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Greetings from Morganton North Carolina

Discussion in 'Introductions' started by SBL, Aug 15, 2021.

  1. SBL

    SBL New Member

    I just purchased my first mini truck about five weeks ago on a whim. Saw one on the road locally and within a few days I became the proud owner a 1995 Honda Acty HA4. The truck is in sound running order and rust free. Unlike many I really have no need of the truck I just like it. Nevertheless, I have decided to complete a full restoration. I have started by rebuilding the front end. Specifically, I have disassembled media blasted and powder coated just about every piece and replaced all rubber bushings with polyurethane. I look forward to sharing my progress and tapping into the vast knowledge this forum can provide.
     

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    Limestone and punimog like this.
  2. Kdub

    Kdub New Member

    Yo! I'm in Morganton, and am just about to pull the trigger on a sambar. Let's meet! Haha
     
  3. SBL

    SBL New Member

    Kdub,

    I would enjoy the opportunity to meet and discuss our mini trucks. My truck is currently disassembled but I'm making steady progress. I just finished rebuilding the leaf springs and plan to install them this weekend.
     

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    Limestone likes this.
  4. Donnie Hines

    Donnie Hines New Member

    Hi guys! I just bit the bullet and paid for my truck today. I am in Selma, NC so once I get my truck from Japan, as long as it runs good, I would def like to ride up.
     
  5. punimog

    punimog New Member

    All the refreshed parts look great. How did you manage all the polyurethane? Did you have to measure them all individually? I look forward to seeing the continued progress.
     
  6. SBL

    SBL New Member

    The polyurethane bushings where a bit of a project. Yes I measured everything individually. I then sourced bushings that were as close as possible to the sizes I needed and machined them to fit. The steering bushings were an odd size so I made them from polyurethane bar stock and turned them on a lathe.
     
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  7. SBL

    SBL New Member

    Just a quick update. I removed the engine mounts cleaned them and poured liquid polyurethane into the cavities. This should prevent any further deterioration and is much cheaper replacement mounts.
     

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    t_g_farrell, punimog and Limestone like this.
  8. t_g_farrell

    t_g_farrell Member

    Can you describe this process using liquid polyurethane? Assume theres heat involved seeing the sand in the pie tins.
     
  9. SBL

    SBL New Member

    It's a very straight forward process. No heat involved. First you need to clean the existing rubber with a good degreaser. Apply a bonding primer (available with the kit) to promote adhesion. Then tape off one side with duct tape (I used gorilla brand; very sticky). I filled three pie pans with a little sand. The sand its used to level the mounts. It's very important to level the mounts since you will be pouring liquid polyurethane into the cavity.
    The Poly comes in two parts. Mix together and pour slowly. The kit makes enough for the three mounts and takes about seven days to properly cure.

    I purchased my poly kit from energy suspensions website.
    Do It Yourself Motor Mount Inserts - Liquid Urethane
    Manufacturer: DST
    Part Number: diymmi
     

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    Limestone likes this.
  10. SBL

    SBL New Member

    Just wanted to share this weeks progress. The completely refurbished rear-end has been installed, along with rebuilt brakes.. The polyurethane reinforced motor and transmission mounts worked out perfectly. Now that everything underneath has been sorted we'll start work on the interior.
     

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  11. SBL

    SBL New Member

    Added air shocks to the rear of my Acty today. Monroe Max-Air MA805 Shock Absorber. It took a little bit of work to get them sorted, but when finished they fit perfectly. I first had to narrow the lower eye by removing 100 thousandths from each side. I then has to shorten the top mounting stud by 5/8 of an inch. I then used a threading die to turn an additional 3/4 of an inch of thread length. I used energy suspension polyurethane bushings,
    (Uppers 66008, Lowers 601670). Because the lower bushings are made for a full size shock eye I cut them in half and turned about 1/4 inch of each side.
     

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  12. SBL

    SBL New Member

    I'm confident other members have experienced a similar problem of the rusted through Acty muffler. I was not particularly excited about spending several hundred dollars for a replacement muffler from a Japanese parts vendor. In addition, after removing the entire exhaust system including the cat I noticed most of it was past its prime. My solution was to construct and entirely new exhaust system. I sourced some 2 inch aluminized exhaust pipe in various mandrel bends from Amazon, along with a tubular glasspack muffler (the longest I could fit to maintain a quiet tone). The flanges were created in CAD and laser cut out of 3/8 mild steel. I'm still finalizing the last hanger and stainless tip. I also achieved the added benefit of removing almost 45 pounds. I'll post some sound in the future. Cheers
     

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    Limestone likes this.
  13. Limestone

    Limestone Well-Known Member

    SBL,
    Your doing a great job with pics and explaining your process, besides the great work your doing!
    We do appreciate you taking the time to share your knowledge and experience!
    Great Pics! Thanks Again!
    Limestone
     
  14. SBL

    SBL New Member

    The the mechanical bits are well sorted, so I started preparing the body for paint this past week. I'm fortunate there is very little rust on my Acty so I thought I would take the opportunity to clean-up a few unnecessary holes. I drilled out the factory spot welds for the Japanese license plate mounts. After welding up all the holes the factory license plate light looked large and out of place, so off it came. I'll use a license plate frame with an integrated led light when the time comes. Next I'm planning on making a fuel door to cover the gas cap.
     

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  15. SBL

    SBL New Member

    Completed the preliminary fuel door prototype today. It took me awhile to get the bracket geometry correct and I incorporated a soft close hinge. The final will be made from 18 gauge steel with a rolled edge and instead of the one self clinching 5mm pen stud I'll use two for more stability. I hope to shape some steel fender flares next week.
     

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  16. Oh-Kei

    Oh-Kei New Member

    outstanding work, congrats.
     
  17. SBL

    SBL New Member

    Thank you for the kind words. I finished the tailgate letters today out of .100 aluminum. I plan on painting them and adhering them on with 3m clear trim tape.
     

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  18. Oh-Kei

    Oh-Kei New Member

    Someone has a water jet it appears?? (jealous)
     

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