Re: The Hillbilly Deluxe dually build
 

I don't know what I'll wind up doing with it. All I know is that I now have three pickups and that's one too many. I only built the stepside to keep myself busy. I've driven it maybe 100 miles since I got it on the road. It just sits for weeks at a time. I just don't like the truck really. I only built it because I got it for free.


http://i276.photobucket.com/albums/k...792143f5b8.jpg

Re: The Hillbilly Deluxe dually build
 

Tx.... Are those the KH 15x8's on the back of the 78 that you got from me?

Re: The Hillbilly Deluxe dually build
 

No sir, they're stock 6 inch wheels on all four corners. Powdercoated white with a set of five dollar swap meet hubcaps. 215/75-15 front, 235/75-15 rear. Spindles and springs front, flipped in the rear.

Re: The Hillbilly Deluxe dually build
 

Gotcha. I'm on the hunt for another pair. Might have to buy them new/aftermarket.

Re: The Hillbilly Deluxe dually build
 

Going to keep the Hillbilly Deluxe?

Re: The Hillbilly Deluxe dually build
 

That's a good one.... :lol:

Oh wait. I have 4 so that's not one too many. Whew, I was worried for a minute.

Re: The Hillbilly Deluxe dually build
 

You can count on it. I've built this truck to be exactly what I want without any regard to resale or any sort of financial sense. I've wanted this truck for 20 years. If I ever sold it, I doubt I'd be able to replace it with as good of one in the future.
I have three trucks, my little Honda daily driver, two trailers, my tractor and more motorcycles than I can think about. Plus Valerie's car. That's too many to keep on top of.

Re: The Hillbilly Deluxe dually build
 

You see if you were closer I'd take the '78 off your hands. It appears to be in better shape than my ole '76. I understand having one too many. At one time I had three squares. I had my '76 Silverado, '74 Cheyenne Super and '87 Silverado. I like the older round eye ones better. I hated the '87. I'm not an electronic nutt. So when the windows didn't work and other crap didn't work it was time to move on. I like simple. I don't do complex.

Re: The Hillbilly Deluxe dually build
 

I'm somewhat frustrated at the pace I'm making on this dually. I guess I'm saying that my patience is wearing a bit thin.

Here is where I stand now...

1) The fuel filler project is complete other than final hardware to bolt the neck to the bed side. I'm using a couple of various screws right now until my McMaster Carr order of stainless steel bad assedness arrives. I'm currently in day number 9 of it sitting at the UPS Atlanta hub. I contacted McMaster and their response was, "UPS is having a hard time making deliveries into Texas. We are aware of the issue. Please continue to follow the tracking number XXXXXXXXXXX for updates as they occur."

2) Front suspension is rebuilt with new ball joints and lots of cleaning and painting. I cut one coil from the springs to lower the front to match the lowered rear. I also installed new shock absorbers at that time. The control arm bushings were tight both upper and lower so I did not change them. I'm still mulling over the tie rod ends (and awaiting next payday to possibly replace). I have a buddy who does me top of the line alignments. When I call in a favor for an alignment, I try to only take him stuff that's 100 percent perfect.

The brake rotors are good and bearings are good. I'm rebuilding the calipers rather than exchange for rebuilt ones because the rebuild kits are a couple of dollars and swapping them out for rebuilt ones is particularly expensive. These aren't the 14 dollar parts store ones like half ton trucks use. More like 40 dollars each. I have new brake hoses to install at that time also.

Currently waiting on banjo bolts, banjo bolt crush washers, and wheel bearing dust caps. Both of my caps are haggard so I ordered new ones. They are particularly hard to find. O Reilly cannot get them, Autozone is back ordered on them. No deal at Summit. I had to order from Rockauto.

Once my Rockauto and McMaster Carr orders make their way here, it should be short work to finish up and bolt the Alcoas onto the front and set the truck on the ground. At that time, I'll bust down the old front wheels and tires that I took off, powdercoat the wheels, install new tires, and bolt them and the last two Alcoas onto the truck to have a full set of new wheels and tires on the ground, and to be able to see the new lowered stance.

I'm not sitting around watching TV here, my hands are just tied until holiday rush at the various shipping companies clears out and my parts arrive here.

Re: The Hillbilly Deluxe dually build
 

Holiday does tend to interfere/cut into that truck time. :lol:

Your are making way more progress than I am. But like you I am gathering stuff.

Re: The Hillbilly Deluxe dually build
 

Brother.... I hear ya. I ordered the steel parts to build my Panhard bar BEFORE the ice storm hit. The lady suggested it might take an extra day or so because of the holiday shipping flood. Then the ice storm hit so everything sat idle & I've been waiting since.

I just picked it up yesterday.

Re: The Hillbilly Deluxe dually build
 

What size bolts are you waiting on from McMaster? Ive got a pile of SS button heads in 5/16" flavor that I could drop in an envelope and send ya. Ive got 1/2", 3/4" and 1" long with nylocks. Let me know if you want me to send ya a handfull.

Re: The Hillbilly Deluxe dually build
 

Good to see ya makin' progress. It's gonna be really nice when it's done. You gonna clean up the paint any?

Re: The Hillbilly Deluxe dually build
 

Ten days, I finally see some progress on the McMaster Carr order. I should have it tomorrow.

http://i276.photobucket.com/albums/k...a0d0e9bc72.jpg

I'm gonna have to do something to it. There was an underhood fire at some time in the past which scalded the paint off of the hood. I've been kind of talking to another member on here who is somewhat interested in buying my 78 stepside. If he decides he's not interested, I might pull the round eye front clip off the 78, straighten it up some, and swap it onto this truck. In my parts stash, I have all new upper and lower moldings for a 73-80 truck. That would all work out pretty slick.

I should have an update today later. I'm headed home from work now and hope to at least get the rotors, bearings, and calipers done up today. Then it will just be a matter of brake hoses, banjo bolts, and grease dust caps.

Re: The Hillbilly Deluxe dually build
 

That storm backed up everything.

Re: The Hillbilly Deluxe dually build
 

Excellent! I am happy to hear that you will be able to plug away at things as you would like.

Re: The Hillbilly Deluxe dually build
 

I've been casually poking away at rebuilding the calipers today.

http://i276.photobucket.com/albums/k...373a902d9d.jpg

Rockauto rebuild kits. Just a few dollars each.

http://i276.photobucket.com/albums/k...30a12b2c3f.jpg

The bores of the calipers had a lot of crunchy junk down inside of them.

http://i276.photobucket.com/albums/k...cbe0670806.jpg

http://i276.photobucket.com/albums/k...6b1143e7f7.jpg

Pistons were pretty skunky too.

http://i276.photobucket.com/albums/k...3160f82e39.jpg

I soda blasted the pistons and then polished the outer surfaces on my buffing wheel with rouge.

http://i276.photobucket.com/albums/k...fe052bc976.jpg

Re: The Hillbilly Deluxe dually build
 

Are they as easy to rebuild as it seems? Barring complications, obviously?

Re: The Hillbilly Deluxe dually build
 

Those pistons cleaned up nice.

Re: The Hillbilly Deluxe dually build
 

Extremely easy. Once you have a clean caliper and a clean piston, it takes maybe two minutes to do one.

There are exactly two parts in the rebuild kit. The sealing ring and the dust boot.

http://i276.photobucket.com/albums/k...e36df65f27.jpg

You install the sealing ring into its groove down inside the bore, then the dust boot into its groove. Then lube the piston and bore with clean brake fluid and install the piston into place. The only part that takes any deftness is stretching the dust boot over the piston. You have to push down on the piston and use a hook type of tool to run around the piston to lift the boot over the piston edge. Easier to do than to try and explain.

http://i276.photobucket.com/albums/k...f9e25fbd22.jpg

Thank you Karl. One step at a time and hopefully I'll someday be finished.

Re: The Hillbilly Deluxe dually build
 

So do most calipers rebuild the same? Like say on a 1/2 ton will it be rebuilt the same way? It looks fairly easy. Those cleaned up nice.

Re: The Hillbilly Deluxe dually build
 

Exactly the same except being proportionately smaller.

Re: The Hillbilly Deluxe dually build
 

Signing up for some great info and great workmanship.

Re: The Hillbilly Deluxe dually build
 

More baby steps fellas. After two full weeks, my order of stainless steel hardware finally arrived. The fuel filler project is now fully complete. These pictures are for those guys who politely told me I was being cheesy for using pop rivets. You were right. It cost more and took a long wait to get the stuff, but this is the more sanitary route. Point taken and constructive criticism is always welcomed. I sometimes lose sight of the big picture.

http://i276.photobucket.com/albums/k...d730b70c18.jpg

http://i276.photobucket.com/albums/k...4073631e86.jpg

http://i276.photobucket.com/albums/k...ea42fb5eb2.jpg

Reminder of what I started with...

http://i276.photobucket.com/albums/k...68b36caeff.jpg


In retrospect, I wish I'd have made another pass with the welder and ground it smooth to make the seam between the bed side and the added section below it more seamless. It very strong and welded thoroughly as is right now. But, the bed side channel had a significant rounded edge so when I welded the extension to the bottom of it, there was a good sized channel that the weld laid down in which is less than flush and smooth. I'm not gonna go back and mess with it though. It doesn't really bother me, it's just something I could have done better.

Am I wearing you guys out with this glacial pace I'm working at ?

I try to never be the guy who says "it will do for now" or "I'll tidy it up later". I try to start a project and complete it in its entirety then move onto something else. Nothing to finish up later. When I run out of projects, I'm done.

Next is finishing up the front suspension.

To recap, I have done the following....

New upper and lower ball joints
Cleaned and painted lots of stuff
New front shock absorbers
New front brake hoses
Rebuilt front calipers

I am still waiting on a bulk order of crush washers for the brake hoses and new wheel bearing grease caps.

But, everything is clean and redone, just awaiting re installation of the rotors, calipers and pads, and brake hoses. I'm still not totally happy with the steering linkage. If I can squeak some money out of the budget next payday, I'm gonna go ahead and do new tie rod ends and adjuster sleeves. Then I'll install new wheels and tires and it will be ready for alignment.

It looks like I'm gonna get about half a day or more of truck time on Wednesday to make some more progress. I've got to go to work tomorrow and then I'm gonna hold over for a few hours Wednesday morning so one of my C shift buddies can get a few hours with his kids before coming to work on Wednesday. After that I hope to get some stuff done. At least until Valerie gets home and I have to come inside and do that holiday crap. I told her the one thing I wanted most for Christmas was some truck time. After 40 years of being drug all over hell on Christmas Day, I wanted one time to do what I wanted. She's cool with that and is off to see her mother for a half day.

Re: The Hillbilly Deluxe dually build
 

Kevin, are you visiting the in-laws for Christmas? I have a Jeep steering shaft here at the house. It's a little crusty, but you are welcome to it for your truck.

Re: The Hillbilly Deluxe dually build
 

Have you considered just filling that seam with some filler and touching up the paint?

I know you mentioned you're not one to go back and touch up a project, but maybe make it part of a new project- pull the fiberglass filler plate, fill in those extra holes, smooth over the "FORD" logo, fill the seam, paint it all, and put it back together.

Re: The Hillbilly Deluxe dually build
 

Damn man, I love you.

I'm scheduled to go over there this weekend I think. I'll ask the boss.

Re: The Hillbilly Deluxe dually build
 

Is that kind of like when y'all said "instead of pop rivets, consider using stainless hardware" which was a nice way of saying "oh hell no, that won't ever look worth a damn, try again."

Re: The Hillbilly Deluxe dually build
 

I wasn't going to point that one out since we'd already dog-piled you about the rivet vs SS fasteners (it was an internal struggle for me :lol: )

Unfortunately.... I suffer the same affliction. I want to complete that 'portion' of the project & check it off my list before tackling the next.

Re: The Hillbilly Deluxe dually build
 

Damnit

I can slick off the seam, but making the filler cup smooth isn't that easy. Its fiberglass of some kind. I have no idea of how I'd effectively fill the two extra holes in it. Honestly, the thought of buying 30 dollars worth of resins and stuff for those two holes isn't exciting me. I agree the welded seam is a craftsmanship issue which I can (will) address with the welder and flap wheel.

Re: The Hillbilly Deluxe dually build
 

Hide them in plain sight. Drill the holes out to the size required for some simple black plastic push plugs....

Re: The Hillbilly Deluxe dually build
 

Scot, that's a good route to take.

This also reminded me that I'm not quite done with it as I forgot to add the bonding strap.

I'll fool with it more on Christmas Day when I next get some truck time.

I appreciate the honest opinions y'all are offering.

Re: The Hillbilly Deluxe dually build
 

Just let me know; I should be around. If it is really supposed to be 63 degrees, I am hoping to be behind the garage making some progress.

It isn't pretty, but seems like it is still tight. I figure you probably have a handle on the pretty part.

Re: The Hillbilly Deluxe dually build
 

Looking good. Those stainless fasteners set it off nicely, it is a good thing you had that idea. ;)

As far as those two holes, do you foresee yourself installing air bags on that truck? That is a decent place to route the valvestems for air bags, keeps them accessible, together, and protected.

Re: The Hillbilly Deluxe dually build
 

I don't foresee any airbags. This bastard is some kind of stout in the spring department. It does look like an extra stainless steel screw would fill the smaller hole though.

I'm glad you like my idea (cough) on the stainless steel hardware. I consider it quite an impressive idea I had (cough).

Re: The Hillbilly Deluxe dually build
 

Kevin, I have really enjoyed the build...great job!

Hope I don't get any slack for this, but here is my thought on the fuel filler. The welded plate needs to be shortened so that its about 1" even all the way around the bottom of the filler piece, with matching radiused corners, then welded smoothed. Plugging the 2 holes as Scoti mentioned would look great and finish it off nicely.

Keep up the great work!

Re: The Hillbilly Deluxe dually build
 

Thaaat's right, I flipped back to the axle rebuild and wiring portion of this thread and saw the massive leaf packs you have.

Thank you for the caliper rebuild pics & process. In the back of my mind I know there isn't anything complicated to them, but it is just something I have not yet done. You mentioned that you soda blasted the pistons before polishing, what media did you use? As many parts as I have soaked and scrubbed and chipped debris off of, I can definitely say that when time, space, & $ permits, I will look into a blast cabinet.

Re: The Hillbilly Deluxe dually build
 

Devin, I just used baking soda. I buy it in 50 pound bags. It's not food grade, it's lower spec, intended for media blasting usage. You can even get it a Harbor Freight. Its a very gentle abrasive. I use it mainly for internal engine parts. It peels gaskets, carbon and dried grease right off but doesn't hurt the parent metal.

Re: The Hillbilly Deluxe dually build
 

I'll second the FORD logo. Nice screws. That logo actually kind adds character.

Re: The Hillbilly Deluxe dually build
 

Are you using this in a hopper separate from your blast cabinet?