That way you cant skin them
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geeves
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Re: The 89 2.6 trooper project

Postby drinksoptional » Sat Aug 25, 2012 8:12 am

I tell myself it will be worth it in the end i would like to put it back on the road by end of year
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Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby drinksoptional » Mon Sep 24, 2012 7:44 am

I stripped out the radiator some pipes, wires  an loosed the bolts for the down pipe . Im getting engine ready to be lifted out then i will drag it onto set of car ramps to get the gear box an props off . Then i will get mates 500kg engine lift an whip the 2.6 out. My friend delivered the 3.1td and we unloaded it onto a pallet on my driveway.

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I have been working when i get time . I removed the front wings and bonnet , i also removed the rear doors.

The rear doors are rusting badly at the bottom i will cut away the crap an replace with new
The wings are rusted too shit at the bottom where they meet the sills that why i removed them also wanted to check the sills behind the wings . i will replace the corroded parts

The bonnet i removed so i can get the 2.6 out and the 3.1 in. I then have to cut a hole for the intercooler


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Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby drinksoptional » Fri Oct 12, 2012 7:01 am

he removed back doors picture  no reason for it but we all like picture post`s  :lol:



Next job was removing the gearbox so i attached a strap to the bighorn and dragged the trooper onto a set of ramps.

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I unbolted prop from the rear diff flange . Then i hit an issue with this bit


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Two bolts were missing on passenger side qand looked like it was welded on when i tried removing the bolt it snapped the mount dropped a bit. The other side i used a blow torch to heat was all i had  it was too windy and cold i ended up snapping another bolt an the other one wouldnt budge so i stopped there  before i snapped another one. Will by some penetrating spray see if i can get that to help
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Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby drinksoptional » Fri Oct 12, 2012 7:02 am

Im back this week GEARBOX

First off i had bought a work lamp on a Tri pod for a tenner chance find in a recycle place  had it in a corner swap me it for a tenner Scottish money  8-)  It had a socket so i swaped that for a plug and fitted a new bulb.  Then out into the garage tent last night.

I wanted the rear shocks off as they are new standard  an the ones on my bighorn are knackered an do not match been like that since i got it in feb.  While i was under there i soaked those siezed bolts with some oil

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Temptation got better of me so the gearbox mount was coming off an with some leg foot action on a bar off those siezed bolts they came  without shearing . Feeling lucky i carried on and started doing the gearbox bolts  while doing them  Kev next door jumped the fence an came to have a nosey and help as he was bored.
With some twisting levering of it came .
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Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby drinksoptional » Fri Oct 12, 2012 8:47 pm

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Next was engine mounts nuts and then we thought " can we lift engine with a scaffolding bar " could we f**k !!


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So that the 2.6 engine ready to be lifted out , quite chuffed now once i get the engine out this build can get going
drinksoptional
Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby drinksoptional » Wed Oct 31, 2012 6:40 am

Engine lifting out day.


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That little plate got ripped off
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Just to get the 3.1 turbo diesel in now

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Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby drinksoptional » Sun Nov 18, 2012 8:44 am

I will let the pictures do the talking.

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The trooper now has a 3.1 td fitted just to get the gearbox exhaust fuel tank fitted then get all the wiring sorted
drinksoptional
Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

Re: The 89 2.6 trooper project

Postby drinksoptional » Tue Aug 18, 2015 7:32 am

Ok jeez been a long time since on here.
well i moved house again life love and illness i still have the mk1. I did get it running and it did drive up a small grass hill of my new house . That is it i have been busy sort7ng the grey Bighorn over last three years i think i got 20 hours of work. Major pita it been ofv the road due to leaky fyel pump and welding lots of it. I try boost some pictures and vidies up soon
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Isuzu Baby
 
Posts: 32
Joined: Wed Sep 14, 2011 6:34 am
Age: 35
Country: scotland
City: glasgow
Vehicle: 97 Vx frontera 2.0 sport
97vx frontera 2.5td lwb
88 isuzu trooper 2.6

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