First Terra-Jet Project, for a Newbie

[Goach2]

Did some degreasing and cleanup with my helper:

https://photos.app.goo.gl/2JT65EW24gTaw3kv5

Also, got the main sprocket out, with a little bit of channel bending. Dragged it out and did some powerwashing as well:

https://photos.app.goo.gl/eGKPGLnfv7L3bEnN7

Looking at the bottom, there are a few pin holes around the drain and in front of a rear tire. I'm trying to figure out how much of this should be replaced. I don't mind a larger patch, if it will hold off replacing it in the future...

https://photos.app.goo.gl/NCPTsTZUPSXWebJK6

[Goach2]

So, I have to start looking at the replacement trans that I have. I pulled the large axle bearings out of the one that was installed and they are 6209 part numbers. The other transmission I believe is from a 1972 model and it did not have the bearings installed when I got it. Can anyone tell me (or show me) if the earlier bearings are the same or different from the newer 1977 ones? Thanks!

[Goach2]

Still trying to find out what bearings I need for the '72 trans, since my manual is for a '77. I sent TJ the receipt for my manual, so HOPEFULLY they will send me a few pages from another.

Oh, also there's this: https://photos.app.goo.gl/rns8V6m3FMYmJAgF6

Starting to cleanup the bottom of the frame now that it's visible. I'm going to see if I can make up a patch that's one piece for this whole section...

[Goach2]

with all the nooks and crannies and the snow outside, decided to treat with a phosphoric acid product instead. Coming along, will paint after.

https://photos.app.goo.gl/UcHVzf673Jy9d5Zj9

[Goach2]

Here's the POR15 treatment, turned out pretty good, going to spray-bomb some rust paint into the nooks and crannies that I couldn't get a brush into.

https://photos.app.goo.gl/BjdHTQidNUrje3o26

Cut out this bit of the floorboard too, hopefully the existing has enough meat on it that I can weld in a patch...

https://photos.app.goo.gl/7tkCELCGpQZrAscL9

[Goach2]

Tacked in place, few more tacks and will clean up the weld, then paint:

https://photos.app.goo.gl/1Fh6vndLz1JJJcVA6

[liflod]

Looking good!

[Goach2]

Got the piece in and painted, still have to clean up the topside welds, but will do that when it's back on it's wheels and easier to get to.

https://photos.app.goo.gl/ZfUjNADYKutkx2ZU7

Cardboard templating done and transferred to some new 16 gauge steel:

https://photos.app.goo.gl/SfxDfZ6kzRznttba7

Need to make some bends in it and prep for welding. This is going to take some time...

[liflod]

That's a lot of welding! I weld small broken pieces of stuff, never anything that large.

[Goach2]

Yes, this will be the largest I have (and likely will ever) tackle in terms of welding. I have done only a few body panels before this, so every job helps build the knowledge.

While it's accessible, I've painted up the patch on the inside, since floor-boards and frame make it hard to get to once it's in. https://photos.app.goo.gl/C3rXhtDp1VJALPFP7 This is two coats of DOM16, which is a Canadian product (Dominion) that is very similar to POR15, but I have found that it sticks to new metal better. I did scuff the whole panel with a flap-disk before applying it though. Hopefully it holds well.

I also applied some weld-thru primer to the flange edges' mating surfaces on both the tub and the patch. Hopefully this keeps the corrosion at bay in side the flanges where they can't be treated after.

https://photos.app.goo.gl/fbZsAfxXuVnxAuts5

[Goach2]

Little bit of welding going on...

https://photos.app.goo.gl/sDAX2T3spgZKTcHX7

[allwheeldrive]

Awesome work man! This is one heck of a rebuild, your really steaming forward at full speed.
Good job with all the pictures.
Terra Jets are great machines and worth the work, they are very capable off road. Their low center of gravity, respectable ground clearance and all time locked 4x4 with those 27" Max IV tires makes them incredible hill climbers and trail breakers.

I could have sworn I'd seen pics and discussed with a terra jet owner how they used the same tranny as a Coot, this looks nothing like it. Kind of odd, I must have been mistaken. Since the machines is a simple AWD set up with no skid steer in theory you could always jerry rig a different 2 speed with reverse transmission out of another kind of ATV and link it up with your drive-train.

[Goach2]

Thanks allwheeldrive, if I didn't teach myself to replace a body panel last year, I would never have tackled a job like this.

Got the piece by the wheel cut out and patched. Now to spot/grind the whole thing until it's water-tight...

Trying to decide now if I want to buy the parts for the early trans, or a new case for the later one. Waiting for a quote from TJ on this...

[Goach2]

Welding and grinding, welding and grinding. At least I have some help...

20200115_181017.jpg20200115_180946.jpg

[Goach2]

Few updates here...

Ran out of shielding gas, lots of welding going on. Also got a drain welded in:
20200125_113921.jpg20200125_164253.jpg

Tub ground out and 2 coats of DOM16 put down:
20200131_182434.jpg20200131_194536.jpg

also, I'm trying to pull the axle out of the spare transmission, but it won't budge and I'm trying to split it to remove. I can get it this far, but then it won't separate any further... any ideas?
20200203_121902.jpg

No clue why my pics all come up upside down...