January 6, 2001

Worked on the radiator shell top. Welded up the two corners which had small cracks. Ground off a patching plate that was welded on below the hood hinge front support to repair some damage, it was done badly. I ground the area flat and built up the surface again with a small diameter rod. Reground it flat again. I'll fabricate a small back up plate and solder it in place underneath to strengthen the area.

January 9

Picked up the fuel bowl from TG's and started to reassemble it. Tony had successfully removed the last remains of the Power Jet Valve, and had installed the new valve. When I pulled it back out to install the new gasket, it was discovered that most of the threads had corroded away. It was only hanging on by a couple of threads, which wasn't enough to use the gasket. I gave Tony a call to see about the possibility of using an insert. He thought it was a possibility so I took the fuel bowl back down to his shop.

When I initially tore down the carburetor I noticed that there seemed to be a part missing inside the governor body. I opened it up once again so I might be able to determine what was missing and what it's purpose might be. The only picture I have to go by is in my copy of TM 9-808, where on page 167 there is a cut away picture of the governor that shows a little bit of the part. I believe it's called the Compensating Spring which has an adjusting screw. It's a 1/4" shaft with an arm that connects it to the Mainspring. There's more of it, which I can't make out, that engages a pin on the cam that's mounted on the end of the throttle shaft. I'm assuming that I need this bit of hardware for the governor to actually work. I don't know anything about governors, so I don't know what effect it will have on the carburetor as it is. I suppose I should I just plan on replacing the governor if I can't locate replacement parts.

January 11

Picked up the fuel bowl from Tony. The helicoil insert did the trick, the Power Jet Valve seats very nicely now. I finished assembling the carburetor. The only glitch I ran into was with the fuel bowl gaskets, they seem to have shrunk. The worst one was the Fuel Bowl to Air Intake Body gasket, the inner opening diameter needed to be opened up almost 1/8" before it'd fit.

January 13

Pulled the various linkages from the carburetor and painted it. Next I fabricated the backing plate for the radiator shell top that will strengthen the area that the hood hinge front support attaches to. Soldered it in place and cleaned up the area.

January 14

Cleaned up the Master Cylinder, primed and painted it. It looks like a replacement since it was in fairly good condition and there wasn't a lick of paint on it.

Then I grabbed the radiator shell top and applied some Peel Away paint remover to see how it works on sheet metal. It takes 24 hours to work so I'll know tomorrow. Applied a regular paint stripper to the grill and head light guards for a comparison. There's a layer of gloss black on the grill that seems to be slowing the stripper. I'll let it sit over night to let it work. The guards have a very thick layer of school bus yellow, the same as what was found on the tailgate. So far these are the only places the yellow has appeared. The left side guard is obviously wrong since it's a late model variant designed for Carryalls without the Blackout driving light. While I'm missing the Blackout light, the mounting holes are there on the fender next to the headlight. An interesting side note, the left side guard has two holes in the top that accepts a secondary guard above, to protect a Blackout light mounted on top of the head light. I've seen one photograph of this arrangement.

January 16

Finished the assembly of the carburetor by reinstalling the choke and throttle linkages and also the governor.

January 17

Finally got a chance to look at the radiator shell top and the grill to see how the paint strippers did. I wasn't real impressed with Peel Away, it had dried out completely and had only taken off the top most layer of paint, not much for the amount work involved. The regular stripper didn't do any better, only took a little bit of paint off. Wonder if the temperature is affecting their performance, been cold lately.

January 18

Tried some AirCraft Remover purchased from my auto paint supplier on the grill and radiator shell top. Industrial strength, industrial fumes! The problem with this stuff is it also softens up the little bit of Bondo Larry used to smooth out his grinding and what not. Since I don't want to redo all of his work, I need to use a sander. I want to ease the paint down to see if there are more markings that might still be hidden, so this is probably the best plan anyway.

January 20

Finished stripping the radiator shell, grill and headlight guards. I sanded the radiator shell down to bare metal exposing all of the minor dents. I'll see if I can't pound them out. Now that the headlight guards don't have a quarter inch of paint on them, I can see that they both are bent pretty good. Since the left side guard is incorrect, I'll be replacing it rather than trying to straighten it.

January 21

Took a wire wheel to the grill today to remove the last remnants of paint and rust. Then I gave it a coat of primer.

January 22

Painted the grill.

I pulled out my hammer and a couple of dollies I've had and haven't used in over 25 years, and commenced to beating the hell out of the radiator shell top. After sanding off the bondo that was on the front nose, I could see that it was pushed in and down a bit. I clamped the two front corners to a piece of 2" angle iron to straighten out the downward bend and pushed the nose back out with a dollie. When I thought it looked pretty good, I gave it a coat of primer. Damn, for someone who doesn't know much about body work, this piece sure looks good! I'm still going to need a skim coat of putty to make it perfect, but it won't take much. A small set back, one of the back corners that I had previously welded cracked again with all of the hammering. I'll re-weld it tomorrow.

Called Steve at VPW and ordered the correct brush guard for the left side headlight. While I had him on the phone, I also ordered everything I need to rebuild the brake and clutch pedal assemblies, as well as a gasket and seal set for the steering gear. He's also going to send me a copy each of TM 9-1808a & b (these are the tech manuals that cover the engine, drive train, chassis and bodies of 3/4 ton Dodges). Now I'll know how this rig is supposed to go together, instead of guessing.

January 23

Welded up the two small cracks on the radiator shell. I built up some extra material to strengthen the area. Ground them down smooth and re-primed the shell.

Did some sanding on the hood, looking for any other markings that might have been present. So far none are evident. There are four layers of paint plus three of primer. The first layer is of course the original olive drab, followed by a layer of what appears to be Forest Service green. Next is the white layer that is seen in the oldest photo I have of the rig. Finally, a coat of olive drab that Larry Watts put on. If it is indeed Forest Service green on the second layer, there may be evidence of the FS insignia on the doors. Looking at the old photo there seems to be something covered over just behind the drivers door. The next time I'm out at the storage yard, I'll have to do some sanding there. The doors are here at my shop, so I'll see about sanding them down in the next couple of days.

January 26

Discovered a link to my Carryalls past today as I was sanding down the passenger door. I uncovered a seven point star! Boy was I thrilled! I had hoped to find something unusual about my rig, and there it was. I remembered there being some discussion on the WWII Dodge forum some time back about unusual stars, so I searched through the archives until I found it again. Awhile back Felix Bax of Holland was inquiring about his registration number and happened to mention he had a seven point star on his door. Gordon McMillan said it was used by the Seventh Service Command. Now I need to find out more about this group. Another interesting point was that Felix's registration number was 2089709-S and mine is 2089727 and both rigs had the seven point star. So Kong has a surviving brother!

After this discovery, I brought out the driver's door and put the sander to it. No markings at all on this one. I expected as much since the spare tire sits in front of this door. I suspect the seven point star will be located directly behind the door in the area that looks sprayed over in the old photo.

I also applied some putty to the radiator shell to smooth out my hammer marks and then sanded it out. Re-primed and discovered a couple of spots I missed. Will hit it again next session.

Mouse over to see star overlay
January 27

Did some research on the internet this evening looking for any Info on the Seventh Service Command. Basically the command was headquartered in Fort Omaha, Nebraska during the war years and served much of the midwest. I'll put together a page on this group as I get more time and info.

January 28

Well someone did a great job of eradicating the star behind the drivers door. So instead of looking at what I hoped was there, I began looking at what wasn't. The area had been sanded down to metal basically in the shape of the 7 point star. But they missed one crucial spot, the tip of the top point! So I was able to pin point it's exact location. This sanding was done directly below the red paint, which was also over the layer of what I believe is Forest Service green. What I find interesting is that they tried so hard to eradicate the star on the drivers side but left the one on the passenger door untouched.

Did a bit of sanding above the battery box, as I've seen pictures of nomenclature in that area. Nothing found though. Here my sanding search ends, I'll keep a watch for anything else when I do a final sanding before the finish coat of paint.

I finished out the day by pulling the left side window regulators. Like the right side, there was about an inch of sediment in the bottom of the window boxes.

Mouse over to see star overlay
January 29

Applied a bit of putty on the radiator shell where I had missed previously. Sanded it out and shot a coat of primer on it.