Re: Rustbuket 67 build "Georgia"
 

Nice progress Dan! I like the gas filler notch too.

Re: Rustbuket 67 build "Georgia"
 

Everything is looking great!

Re: Rustbuket 67 build "Georgia"
 

You've come a long way since I last checked your thread. Looks good, really like the silver control arms, and I'll be copying you on that filler notch most likely! Great job.
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Re: Rustbuket 67 build "Georgia"
 

I just went through your entire thread at work (shhh... don't tell my boss). You've done quite a bit of work. I do have one question, if you don't mind. When you did your exhaust cut out in the cross member, are the pipe sections you welded in necessary, or just preference? I ask because I think this is the route I'm going to go with, but seeing the wedge cut into the factory piece, I'm thinking it was meant to have a little flex, and the pipe doesn't allow for that. Maybe I'm over thinking it? Nice progress, and great job so far.

Re: Rustbuket 67 build "Georgia"
 

Thanks Nick!

Thanks Jim

Thank you, I would like it a lot more if I didn't need to notch it :sumo:

ThANKS MJ

Thank you Johnathan

Thanks Jimmy, and thanks for the tip on the ECE backing plates. I have some out in the garage now.

Thanks for checking out my truck.

I agree with you that the welded in section of round tube is not really needed. If you take a look at the ECE crossmember and other aftermarket crossmembers it is just a cut out. My reasoning was we only had 4.5" round at work so that is what I used. With the 4.5" my cutout was on the edge of the radius of the bend so I thought welding in the reinforcement would be a good idea. Ideally I would like to have used 3.5" round with no reinforcement. I work with engineers all day so I understand the overthinking, I do it all the time. slows me down :devil::lol:


I finished the tank notch and mounted the tank for the last time. I have been working on several other things and stocking new parts but the pic situation here is too much of a pain to post pics. I will try to sign up with photobucket in a while and try that out.

We have also been taking care of a few things with an insurance claim at the house too, new roof, gutters going up right now, I have to paint the back porch,garage door and overhangs and have a new shed built. This is taking up much of my "spare" :lol: time.



Ellie wants to post some smilies:

:waah::mm::devil::tee::whine::flagw::hi2:

Re: Rustbuket 67 build "Georgia"
 

I love the picture from the back with the cab on the frame. Almost like looking at a womans backside. Great job with the fab of the notch. :metal:
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Re: Rustbuket 67 build "Georgia"
 

Sexiness :smoke::lol:

Attempting to link through photobucket.

Trimmed the notch down getting ready to weld.

http://i1329.photobucket.com/albums/...ps448024cd.jpg

Welded in, smoothed out just a little bit.

http://i1329.photobucket.com/albums/...ps4aacaee5.jpg


Welded in with a little primer, it was raining on and off when I was trying to work:uhmk:

http://i1329.photobucket.com/albums/...ps5343440c.jpg

Another shot in primer. Not the prettiest welds. I need to buy a bigger welder soon. The Millermatic at work has me spoiled.

http://i1329.photobucket.com/albums/...ps6a3f63dc.jpg

Re: Rustbuket 67 build "Georgia"
 

I had to notch out the rear crossmember to clear the notch.

http://i1329.photobucket.com/albums/...psd80559e6.jpg

Re: Rustbuket 67 build "Georgia"
 

I will finish uploading and updating after lunch. Photobucket works pretty well. I dig it :smoke:

Re: Rustbuket 67 build "Georgia"
 

Lookin good there stud!

Re: Rustbuket 67 build "Georgia"
 

Thanks Chief, I have been watching your new build thread. Dont think I commented yet though. Looks like a great start:metal:



Tank notch painted with tank installed, again....


http://i1329.photobucket.com/albums/...ps2258171b.jpg

http://i1329.photobucket.com/albums/...ps183ae97a.jpg

http://i1329.photobucket.com/albums/...ps8be31a31.jpg

http://i1329.photobucket.com/albums/...ps10123be8.jpg

I really wish the fill neck was .75" taller. If it were it would fit perfect between the frame and bed floor. Oh well done with it now ;)

Re: Rustbuket 67 build "Georgia"
 

Looks good Dan!!
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Re: Rustbuket 67 build "Georgia"
 

These pics show how it is mounted directly to the underside of the frame. I used two 1/2" bolts on each side through existing holes in the frame. A typical receiver hitch wont fit with the Boyd tank but I found the CPP hidden hitch will fit. I may have to get one of them someday;)

Driver side

http://i1329.photobucket.com/albums/...psf5282544.jpg

Passenger side

This shot also shows some .25" rubber strips I cut on the shear to go between the tank and frame. Not sure if I need to use them or not. Any thoughts??

http://i1329.photobucket.com/albums/...ps4727bc8a.jpg

Here are a couple shots of the tank installed. Sure looks purdy:smoke:

http://i1329.photobucket.com/albums/...ps745ca860.jpg


http://i1329.photobucket.com/albums/...ps021c3b52.jpg

I also torqued all the hardware on the rear and marked them with a sharpie so I don't forget :uhmk:

Re: Rustbuket 67 build "Georgia"
 

That sure looks nice, super job. I know you used lock washers and nuts to bolt in the tank, I think I would use locking nuts, just to be extra safe...Jim

Re: Rustbuket 67 build "Georgia"
 

Here are my rear shock relocators. I started these a long time ago but I decided I was going to copy robnolimit instead of this style. BUT the nolimit shock relocators would interfere with the Porterbuilt track bar bracket on the driver side of the frame. Sooo back to plan A.


Upper shock mounts removed and marked. Be careful they are not symmetrical.
http://i1329.photobucket.com/albums/...ps7fd5cee2.jpg

Cut them up with the plasma. Probably should have used a straight edge. They cleaned up fine on our vertical belt sander. Love that tool ;)

http://i1329.photobucket.com/albums/...ps193ec426.jpg

All cleaned up.

http://i1329.photobucket.com/albums/...psfd942134.jpg

Painted and installed.

http://i1329.photobucket.com/albums/...ps2a703a31.jpg

http://i1329.photobucket.com/albums/...ps98614a02.jpg

Re: Rustbuket 67 build "Georgia"
 

The idea on the upper shock re-locator is to move the hole up and BACK for more travel and to straighten them back up as before lowering.

Here is a link where I got the measurements.

http://67-72chevytrucks.com/vboard/s...d.php?t=359399


Or you can just buy them from ECE or CPP.

I am doing my lowers like the ECE and CPP version from my own measurements rather than modifying the stock lowers to work. Here is a pic of my experimental shock fitting jig. Once I decide on a hole to use I will make some out of 3/16.

The lower mounts flip the tab down rather than up as original and maybe a little forward for better angle and more travel.

http://i1329.photobucket.com/albums/...ps427e2f5f.jpg

Re: Rustbuket 67 build "Georgia"
 

Thanks Kyle!

Thanks Jim, You have a very good point. I was always told to use large flat washers when bolting aluminum like this but that kinda takes away from the lock washer doing its job. I will get some nylocs on there next time I go to the hardware store.

Re: Rustbuket 67 build "Georgia"
 

Mounted the Idler arm bracket and idler arm. Moog of course ;) painted with Seymour cast blast. I really like the cast blast finish. Looks new but wont rust like a raw part.

http://i1329.photobucket.com/albums/...psf684985f.jpg

I also have the pitman arm but cant put it on yet because I noticed my blasted/cleaned/primered steering gear started oozing fluid so I bought a gates reseal kit. waaaa

Re: Rustbuket 67 build "Georgia"
 

Dan, that puppies coming right along! All you lack now is finishing up. :smoke:

Re: Rustbuket 67 build "Georgia"
 

Everything is looking great! Have not been on here in way way too long and I am happy to see that you are doing a fine job at keeping on going. So many thing I love about your build!

Re: Rustbuket 67 build "Georgia"
 

Nice Clean Work!

Re: Rustbuket 67 build "Georgia"
 

Read through the whole thread, and I am impressed! Great job on the rust repair and chassis looks awesome. I wish I was as resourceful as you are, keep up the pace and soon you'll be ridin'!

Re: Rustbuket 67 build "Georgia"
 

Nice work on the shock mounts Dan. Keep up the hard work.

Re: Rustbuket 67 build "Georgia"
 

Thanks Steve, yeah a bunch of finishing up :ito:

Thanks, glad to have you back

Thanks Bompenstein!!!

Thanks Buck, resourcefull=cheap!:lol: I wish I were smart enough to find a truck like yours to start with. I didn't plan on a frame off when I bought my truck. The dang snowball just ran me over :lol:

Thanks Mike!


SO where was I? I punched holes in the rubber strips for between the frame and tank, installed them and changed out the nuts in favor of nylock lock nuts. Then I was messing around with some gas tank filler hose trying to figure where the filler will end up. I wanted it behind the rear wheel well in the floor but I really don't see how to make the turn up that close to the floor other than welding a sharp radius 90* pipe to a filler neck. Probably end up with a filler on the inner bedside or flush mount in the top of the bedside where the stake hole used to be. I will figure that out later once I put the bed together. I decided to go with a wood bed floor so I have a steel floor I need to get rid of.


http://i1329.photobucket.com/albums/...ps0c90c7b6.jpg

http://i1329.photobucket.com/albums/...ps6e5be6a2.jpg

http://i1329.photobucket.com/albums/...ps41ee252f.jpg

http://i1329.photobucket.com/albums/...psf5f547de.jpg

http://i1329.photobucket.com/albums/...pse7d1b841.jpg

http://i1329.photobucket.com/albums/...psa4318516.jpg

http://i1329.photobucket.com/albums/...ps03cbe781.jpg

http://i1329.photobucket.com/albums/...psa12bea05.jpg

Re: Rustbuket 67 build "Georgia"
 

Now back to the rear shocks and lower mounts.

I decided to use this hole :lol: It is just mirrored off the original bracket on the opposite side. The other holes just didn't work out as I thought.

http://i1329.photobucket.com/albums/...ps49233c5e.jpg

I cut the brackets with the plasma and smoothed the edges, and formed on the press brake. Time for a test fit.

http://i1329.photobucket.com/albums/...ps5d67df6e.jpg

http://i1329.photobucket.com/albums/...psd89174cc.jpg

I ended up having to obround one of the holes because my u bolts are a hair over bent, Just to make installation easier. Then I made some gussets to add a bit of overkill to them.

http://i1329.photobucket.com/albums/...psa2efc59c.jpg

I put the new brackets on and installed new .5" x 2.5" bolts, press fit ;)

http://i1329.photobucket.com/albums/...psaafd703d.jpg

Re: Rustbuket 67 build "Georgia"
 

I bought some Monroe gas max shocks dirt cheap on rock auto and painted them to match the KYBs on the front :lol: Once I had them and mocked them up I realized I needed to add a .25" spacer on the lower mount to keep the shock tube from contacting the bracket so I made a couple spacers.

http://i1329.photobucket.com/albums/...psa1a62119.jpg

Now that everything was clear I installed the shocks and snapped a bunch of pics, everyone loves pics right ;)

http://i1329.photobucket.com/albums/...psddb87e13.jpg

http://i1329.photobucket.com/albums/...psd63be027.jpg

http://i1329.photobucket.com/albums/...ps8d510258.jpg

Paint was a little soft on this bracket :(

http://i1329.photobucket.com/albums/...pscae8f199.jpg

http://i1329.photobucket.com/albums/...ps675d2d7f.jpg

http://i1329.photobucket.com/albums/...psa463e720.jpg

http://i1329.photobucket.com/albums/...psdde0fc72.jpg

http://i1329.photobucket.com/albums/...ps1bf0acf4.jpg

http://i1329.photobucket.com/albums/...ps29da756d.jpg

http://i1329.photobucket.com/albums/...psb93dbdbc.jpg

http://i1329.photobucket.com/albums/...ps683447aa.jpg

http://i1329.photobucket.com/albums/...psbaf445bd.jpg

http://i1329.photobucket.com/albums/...ps70f2189a.jpg

http://i1329.photobucket.com/albums/...ps6cfa0bb0.jpg

http://i1329.photobucket.com/albums/...ps9a7282e3.jpg

Re: Rustbuket 67 build "Georgia"
 

Now I have plenty of shock travel and it didn't cost me anything other than spare time :metal:

Next up is the steering gear, When I blasted it and primed it fluid started seeping out of somewhere so I bought a seal kit. I removed the pitman arm nut and rented a pitman arm puller. Time to read the instructions :lol::uhmk:

http://i1329.photobucket.com/albums/...ps2fe709bc.jpg

http://i1329.photobucket.com/albums/...ps176156ad.jpg

Re: Rustbuket 67 build "Georgia"
 

I was able to change my seals out without disassembling the entire box. Just dig the old ones out with a pick or small screwdriver and tap the new ones in. I have done full rebuilds before and it's a pain in the butt and probably not needed.

Re: Rustbuket 67 build "Georgia"
 

I too am curious about your steering gear! If you rebuild the whole thing be sure to show us pictures! I'm always worried about sand having possibly worked into the gear but maybe that's not a concern? Looking good!
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Re: Rustbuket 67 build "Georgia"
 

Dan, great job on the shock bracket, etc., love the pics....Jim

Re: Rustbuket 67 build "Georgia"
 

Awesome build!

Re: Rustbuket 67 build "Georgia"
 

That is what I was hoping I could do, so I took your advise and it worked great. Thanks


I figure my $20 tractor supply blaster is not tough enough to blast through the seals. Just incase, I left the rag joint, pitman arm, and hoses installed when I blasted it.

Thanks Jim!

Thanks I like yours too!

Update with pics up in a minute......

Re: Rustbuket 67 build "Georgia"
 

removing the rag joint and pitman arm.

http://i1329.photobucket.com/albums/...psfac99600.jpg

http://i1329.photobucket.com/albums/...ps38fe313c.jpg

Then you can remove the cover bolts and remove the pitman shaft. make sure the gear is centered or it wont slide out. if you remove the adjuster nut count the threads or measure the length of the threaded part.

http://i1329.photobucket.com/albums/...psb7199b48.jpg

be right back, little man is crying again...

Re: Rustbuket 67 build "Georgia"
 

Okay little man is asleep...


on the rag joint end (sorry forgot the technical name) there are two seals, the outer seal pulled out pretty easy. The inner seal didn't want to leave so I had to resort to drastic measures. I screwed a sheetmetal screw into the seal and yanked it out. :lol: I must not have take a pic before I put the new seal in but here is a pic of the old seals and the new seals installed.

http://i1329.photobucket.com/albums/...ps3d977641.jpg

http://i1329.photobucket.com/albums/...ps7ff61be3.jpg

You will need a good set of snap ring pliers. I had to borrow a real set from Daniel (suspect) once I broke a new pair from autozone attempting to get the first snap ring out. Thanks again buddy!

Back to the pitman shaft seals. There are 2 washers and 2 seals behind the snap ring like so: washer,seal,washer,seal. They are accessible from the other side of the box once the pitman shaft is out so you can push them out pretty easily.

http://i1329.photobucket.com/albums/...pse95d3ab1.jpg

Cleaned up the bearing, I guess I should have got the rebuild kit instead of the reseal kit. The reseal kit didn't come with the bearing. Oh well there is some corrosion where the pitman shaft rode on the seals that was the source of my leak so I don't plan on this lasting forever anyway.

http://i1329.photobucket.com/albums/...ps41e5bc91.jpg

new seals installed for the pitman shaft. I gently tapped them in place with a socket.

http://i1329.photobucket.com/albums/...ps5545a3c7.jpg

The great thing about the Gates seals is that they are the exact same as original and even have the same numbers on the seals as the ones I took out so there was no guess work as to which seal went where.

Re: Rustbuket 67 build "Georgia"
 

I watched a youtube rebuild video and they say that if the middle gear is taller and different shaped than the outer gears that means it is a variable ratio box. Anyone know if this is true?? here are a few pics of the gear.

http://i1329.photobucket.com/albums/...ps1d42798d.jpg

http://i1329.photobucket.com/albums/...ps3c85af9d.jpg

http://i1329.photobucket.com/albums/...ps339c1307.jpg

Re: Rustbuket 67 build "Georgia"
 

So I put it back together, painted it and installed.

http://i1329.photobucket.com/albums/...ps1722443e.jpg

Then I finally installed the new pitman arm, tie rods, and sway bar. I used energy suspension sway bar bushings and ECE lowered sway bar mounts. THe sway bar mounts were too short for my drop yet the stockers were too tall so I have a temporary spacer (1" sq tube) in there until I make a better looking spacer. I wish they used end links on the sway bars :lol:

http://i1329.photobucket.com/albums/...pse8c42d57.jpg

http://i1329.photobucket.com/albums/...ps4484a829.jpg

http://i1329.photobucket.com/albums/...ps610fa16f.jpg

http://i1329.photobucket.com/albums/...psf0202c91.jpg

http://i1329.photobucket.com/albums/...psc600a29a.jpg

http://i1329.photobucket.com/albums/...ps007be7d7.jpg

http://i1329.photobucket.com/albums/...ps88f9e3ce.jpg

http://i1329.photobucket.com/albums/...ps5474a6c7.jpg

http://i1329.photobucket.com/albums/...psbe9e54ee.jpg

Sorry it's hard to get good pics on the front driver side the way I have it shoved against the front wall. I have to install the lower shaft nut grease zerks, tighten everything down to spec, install cotter pics and get to lubing her up.

What kind of grease do you guys recommend these days??

I am going to order a complete stainless brake line set from inline tube with the '72 front lines and the '67-70 rear lines next week. Then I guess I need some calipers and pads eh?

Re: Rustbuket 67 build "Georgia"
 

Looking great Dan, everything looks super clean.

Re: Rustbuket 67 build "Georgia"
 

Very informative series on the gear box overhaul. I still have to do that one myself. I've been leaning towards pull-a-part for a later model box. I understand they take less turns of the steering wheel lock to lock.
I can't answer about the variable ratio. I used Mobil grease from Autozone I think.

Re: Rustbuket 67 build "Georgia"
 

Thank you Scott :metal:

Thanks Mike, rebuilding one of these is much much more than what I did. I figure there are plenty squares at pull a part if I need another. Mine is a later box, '84 I think. I am hoping it is the variable rate but finding info on these is like catching a jackalope. :lol: I read that you can check the spid on a squarebody to find which gear box it has. I don't remember if they have words on the spid like ours or just the code.