M416 to a M100

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Finishing up all the welding today. Had to put pockets in to clear the drain plugs in the tub.

Put a crossmember in to support the batteries inside the tongue box.

Put 3/4” led markers up front in case the super troopers of the DE state police want to hassle me.

Took all the brackets off, pulled all the harnesses off and hit the frame with a wire wheel. Tomorrow it gets por-15 and then everything goes together for real.

I bought a HF tongue box and it fits pretty good.

I got new lenses for the tail lights. They already have led bulbs in them and the convoy lights will be on a switch for fun.

 

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I ordered a new parking brake handle but the surplus place sent me the wrong one. It’s going to get relocated on the inside passenger tongue rail with an additional bellcrank and custom rods and clevises.

Shock mounts cut from the original brackets and welded on. I didn’t have good measurements so I looked at pictures and took a swag at it.

Cleaned, wire wheeled and degreased. Installed the last two rivnuts for the tongue box and then started painting.

 

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Got the bottom of the tub coated with por-15. Then did the bottom of the frame.

Installed the marker light so I wouldn’t lose them.

Marveled at my lack of welding skills before I painted over them. If you want to hide your ineptitude I recommend por-15.

Then I installed a new pioneer stereo into my wife’s FJ Cruiser because she wanted wireless CarPlay and I wanted vehicle gauges.

 

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Lots of progress the last week or so. Spent the week in San Diego for work so lots of stuff was waiting for me when I got home.

Picked up a legit m100 canvas reproduction top.

Got the leaf spring brackets cleaned and painted and then mounted for the last time.

Late last night after a lot of painting I hung the leaf springs and axle.

 

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This morning I was ready to see if the thing was going to be a trailer. Mounted the wheels and pushed it outside. Surprisingly everything fits.

Then back to the grinder. Got the landing leg and the safety chains cleaned up.

Two trips to TSC (I should buy stock) because military safety hooks are too thick for regular end links. Decided on some new chain to save me some time.

And finally, no more chassis paint. Bonus points if you can name the WF raffle prize in the picture.

 

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I have to drive my oldest to and from summer camp the next two weekends and I have to go to NM for work in two weeks so the thrash is on to get the wiring and tub painting done. My hvlp gun, mixing kit and respirator came today and the OD paint will be here on Tuesday.

I haven’t decided on diy bedliner or having someone do it but I might just drive it to linex to save time.

Got some wiring done.

Final connections inside the tongue box.

Then out to the tongue with the vehicle connector.

 

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Discovered that my m416 hub on a m100 axle swap is not plug and play. The backing plates and brakes are the same but the m100 spindle is 1/4” longer between the bearing surfaces. The bearings are the same bore size so I’m going to run an 1/8” inner spacer on the spindle to bring the hub out to the right place on the spindle. I checked the bearings and they run where they’re supposed to if we add a little room behind the inner bearing.

Nate and I couldn’t find any creative solutions on the internet, just a lot of they’re not compatible. I’m hoping this is an easy fix and gives people an option if they have bad m100 hubs. There are no reproduction hubs anywhere but there’s still lots of m416 parts in the surplus yards.

 

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It will take a little dremel work, but these washers were 10 for $7 on amazon and they have the 1.625 inner diameter for the spindle.

Friday was my only day off this weekend to work on the trailer so I had to hustle. I couldn’t have asked for a better day. Low humidity and 68-70 degrees outside.

Turned the garage into a paint booth.

I have never painted anything besides a brush or a rattle can. I’ve watched car shows for years and professionals make it look easy

 

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I ordered ww2 correct olive drab from a paint company called Gillespie and mixed it 1:1 to spray out of the best Chinese hvlp gun I could buy on amazon ($36). My first couple of passes were a mess because I had the air pressure too low but I figured it out and it went ok for not knowing what I was doing.

The paint leveled out a lot better than I thought and covered up a lot of my mistakes. She’s a ten footer but I can say I painted it myself.

 

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Lots more details to post but today was a big day.

 

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So after the paint we got the tub put on the frame. All of my mount tabs lined up.

New tail light brackets showed up so I test fit them. The modern tail lights are bigger than an M100 so it was a little tight to the tub.

I fixed it by adding a 1” spacer and a longer bolt for some clearance.

 

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Did a quick test fit of the fenders. Really the first time since Nate and I did the math on the frame crossmembers that we would know whether or not the axle is in the right place. It’s pretty damn close.

I had to get it weighed for registration and we still had a hub bearing clearance problem. I found washers on amazon with the correct ID but the spindle has a chamfer. So I dremeled it a bit to fit.

Ground the OD down so the inner seal would fit and slid it down the hub.

Slid the hub on and instant M100 spindle M416 hub marriage. I haven’t found anyone on the internet that has done it (or needed to) so I’m claiming to be the first.

 

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Got some fender hardware and installed it so we could go to the weigh station.

Then towed it to the scales for the first time. The hubs didn’t explode so it must be ok.

Any guesses on weight?

Had a spare Friday last week so I mixed up some more OD and cleaned the fenders up. I sprayed a bunch of coats on both sides. It was 80 degrees out but the humidity was only 50%.

Then I got the NOS wheels I bought on eBay and sprayed them to match. I bought them from a surplus place for $40 a wheel. They have a 1988 build date.

Finished up the last of the painting with the tail light brackets.

 

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Installed fenders and pulled it out to test fit the canvas cover I bought. I spent some time hacking up a synthetic winch extension to make ropes instead of the old school WW2 correct ones.

I’m not done yet, but it’s looking like a trailer.

The M416 wheels were designed for bias ply tires and tubes. The valve stem hole is 5/8” instead of 1/2”.

I got TR415 valve stems from an American company called Milton and got this kick ass box.

The TR415 is designed for tractor wheels so it’s got the right size for the bigger hole. I ordered the installation tool with the parts.

 

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Decided to put the license plate in the middle. It's screwed to a amazon bracket with a spacer I made to recess the bolt.

Putting the light and license plate brackets on the same bolts that hold the tub to the frame has saved me from having to drill extra holes in it.

Threw the kid in the tub and we scrubbed it with simple green and scotchbrite, then degreased with alcohol. The raptor liner folks recommend sanding, but I think it's because a pickup bed typically has clearcoat on it. I figured this would be ok.

Masked off under the rail. I watched every scout in the troop throw stuff in the trailer at camp and slide every tote down the rail. So the rails will get lined and hopefully that seals up that seam enough that it doesn't rust in the future. I used Trimwire masking underneath the traditional masking tape for a clean edge since the bedliner is thick.

If you haven't used masking tape with a drop cloth attached to it, you're missing out. I wrapped the trailer in plastic in about 2 minutes.

And this was about 20 minutes after I sprayed. It was pretty easy, it doesn't really come out as a fan pattern, but you can see where it lays down and you can work it for even thickness. I used the whole gallon kit, which was really two good thick coats and a quick spray to even the texture at the end. The color doesn't match, but I knew that going in. I like it better than black.