Re: My version of the s10 swap
 

Yes, it's the gen II 55288-VUE-A evaporator that comes with the Sure Fit evaporator kit. I have the under dash panel too, I don't care for the plastic look but when it's painted to match the dash it'll look OK.

http://i869.photobucket.com/albums/a...ps6d12cc25.jpg

Today so far has been working on the latches. I have Altman easy latches, but I had previously chopped up my door jambs trying to use regular bear claw latches. For these reasons and because my passenger side door jamb was just a shade bigger than the actual door, when bolted all together there was metal on metal rubbing. My solution is to further modify the door jambs to eliminate the 1/8" thick plate Altman supplies and fit the jamb to the latch, and then then drill it for the latch pin. Also, when I closed the door I had metal on metal contact right about where the door would be in the closed position. To avoid chipping the paint all off when the doors are closed in the future I needed to make some room here.

This picture shows the contact I had when the doors were closed, with the outer door panel being flush with the cab corner:
http://i869.photobucket.com/albums/a...psa95da866.jpg

I felt that I needed to gain about 3/16" so that there wouldn't be any contact under normal use.

Getting to a clean slate:
http://i869.photobucket.com/albums/a...ps431545e0.jpg

It still hit at the "inner" lip, so more clearancing was required. Here is where I had enough that I could stop:
http://i869.photobucket.com/albums/a...ps7f912b6e.jpg

This allows me about 3/16 that the door can go in past "flush" without hitting any metal. The striker will be adjusted so it doesn't go in this far, but this way I shouldn't chip off any paint.
http://i869.photobucket.com/albums/a...pse69a9ea9.jpg

Re: My version of the s10 swap
 

I was able to get most of the way through the passenger side. I have to do a little more finishing of the welds and then I'm going to plate the back side for reinforcement, but I do like how it's turned out.

http://i869.photobucket.com/albums/a...ps6fd2cebc.jpg

http://i869.photobucket.com/albums/a...psde856d63.jpg

http://i869.photobucket.com/albums/a...ps4502e8f5.jpg

The door closes good, latches smoothly, and doesn't hit the jamb anywhere! Now to do the same for the driver's side...second one is always easier and quicker. Not to mention that side fit better to begin with.

Re: My version of the s10 swap
 

Last night I worked a little bit on getting ready for gauges. I started with a new fuel pickup/sending unit for an s10. This has the 0-90 ohm sending unit. I couldn't get the New Vintage gauges with this same setup, so I had to use their sending unit. I wanted to keep it all packaged together, like the factory did it so I had to do some modifying.

Here's the gauge:
http://i869.photobucket.com/albums/a...n/DSCN0372.jpg

Here's the donor parts:
http://i869.photobucket.com/albums/a...ps3d951a1f.jpg

First I did a little research to see how close the "swing" was on the old vs. the new sending units...turns out they were pretty close:
http://i869.photobucket.com/albums/a...ps40137151.jpg

My adapter plate I had to make because the bolt pattern and footprint of both sending units were very different. I mounted it so the pivot point was in the exact same place as the old one was, and used the s10 float and arm on the New Vintage sending unit. I had to slightly modify it to work.
http://i869.photobucket.com/albums/a...ps25641a43.jpg

And here it is all done...almost. I have to pick up some longer 5/32" rivets to permanently mount it and need to solder the wire.
http://i869.photobucket.com/albums/a...ps955b8699.jpg

Re: My version of the s10 swap
 

Now I'm looking into the other sending units. For the water temp I bought the Autometer 2277 adapter. This isn't really a viable option unless you're using the short Autometer sending unit. Since I'm using the New Vintage sending unit, I couldn't drill out the hole in the center of the 2277 adapter large enough to work. The minimum outside diameter on the adapter is .388. The smallest fractional drill bit that would allow the temp sending unit to fit is 5/16, or .3125. That would leave a wall thickness of half that difference, or .038". Seeing how this fitting would have to be tightened enough for the copper washer to seal it, I didn't think that would work.

Plan 2: drill and tap the head larger for a different fitting to adapt to the 1/8" NPT sending unit. I dug though my parts and found a 1/4" x 1/8" NPT bushing, perfect! The OD of this fitting is .053" larger than the 12mm original fitting, so less chips = less chance of filings in the water passages. I'll grease up a drill bit and drill out the head, then grease up a tap and tap it out to 1/4" NPT and screw the fittings into it.

Top - original plug in head, Left - 1/4 x 1/8" bushing, center right - Autometer 2277 adapter, bottom - New Vintage sending unit.
http://i869.photobucket.com/albums/a...ps199893cb.jpg

Re: My version of the s10 swap
 

Quick picture of the completed assembly, complete with the correct fuel pump for the 5.3 and the line adapters that will adapt to my nylon fuel lines. No $$$ AN fittings for me, I think I'll end up with a combination of nylon and hard lines to feed the engine.
http://i869.photobucket.com/albums/a...ps64136f27.jpg

Re: My version of the s10 swap
 

I took a break from progress this weekend so that I could get some additional education. I'd very much recommend Ron Covell's workshops to anyone wanting to learn more about metalshaping. This is the 2nd one I've attended, and I definitely learned some tips that I will use on my projects.

Ron making a wire buck:
http://i869.photobucket.com/albums/a...ps4ca3abc6.jpg

Hammerform, this one I for sure will use:
http://i869.photobucket.com/albums/a...ps4c58ec53.jpg

Testing out the prototype MetalAce rigid frame wheel:
http://i869.photobucket.com/albums/a...ps14467133.jpg

And fine tuning a part:
http://i869.photobucket.com/albums/a...ps35bf8285.jpg

Re: My version of the s10 swap
 

I wish I could attend a few of his classes...Jim

Re: My version of the s10 swap
 

thats cool, these classes seem to be coming more and more popular. which is cool, everybody wins and it helps keeps the art alive. Gotta spread the seeds. I'd like to attend a class by gene winfield just cause he's a legend in action. I'v met him and watched him chop at autorama. that Ewheel looks awesome, can't wait to get one along with some other essentials I'm missing!

Re: My version of the s10 swap
 

I've been chipping away at things a little at a time. I finished up the driver's side latch. I basically did the same as I did on the passenger side.
http://i869.photobucket.com/albums/a...ps3da33be3.jpg

http://i869.photobucket.com/albums/a...ps136b12bf.jpg

I got the seat mounted and drilled the holes for the 88 chevy seatbelts. When I pop the cab back off I'll make reinforcements under the floor to spread the load.

Also in trying to finish up things in the cab that are needed before paint I mounted my fuse panel and started to figure out a parking brake pedal. I thought it would be cool to use a 40 ford style handle for the parking brake, but after getting seriously outbid on eBay I decided to take a different route. I ended up with a Jeep YJ parking brake pedal for $25 + S/H, brand new. I chose this because the "lever arm" is longer than many and this would put the ugly body of it further up under the dash. It also had the built in release which I liked.
http://i869.photobucket.com/albums/a...ps41e662ed.jpg

http://i869.photobucket.com/albums/a...psdf7a7ef9.jpg

http://http://i869.photobucket.com/a...ps6cc8a27c.jpg

I have to modify how it mounts because it goes in the same vicinity as the hood spring mounts, but that's no big deal. Hopefully I'll get that done this weekend and then on to cleaning up a bunch of things from the back end. Got the bushings out of the springs and the frame, that wasn't fun. I'll put the new ones in and clean and paint a bunch of small pieces, and then see what I have to do to my 9" rear to get it ready to go.

http://i869.photobucket.com/albums/a...ps562feee7.jpg

http://i869.photobucket.com/albums/a...ps5a99df90.jpg

Re: My version of the s10 swap
 

nice work, really diggin that ebrake. Might have to look into that.

Re: My version of the s10 swap
 

Good tidbit on the ebrake setup. Nice work on the door latches. Question, why does everybody use bear claw type latches as opposed to using ones out of a newer vehicle? I played with a truck the other day that had bear claw type latches and found they were loud compared to the ones in my donor 1995 Buick Roadmaster. The Roadmaster latches are smoother and close nicer. A builder I know feels the same. He uses mid 90's civic latches in all of his builds.

Re: My version of the s10 swap
 

I used the Altman latches because I wasted hours and hours messing with standard bear claw latches and trying to maintain the original turn down outside handles...and I just wanted to be done with that. If you were using pushbutton handles or shaved handles I'd see no issue in trying to use some stock latches off something. The other issue that may be present with these trucks is that the window track is really close to the door jamb, so the replacement latch would have to be very slim or you'd have do more surgery to get it to work.

Re: My version of the s10 swap
 

I used the Altman latches for the same reason, keeping the OE door handles. I also had similar fit problems in the jam. I just finished the driver's side. I'll start the pass. side soon.

Unfortunately I decided to go with the Altman's after everything was painted so I had to try to modify things with out having to repaint. I basically had to move the door side of the jam in to get clearance for it to close. A little trimming, a little hammering. It's all good.

I like how you fixed your jam. I would have done the same if I had thought of these latches sooner.

Re: My version of the s10 swap
 

A little cutting, a few holes drilled, some tabs done and the parking brake is mounted. I like it.
http://i869.photobucket.com/albums/a...pse52848bf.jpg

http://i869.photobucket.com/albums/a...ps2e6c26ff.jpg

Re: My version of the s10 swap
 

looks great, might have to cop that same pedal!!!

Re: My version of the s10 swap
 

Not a lot of visible progress, but progress none the less. I now have the battery mounted under the hood. I was able to mount it off the firewall and the inner fender, and get it looking pretty good. I would have liked to have it farther from the engine, but there is plenty of clearance and the hood spring clears the other side so this is where it is.

http://i869.photobucket.com/albums/a...ps166660bb.jpg

http://i869.photobucket.com/albums/a...psf4e0f5c9.jpg

I also pulled the gas tank out and did some more welding on the frame that I was leery to do before with the tank in place. The spring perches on the rear axle were also welded up. I'm now getting ready to set up the new gears that will arrive tomorrow. Feels bad to replace 3.50 gears with 3.50 gears, but the old ones had some pretty deep rust pits in about 20% of the teeth...so here I am.

http://i869.photobucket.com/albums/a...ps53694c6a.jpg

Re: My version of the s10 swap
 

I installed new 3.50 gears and track lock into the 9" after cleaning it up. The old 3.50 gears were too pitted with rust to run. While pressing on the pinion bearings the original pinion support cracked, so I had to order a daytona support and the corresponding larger pinion bearing. All said and done, the 9" was way too expensive and if I had it to do over again I'd use an Explorer 8.8" in a heartbeat. Oh well, it's done now.

http://i869.photobucket.com/albums/a...psc914e4e7.jpg

Cast coat iron Duplicolor on the 3rd member:
http://i869.photobucket.com/albums/a...ps0eb40bae.jpg

http://i869.photobucket.com/albums/a...psb42c1296.jpg

I also needed a way to change oil in the diff without pulling it completely back apart in about 500 miles for the gear break-in. I bought a parts-store magnetic oil plug for an engine that had 1/2" threads and did some more welding. Now I have a magnetic drain plug on the rear axle!

http://i869.photobucket.com/albums/a...psfe24a28e.jpg

Re: My version of the s10 swap
 

I had the day off work today and I had a goal of getting a bunch of misc. pieces sprayed with epoxy primer and chassis black. After spending some time in the morning getting parts hung and everything ready, I was able to spray. Got the primer on before the kiddos got off the bus from school, and the chassis black paint right after that. Now to paint the rear springs with POR and get ready to assemble it and have a rolling chassis again, this time together for good!

Parts hung:
http://i869.photobucket.com/albums/a...ps4209cf2c.jpg

Mixed up and ready to go:
http://i869.photobucket.com/albums/a...psb0c63aa2.jpg

2 coats of epoxy:
http://i869.photobucket.com/albums/a...ps36f4c8e8.jpg

http://i869.photobucket.com/albums/a...psd81a2a77.jpg

And 2 coats of chassis black, out in the sun to bake on:
http://i869.photobucket.com/albums/a...ps6ba9461b.jpg

I'm very much a newbie with all things body and (non-spray can) paint related. I did it this way to prove to myself that I could do it. I think body panels will be much easier, because they're large and flat and more paint will hopefully go on them vs. in the air.

Once it's back together and rolling, the cab will come off to get buttoned up and the brake and fuel lines will be run! Hopefully more progress soon!

Re: My version of the s10 swap
 

Oh yeah, had to have a little Cross Canadian Ragweed playing on the garage Pandora after seeing Cody Canada and the Departed last night. You Texas/Oklahoma guys have it so good with your music scene.....

http://i869.photobucket.com/albums/a...ps5b4fd091.jpg

http://i869.photobucket.com/albums/a...psd7ca69cc.jpg

Re: My version of the s10 swap
 

Exciting day today. I was able to put some things together that won't have to come back apart!!

The boys got to learn about what shackles are, how anti-seize is applied, and what torque specs are. They think it'll last another 60+ years this way:
http://i869.photobucket.com/albums/a...psa063f55a.jpg

http://i869.photobucket.com/albums/a...psa2ba4622.jpg

And the duplicolor "cast coat iron" paint is more green than I expected, but oh well.
http://i869.photobucket.com/albums/a...ps85403486.jpg

Then I went searching around for brake parts I took apart 2 years ago (found 'em)....and spent some quality time cleaning and painting some more small pieces. Tomorrow the rear end should get buttoned up and the wheels back on, and if the parts stores are open I should get the front coil springs back on and the truck sitting back on the ground! Then the garage needs a serious cleaning!

Re: My version of the s10 swap
 

Good looking crew you got there, rear section looks great...Jim

Re: My version of the s10 swap
 

More notable progress today. It's a roller once more, this time for good! I worked on cleaning and painting all the small parts for the brakes last night and this morning got them put together. I know these were made for C-clip axles and I used them with bolt in axles but man, no room to work!

Buttoning it up:
http://i869.photobucket.com/albums/a...ps375ae1a3.jpg

http://i869.photobucket.com/albums/a...pscfa89c88.jpg

Yes, I'll paint that caliper:
http://i869.photobucket.com/albums/a...psdb6f45d4.jpg

It felt really good to roll it partly outside and sweep the garage floor. My wife was more excited about me sweeping the garage floor than getting it rolling. Something about tracking the primer/paint dust into the kitchen all weekend....

It was quite a chore wrestling those front coil springs back in place. I rented a coil spring compressor from the local parts house to help, but it was still a bear. It would have been much easier had I not had the insulators to deal with. The s10 had rubber insulators top and bottom, and getting the coil popped into place without squishing out and mangling them was a feat in and of itself. But, if that's what it takes for a quiet ride it was worth it.

http://i869.photobucket.com/albums/a...ps0ff481da.jpg

Gas tank, brake and fuel lines and this part is done!
http://i869.photobucket.com/albums/a...psc7782add.jpg

http://i869.photobucket.com/albums/a...psc34bfdb8.jpg

Very soon the cab will come off for the last time. I need to finish welding some seat belt reinforcement under the floor, seam seal and raptor line the bottom, and paint the firewall and dash and then it can go back on the frame for good. Then wiring starts!

Re: My version of the s10 swap
 

Looking good!

Re: My version of the s10 swap
 

the rear end looks killer. great feeling coming in to the wiring stage, really starts to make it feel like the thing can be finished.

Re: My version of the s10 swap
 

Miscellaneous things done this weekend. My rear calipers are freshened up with new slider boots, new pads, and paint. The rear brake line on the axle is bent up and installed.

http://i869.photobucket.com/albums/a...psbeb07a22.jpg

I also started to play with the fuel system. That started by installing my sending unit/pump assembly. I think putting this together with the SUR&R nylon line kit is going to be a snap! I found an OEM fuel filter that uses 3/8" push connect fittings, that way finding a replacement and replacing it will be easy. Basically, using the supplied adapters at the fuel pump and push connect fittings running the lines should be easy....unless I decide to complicate it by adding some lengths of steel line in there. Actually running the lines will wait until I have the cab off, but it's motivating to see how easy it can be.

Fuel needs to go from here:
http://i869.photobucket.com/albums/a...pse7429211.jpg

Through this:
http://i869.photobucket.com/albums/a...ps7cfa4247.jpg

And up to here (and back for the return trip):
http://i869.photobucket.com/albums/a...ps0665fc1f.jpg

Fastened down here and there with these:
http://i869.photobucket.com/albums/a...psc27755fd.jpg

Re: My version of the s10 swap
 

Where did you get your fittings, with that style clips???...Jim

Re: My version of the s10 swap
 

looking good, cool snap ons, nice exhaust too.

Re: My version of the s10 swap
 

http://www.surrauto.com/fuel.html

Push the little colored button and off they come, no tools required!

Thanks! More info on the exhaust a few pages back.

Re: My version of the s10 swap
 

cool fuel line and fittings, so did you buy a kit? how much was it?

Re: My version of the s10 swap
 

Thanks...Jim

Re: My version of the s10 swap
 

Yes, it's a kit:
http://www.amazon.com/S-U-R-R-Auto-Parts-KP1200-Re...

Re: My version of the s10 swap
 

Radiator is now in. I used a 19x24 from a custom radiator shop in SE Minnesota, and ever since I pulled it out of the box I have been disappointed with it. Welds are sloppy looking, mounting flanges are warped from welding, and it generally does not look like it was made by a professional radiator shop. Nevertheless, I'm going to use it....so I finally decided it was time to build some mounts.

I whipped up some brackets and did some mocking up:
http://i869.photobucket.com/albums/a...ps6fdc0da9.jpg

Yep, it'll work:
http://i869.photobucket.com/albums/a...psfabef37a.jpg

And everything fits, so this is where it will live:
http://i869.photobucket.com/albums/a...psc971ed53.jpg

Assembled with clekos and now looking at condenser fitment....that'll work too.
http://i869.photobucket.com/albums/a...ps61918ab9.jpg

And it'll tuck nicely behind the latch panel:
http://i869.photobucket.com/albums/a...ps738e6d9a.jpg

Re: My version of the s10 swap
 

looking good. There are sooo many options now days for aluminum rads. they are getting better and less expensive. as long as it keeps you cool thats what matters. I agree though it is nice to see some craftsmanship, fortunately most all your rad will be enclosed.

Re: My version of the s10 swap
 

Spent some time on the phone with tech help from Vintage Air to find out how far the condenser should be mounted from the radiator. 1/2" max without having a shroud between the two is what they said, and due to interferance with the radiator tanks the closest mine can get is 5/8...and that's not taking into account any brackets. So, I put that on hold so I can come up with some great ideas and worked on radiator hoses.

I used my tried-and-true method of bending TIG wire around to the shape I need the radiator hoses to be, and then going to NAPA and browsing the wall of radiator hoses. I came home with $180 worth of radiator hoses.

Here's the candidate pool:
http://i869.photobucket.com/albums/a...psd30f6022.jpg

After not too long of holding them in the approximate area, eyeballing, and figuring... I found a top hose that would work (with modification of course).
http://i869.photobucket.com/albums/a...ps02c659fc.jpg

Looks good:
http://i869.photobucket.com/albums/a...psca1e26cd.jpg

Now to the bottom. I again wanted to save $$ here and avoid having to buy an aftermarket straight water neck. Mission accomplished:
http://i869.photobucket.com/albums/a...ps23bc2536.jpg

Both the hoses in the same view:
http://i869.photobucket.com/albums/a...ps8528e628.jpg

And here are the scraps and the "templates". Not bad.
http://i869.photobucket.com/albums/a...ps467bb8aa.jpg

The last step in this process was to return $140 worth of radiator hoses to NAPA. So now I'm $40 into some off-the-shelf radiator hoses, and the part numbers will be documented in a sheet in my toolbox should it ever need new ones.

Re: My version of the s10 swap
 

This weekend I tried to concentrate on getting my hood latch panel installed again. It took some doing, but I did get it put back together and it's very solid. I can use my un-modified panel, which was the goal here.

Here's the new piece from the side:
http://i869.photobucket.com/albums/a...ps42d3224b.jpg

And from the front:
http://i869.photobucket.com/albums/a...ps2024022a.jpg

Fits good here:
http://i869.photobucket.com/albums/a...ps87070c6e.jpg

And here:
http://i869.photobucket.com/albums/a...ps454c577f.jpg

So now that I had something there, I used it to mount the A/C condenser off of.
http://i869.photobucket.com/albums/a...pse7fc71b3.jpg

And now that I had the condenser mounted, next up is the tranny cooler. I ran out of time, but here you can see where I'm headed with this:
http://i869.photobucket.com/albums/a...ps6173ead4.jpg

Re: My version of the s10 swap
 

Turned out nice. Nice fab work.

Re: My version of the s10 swap
 

nice!

Re: My version of the s10 swap
 

What Paint did you use on the chassis and suspension components?

Re: My version of the s10 swap
 

Thanks Mick!

I used SPI epoxy primer, and then this:
http://i869.photobucket.com/albums/a...psf78eb97a.jpg

I also have a couple matching cans of aerosol for touch ups when I have to grind some back off and weld something to it.

Summer time is sometimes hard to find time for it all. There are family activities, canoeing down the river, summer concerts, etc.

Got to see Jason Isbell and the 400 Unit, fantastic show!
http://i869.photobucket.com/albums/a...psa438d8fc.jpg

This coming weekend is Goodguys in Des Moines. This will be the 4th consecutive year that I "missed" because my truck is torn apart. This makes me remember back when the truck was running and driving....oh if I could have just fixed a few things instead of EVERYTHING.

4 years ago:
http://i869.photobucket.com/albums/a...0/P7170003.jpg

http://i869.photobucket.com/albums/a...0/P7170004.jpg

http://i869.photobucket.com/albums/a...0/P7170005.jpg

http://i869.photobucket.com/albums/a...0/P7170006.jpg

Next year. I've said that every year, but this time I really mean it!

Re: My version of the s10 swap
 

I have found time to chip away at it a little more. After finishing up the tranny cooler mount, I decided that I needed to add some strut rods to hold the nose up like the original truck did. Since my radiator support is totally custom, I had to come up with a new way to do it. I decided to make it adjustable so I could fine tune the hood gap against the grille. Here's how I took that concept to completion:
http://i869.photobucket.com/albums/a...psc96a9589.jpg

Adjustable:
http://i869.photobucket.com/albums/a...psf93feeae.jpg