With Algernon back on the road now for about 6 months, I thought I throw this in as sort of an update to what has happened since first getting him back on the road.
First, there was the Small Electrical Fire (TM). Because it was summer and the mounting was different, I decided to not re-install the heater until the fall. However, I failed to remove the lead from the fuse block that goes to the blower switch. On my way to have the brakes pressure bled, the bullet connector on this lead contacted the steering column shorting out the entire vehicle and starting the fuse block on fire. The only major casualty was the voltage regulator.
About two weeks and 40 or so miles after repairing the electricals, the brakes failed in traffic. Lucky for me everyone was paying attention and I didn't get into an accident as I rolled through that red light... Gathering my wits (and a clean pair of shorts) I limped home on side roads using my gears for brakes.
An analysis led me to the ultimate cause of the entire Frame Replacement Adventure. The brake light switch was leaking. Back in the fall of '95 I had a similar problem when it first got cold, the brakes got really soft. I surmise that water had collected in the switch and froze causing it to crack. Maybe, maybe not. But at the time I didn't know the cause which made me want to start with the master cylinder. Getting to the master cylinder required pulling the wing. When I started to pull the wing, the bulkhead began to crumble. The rest you know. I guess *I* cracked then :-)
Fixed the brakes, bled them myself this time with a helper, and in the process I decided to replace both rear adjusters.
I ran most of the summer with all the doors off, and that was very pleasant. Putting the doors back on was relatively painless, although the rear hinges needed to have the pins drilled out. I replaced all the pins and balls.
I constructed a mounting plate for the heater out of a piece of galvanized sheet metal, using the old bulkhead as a template. Installing the heater was pretty easy (although kind of messy). Now that it is clean, the controls properly connected (SPOT my first winter: had the damper and hot water controls reversed), I'm staying nice and toasty.
I did a lot of the usual 'routine maintenance' stuff, including rebuilding the carb and blocking off the unused port per the British Pacific tech info. sheet.
I believe that the truck is better now than it has been in a long, long time. The front axle still needs work - new swivel balls, etc., the I need to rebuild the handbrake and replace the oil seal behind it. The new oil seal on the front output shaft also leaks and should be replaced.
Just a couple weeks ago I had the opportunity to actually go off-road with it for the first time. I was slightly nervous, but confident that all the bugs were worked out. The driving was good fun with no problems. Not too challenging but just perfect for a first time on the trail.
I also managed to get it stuck for the first time a week later, not on the trial but in my alley. With my tires, it takes about a bumper's depth of snow to stop me. A few minutes with a shovel and low range and I was out of there. But I was the only one that made it out of the alley that day...