Later this year will mark five years of ownership and near-daily driving of this thing. I gave a one year update, then we last checked in I’d done a round of upgrades to prepare for a track day at Buttonwillow with Jack Baruth of The Truth About Cars. Since then, it’s received two major upgrades/fixes:

• I replaced the tall 2.80:1 open differential with a 3.25:1 Detroit Tru-Trac helical-gear limited slip. The drop-out 3rd member makes changing a differential a “couple hours in your driveway” kind of thing instead of a “two days at the mechanic” kind of thing. Plus, you can keep your old unit around as a spare. The new lower gearing hurts highway cruisability, but my current commute is only five miles of surface streets.
• I knocked down some of the worst rust on the car in the roof gutters, wheel wells and tail lights. I did what you’re not supposed to: wire brush, Eastwood rust converter, bondo and primer. It’s starting to poke back up, but still better than it was. I also learned this car’s on at least its 4th coat of paint.

That’s the good, but the following issues brewing (or have already come to a head)

• The odometer died at 25999. According to the previous owner, the 6th digit is a 1, but I’d expect an odometer to function longer than that. Given the mystery mileage and the fact that it’s a non-original drivetrain, I’m not sure the mileage means anything anyway.
• The steering (that I rebuild 4 years ago) is loosening up again
• There’s a slight vibration out of the front end above about 65
• Sustained Rain = wet carpets (and drips behind the dash board). This is probably going to have consequences for my carpets and floors. Hopefully it’s the dried out windshield seal and not completely clogged and rusted vent drains.
• Second and third gears crunch a bit on engagement if I’m rough
• On the way to Buttonwillow for LeMons, the generator light came on. It ran fine all weekend until the voltage dropped low enough for the engine to stumble right as I pulled in the driveway. I’m trying to figure out if it’s the generator, voltage regulator or the 50 year old, decrepit cables at the root of my issue. I may or may not use this as an excuse to upgrade to an alternator and put the battery in the trunk.
  • I picked up an alternator and regulator from a junkyard 1970 Fairlane wagon over the 4th of July weekend. Brackets for the conversion are on order, so I sure hope it’ not a dud.

Long term, there are two major upgrades I’m hoping to find the time and budget (or sponsor…?) for:

• The “right” thing to do for the paint and body would be a complete down-to-the-metal rework, along with new weatherstripping everywhere. I don’t really care to have a perfect super-nice paint job, it’s just a matter of efficiency to get it all done at once. However, given the price tag, I’m trying to figure out how long I can stall on that, or if I should just keep playing whack-a-mole with the worst of the body spots.
• The suspension (whole chassis, really) needs a similar treatment: steering and control arms, new rear leaves, subframe connectors, etc. I could probably get away with just a few replacement parts, but thanks to sharing a chassis with the Mustang, there’s no shortage of reasonably priced upgrades available. 

The reasons why the Wagoneer frustrates me, I’ve documented previously. Most annoyingly, it’s lousy at keeping water out or oil in. Though, it does just keep doing its job. It’s hauled all the supplies for my house remodel work, along with a few dump runs. It gets tons of compliments and looks great, I just want it to be more capable and functional.

Some updates

• I rebuilt the 2-barrel Rochester 2G carburetor. It was a $50 kit and a few nights on the bench to take it apart and put it back together. I’m 100% certain it’s about 90% correct.
• I parted out that 1976 Wagoneer donor, then its carcass made an appearance at The Truth About Cars
• At some point I installed a new starter (which I’d forgotten about until I saw the picture on my phone)
• I attempted to fix my crapped-out gas tank sending units (there are two tanks). After replacing the front tank’s it was apparent the issue’s the gauge voltage regulator that sends 5V out to the sender, which is a Willys hand-me-down part better replaced by a solid-state DC-DC voltage regulator. Also, the seal around the sending unit no longer seals, so I can’t fill the tank all the way. I never did get around to pulling the rear tank. One step forward, two back on that one…
• I picked up a complete weatherstrip kit, of which I’ve installed about 20%. The tailgate pieces don’t fit my older-chassis Wagoneer, so I’ll have to get creative to get that opening water-resistant.
• Lastly, I picked up a set of front floorboards to replace the rusty ones. They’ve been on the shelf for over a year now.

Looking forward, there’s an endless to-do list, but here’s what’s most likely to be done:

• Install all the stuff I already have
• Whack-a-mole various paint/body issues
• Shop for disc-brake Dana 44 front axle from a Scout
• Shop for either 4″ or 6″ lift to replace the harsh but sagging 2.5″ lift that’s on it now
• Use intake manifold oil leak as excuse to upgrade to four barrel intake and quadrajet carb (or efi system)
• Install electric puller fans
• Install AC system that came with car
• Re-install/refresh stereo system that came with car
• Refurb door panels

On some level it’s tempting to put the thing on jack stands, tear out the entire suspension and drivetrain and replace it with all newer, upgraded stuff. For all the money I’d spend fixing or upgrading the existing engineering, I could probably swap the whole donor drivetrain from something with EFI, AC, overdrive and disc brakes. Then again, for the money I’d spend doing either of those, I could sell the Wagoneer and pick up a 1991 Suburban 2500, get the equipment I want and probably come out dollars ahead. Then yet again, that logic sounds familiar. So in the mean time I’ll just keep driving it and working on the to-do list.

For the time and money I’ve spent on my 1959 Bay Area Tract House, I could’ve bought a BMW e9 3.0CS and turned it into this thing. Hopefully it’ll all pay off in precisely the way car upgrades don’t. Over the last two years I’ve DIYed:

• A garage laundry room remodel to get rid of an extra wall create some space and add a garage sink
• My front and back landscaping to add six garden beds, grass and sprinklers
• A complete garage re-org to add shelves and a computer/work bench
• Built a chicken coop for our four newest family members
• …And I’m currently nearly completion on a complete remodel of my kitchen, including electrical, plumbing, floors, cabinets and some structural changes to an opening between rooms.

I can’t wait to be done with the kitchen, as the garage can go back to being a garage and I can get back to burning nights and weekends on cars.