Re: Rustbuket 67 build "Georgia"
 

Sweet looking, wish I had a machine like that to work with, lucky guy...Jim

Re: Rustbuket 67 build "Georgia"
 

That's one awesome build bro! I love it!

Re: Rustbuket 67 build "Georgia"
 

Great work dan!

Re: Rustbuket 67 build "Georgia"
 

Impressive, I wish I had that skill or even access to one.

Re: Rustbuket 67 build "Georgia"
 

Did a search about patch panel installs and ended up spending all evening going through your thread. I've been struggling with staying on track with my original plan but after reading yours I've decided that I'm not crazy, lol.
I really like what you've done so far and can't wait to see this thing progress. Thanks for the inspiration.

Re: Rustbuket 67 build "Georgia"
 

"Thanks D, You have been doing great with your new floor. Keep on truckin'


Thanks, Dan! I was wondering where you have been hiding! It's looking good. I love the custom hangers and gaskets you made. That is really sweet! Hoping to install the floor this weekend, pending the weather and the availability of help!

Re: Rustbuket 67 build "Georgia"
 

Thanks Jim, we have a few handy machines at work ;)

Thank you Terrance yours is awesome, Mine is just a pile of parts. Seems like it anyway. One piece at a time, she will be complete someday.

Thanks Kyle, slowly but surely!

Thanks, The Water jet is pretty easy as far as skill goes. I guess I am lucky to have access to some cool machines and G-job friendly management.

I'm the crazy one. :lol: Glad my insanity can inspire others. Keep on truckin' I will have to check your out.

Thanks D, I keep planning on finishing stuff soon and it takes months. Oh well, Dang kids expect someone to feed them and watch Dora/Diego movies with them. I was thinking if I could sneak my truck into the shop at work I could get some work done. Just figure out how to explain that one to the boss. :smoke:


Back to the exhaust.... I wanted to say that the best way to cut exhaust pipe is with a ridgid tubing cutter. Way too easy and clean.

pics coming right up....

Re: Rustbuket 67 build "Georgia"
 

Pics..

http://i1329.photobucket.com/albums/...ps5uhkxqxk.jpg

Re: Rustbuket 67 build "Georgia"
 

OK. Had to update my 'puter.

I put the cab back on to make sure I was not about to make any big mistakes. Looks like the passenger header is tight as expected but clears just fine by the floor pinch weld.

http://i1329.photobucket.com/albums/...psuwzz1fyv.jpg

I can get a finger in there.

http://i1329.photobucket.com/albums/...psoxf32nfg.jpg

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

Now for the good stuff. I sure was about to make a mistake at the rear. I needed the exhaust to move back a few inches before kicking up. Anyone ever tell you measure twice cut once? "it's easier to shorten something than make it longer"? Well I sure cut this piece too short and had to extend it.

http://i1329.photobucket.com/albums/...ps9cwoum8j.jpg

And now it clears the back of the cab. A little high on the left pipe in this pic.

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

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

Just checking clearance with a bed cross sill here.

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

Re: Rustbuket 67 build "Georgia"
 

Here are a couple underneath shots with the cab on before I burned in the rear of the exhaust.

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

My "H" pipe does hang down 2" below the bottom of the frame but hey I decided a static drop is what I am going with so it works.

http://i1329.photobucket.com/albums/...psbmj84jpy.jpg

Re: Rustbuket 67 build "Georgia"
 

Back to the rear. I made a cut and got the pipe flanges more appealing to my eyes (level).

http://i1329.photobucket.com/albums/...psvaukl7cy.jpg

http://i1329.photobucket.com/albums/...psc9kpufne.jpg

Welding the flanges on. Not perfect by any means but I think it turned out very well.

http://i1329.photobucket.com/albums/...psbz7omnin.jpg

The rest of the exhaust coming together.

http://i1329.photobucket.com/albums/...ps2ibikckk.jpg

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

http://i1329.photobucket.com/albums/...ps12pp4cbk.jpg

Had to add a couple inches to the mufflers since they were used. I wanted to have a standard length muffler so I can swap them out if these are too loud or I am to old. I welded these extensions to the flanges at work, the Millermatic machine at work kills my Hobart.

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

Pipes back on for the last time. CLearance is good all around.

http://i1329.photobucket.com/albums/...psm9y16kpb.jpg

http://i1329.photobucket.com/albums/...psdyzw9kzb.jpg

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

http://i1329.photobucket.com/albums/...ps9mp8gv6b.jpg

http://i1329.photobucket.com/albums/...pslzfv334e.jpg

Sorry about the gloomy lighting. ran out of daylight there.

Re: Rustbuket 67 build "Georgia"
 

I made some hangers for the rear to hang from the shock crossmember similar to the front hangers.

http://i1329.photobucket.com/albums/...psbuqk3zsd.jpg

http://i1329.photobucket.com/albums/...psi6bpxcds.jpg

Next I got the muffler flanges welded on and a little spray paint.

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

Installed the mufflers and fitting up the tailpipe/dumps.

http://i1329.photobucket.com/albums/...psvut2nzmk.jpg

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

http://i1329.photobucket.com/albums/...psxlq4zh2r.jpg

I took the tailpipes back off for final welding and snapped a few pics while the paint was drying.

http://i1329.photobucket.com/albums/...ps6bcfs5bc.jpg

http://i1329.photobucket.com/albums/...ps26iltpw0.jpg

http://i1329.photobucket.com/albums/...ps6mnutask.jpg

Re: Rustbuket 67 build "Georgia"
 

I love those homemade exhaust hangers. So cool.

Re: Rustbuket 67 build "Georgia"
 

Dumps back on, almost done with the exhaust!

http://i1329.photobucket.com/albums/...psv7mo6kr6.jpg

I left the dumps long for now. I figure I will cut them to length once the bedsides are back in place to make sure it ends where I want it to.

http://i1329.photobucket.com/albums/...psr8yd37jy.jpg

http://i1329.photobucket.com/albums/...psp7thxayh.jpg

More pics

http://i1329.photobucket.com/albums/...psqfae9vld.jpg

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

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

http://i1329.photobucket.com/albums/...pstjzwtd4v.jpg

http://i1329.photobucket.com/albums/...pswsjm8blo.jpg

http://i1329.photobucket.com/albums/...pskoqec0vw.jpg

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

Plenty of room between there.

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

I have one more seam to weld on the exhaust under the cab but that should wrap it up. :metal::metal::metal:

Re: Rustbuket 67 build "Georgia"
 

Thanks, Stainless works makes something very similar. :exit:

http://stainlessworks.net/index.php/...r-weld-on.html

The snapper grommits are Jegs brand. I think made by SW, Jegs are red, SW are blue.

http://www.jegs.com/i/JEGS+Performan...09025/10002/-1

The mufflers are IMCO "international muffler company" Flowmaster knock offs that were pulled from (hardly used) an old truck I used to own.






BTW... Awesome truck you have there I was reading your new thread the other day, Wow! I love it!

Re: Rustbuket 67 build "Georgia"
 

Nice work Dan! Glad to see you back at it. Looking forward to more updates.

Re: Rustbuket 67 build "Georgia"
 

Dan, exhaust looks great, nice work...Jim

Re: Rustbuket 67 build "Georgia"
 

Thanks Scott, I see you have made quite a few changes. Love the new engine. :metal:

Thank you Jim, One step closer. ;)

Re: Rustbuket 67 build "Georgia"
 

Incredible detail Dan.. Great job...

Re: Rustbuket 67 build "Georgia"
 

Looking great! Amazing work you are doing.

Re: Rustbuket 67 build "Georgia"
 

Looking good, Dan!

Re: Rustbuket 67 build "Georgia"
 

Thanks Mark!

Thank you Darien


Thanks Steve, appreciate the compliments.




Well I have not been doing a whole lot recently, mostly hangin' out in the gym when I'm not with the kiddos.



I started putting the accessories back on the engine but had an issue with the powersteering pump. I assumed since I had a '97 pump and '84 gear and hose I would be cool but.... in '97 GM started something awesome called speed sensitive steering and that made it a bear to find a hose to fit the pump in this chassis. I knew you could change the flow control valve assembly on virtually any GM pump so I dismantled the speed sensitive steering thingy and went to LKQ pick your part to find an o-ring hose flow control valve.

Here is a diagram of the fitting, if you didn't know the pumps are the same if you need to swap between flare and o-ring fittings.

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

I walked around the yard looking for a perfect donor... hoping I would find a pump just laying there all alone to save myself the headache of pulling a pulley and brackets and boom there it is. :smoke:

http://i1329.photobucket.com/albums/...psen1pzzk8.jpg

Pulled the flow control valve fitting out.

http://i1329.photobucket.com/albums/...psome3mskk.jpg

here is the standard o-ring fitting/valve on the left next to the speed sensitive thingy valve and of course the pump on the right.

http://i1329.photobucket.com/albums/...ps5jiuov62.jpg

Put the "new", old fitting in the pump.

http://i1329.photobucket.com/albums/...psq7snwtus.jpg

http://i1329.photobucket.com/albums/...psvu7oqeh2.jpg

Now I can use the '84 o-ring hoses thta match my pump.


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

And there you have it a '97+ SCS pump with 80-96 o-ring fitting/hose. Yes it works for flare fittings too, just pull the valve from the correct year truck you need.

Re: Rustbuket 67 build "Georgia"
 

Here are the hoses as installed. they are floating about 3/4" over the frame, maybe because they are for a late square body?

http://i1329.photobucket.com/albums/...pspq0ioqir.jpg

http://i1329.photobucket.com/albums/...pshtnq0c4q.jpg

I plan to put a clamp block there to secure them.

With that done I installed the harmonic balancer. Don't be a fool, use the tool!

http://i1329.photobucket.com/albums/...ps2h92exjz.jpg

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

Re: Rustbuket 67 build "Georgia"
 

I decided not to reuse the problematic CSFI poppet injector assembly although it was running fine when pulled. I rubbed together enough pennies for a real MPFI injector upgrade. This whole design is well, odd.. Anyway here are some pics.

The "Spider" :lol:

http://i1329.photobucket.com/albums/...pswevoyu3v.jpg

the new mpfi injectors. I would imagine having all this crap under the intake in the airstream may be its own air flow restriction.

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

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

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

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

http://i1329.photobucket.com/albums/...psg63dai0g.jpg

Re: Rustbuket 67 build "Georgia"
 

To finish off the accessories I decided to change over to an OE type non ac setup. This meant just buying a ribbed pulley and a new belt which I needed anyway. I did however need a spacer, bolt and washer so back to LKQ for the goods. Here is the ribbed idler pulley with the LKQ yard spacer,washer, and bolt ready to install. the spacer and hardware is the same for smooth or ribbed idlers if you need one.

http://i1329.photobucket.com/albums/...psz7sjoh9o.jpg

http://i1329.photobucket.com/albums/...psmoa6nues.jpg

I installed the upper intake and throttle body and while at LKQ I picked an S10 4.3 intake hat to replace that disgusting GMT vortec box thing and swap sides with my intake. I ordered a cheap Ebay S10 cold air intake kit also, just waiting on the brown truck to deliver that. Here are a few pics as she sits now.

http://i1329.photobucket.com/albums/...psypwjq6fs.jpg

http://i1329.photobucket.com/albums/...pssqjzq7db.jpg

Re: Rustbuket 67 build "Georgia"
 

That is a strange looking EFI. 'Spider' is a good term for it.

So no A/C in wonderfully hot and humid OK? You are tougher than me. :)

Great to see some progress again, though!

Re: Rustbuket 67 build "Georgia"
 

nice build!

Re: Rustbuket 67 build "Georgia"
 

Hey Dan,

What's going on? Your last post was in April! How's everything going?

-Darien

Re: Rustbuket 67 build "Georgia"
 

is this truck still being worked on? it's like you fell off the face of the earth

Re: Rustbuket 67 build "Georgia"
 

Yeah that goofy spider is what all the "vortec" 96-98 trucks got, the ones everyone wants the "vortec" heads from. I would love AC but that will be a much later addition. Thanks!

Thanks, I dig your square!

Slow goin' D.. very slow!

Yes it is but rather slowly and not very consistently though. I have my cold air intake complete, installed radiator and rad hoses, made some hard lines for fuel from the rear and a few other things. I will try to get my pics together and post a real update this weekend. Things have just been very busy with two small ones around here. I'm preoccupied with potty training, soccer practice, swimming lessons and trying to keep the little guy from breaking all my sunglasses and preventing them (and myself) from killing each other :lol:. I have been collecting parts and getting rid of some old stuff and getting ready for some big progress soon.

Re: Rustbuket 67 build "Georgia"
 

Hey Dan, glad to hear you are still around and kicking, even if you are kicking slowly.

I have been distracted with a bunch of stuff going on myself, but am hoping to get back to it in the next couple of weeks.

Hope everyone is doing well. Hope to see some pics and progress soon.

-Darien

Re: Rustbuket 67 build "Georgia"
 

Dang Dan,,, nice work on the exhaust!!! Are you going to be in the Lewiston Idaho area any time soon?? I could use a little help on my exhaust!! What made you choose Flowmaster mufflers? looks like it's been a while since any new updates,, any news on the latest??

Re: Rustbuket 67 build "Georgia"
 

I have been wondering what's going on with Dan as well! It's been almost a year since he has posted.

Re: Rustbuket 67 build "Georgia"
 

Still here...

So this is where is started with the passenger side rot.

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

http://i1329.photobucket.com/albums/...ps6efcp40b.jpg

http://i1329.photobucket.com/albums/...pssmzb0mzb.jpg

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

http://i1329.photobucket.com/albums/...pszes0vdgk.jpg

Rusty **** box.

With that all cut back out of the way I began to fit up the outer floor extension. I reall couldn't ask for a better fit.

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

http://i1329.photobucket.com/albums/...ps6usgatce.jpg

This time I cut around the hump because it doesn't match up too well with the OE floor. Also had to open up the seatbelt attaching home quite a bit. Still a great fit compared to the other side of the truck.

http://i1329.photobucket.com/albums/...pst2nkzdte.jpg

With that all lined up I prepped the outer floor by removing the black EDP off all mating surfaces and edges to be welded. I applied UPol copperweld to all overlapping surfaces once sanded.

http://i1329.photobucket.com/albums/...pss8fqq1ab.jpg

http://i1329.photobucket.com/albums/...psufkq6yb7.jpg

http://i1329.photobucket.com/albums/...psvs4fxqm8.jpg

Next up I sand blasted and sand blasted and blasted some more. That crap was in my ears and nose and everywhere. Once blasted clean, I coated the cab supports with Eastwood rust encapsulated and again used Upol copperweld on all overlapping surfaces.

http://i1329.photobucket.com/albums/...psogwrm9qd.jpg

http://i1329.photobucket.com/albums/...psh5afcqek.jpg

http://i1329.photobucket.com/albums/...ps9ltlwfta.jpg

Burning the floor edge in. I plug welded it to the cab supports but I didn't get a pic before sanding those smooth.

http://i1329.photobucket.com/albums/...pskt4ksjro.jpg

http://i1329.photobucket.com/albums/...psczsvp5m0.jpg

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

Making it smooth. Grind, sand, sand. Gotta love those Roloc disks!

http://i1329.photobucket.com/albums/...pst2nrlsua.jpg

Almost done.

http://i1329.photobucket.com/albums/...psyg5mphnf.jpg

There she is. Good as it's going to get for a floor.

http://i1329.photobucket.com/albums/...psvdrhlqh0.jpg

http://i1329.photobucket.com/albums/...pslyxs2bcc.jpg

http://i1329.photobucket.com/albums/...ps0za3fmge.jpg

A little primer to keep from flash rusting.

http://i1329.photobucket.com/albums/...ps82jeftpb.jpg

http://i1329.photobucket.com/albums/...ps5vcmp5wx.jpg

http://i1329.photobucket.com/albums/...psk3n80qrp.jpg

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

Next up the rear pillar or "b" pillar. This part is awful. I had to slice and dice and flatten and reform and talk dirty to get this piece into submission. Grrr.

http://i1329.photobucket.com/albums/...psk5lhz9jb.jpg

http://i1329.photobucket.com/albums/...psls7wqpvs.jpg

Back side of the b pillar.

http://i1329.photobucket.com/albums/...psxr1deg0r.jpg

Needs to be finish welded across the seam but done for the moment.

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

Moving on to the kick panel.

Here's what's left of the "a" pillar, blasted clean.

http://i1329.photobucket.com/albums/...pszoyqsp7s.jpg



http://i1329.photobucket.com/albums/...ps8ktcrj9a.jpg

Once again, sanding all mating surfaces to plug weld and coated with copperweld primer. The kick panel is a pretty good fitting patch. No big complaints there. Well one complaint. The kick panel fits great by itself, the "a" pillar seems to fit great by itself but the kick panel and "a" pillar do not fit together very well with one another.

http://i1329.photobucket.com/albums/...ps5jfbmbwe.jpg

http://i1329.photobucket.com/albums/...psayipw1w9.jpg

http://i1329.photobucket.com/albums/...pskvj88mly.jpg

http://i1329.photobucket.com/albums/...psdy0bbdhw.jpg

http://i1329.photobucket.com/albums/...psqbec9ppu.jpg

I am going to have to do some serious cowl repair and pull the firewall back in. It had a gap at this seam from the factory. Or at least since I got it. You could see how the spotwelds pulled the metal across the gap. There were big gaps between each spot weld.

http://i1329.photobucket.com/albums/...psjcknd5dq.jpg

Here she is welded in. I did not weld it to the firewall yet, I have to whip up a patch to fill in above this piece and part of the cowl.

http://i1329.photobucket.com/albums/...psuf6zyeoi.jpg

http://i1329.photobucket.com/albums/...psbqdc6yrh.jpg

Now I am fighting the "a" pillar. It is giving me hell so far. I cut it down but it sticks too far out, like it's too tall. I sliced it vertically so I can get the hinge mount surface to sit flush. I am almost satisfied with it and hope to have it burned in soon. Here an early test fit pic. It appears to fit well in the picture...

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

I will say that the rocker panel is a great fit in every test fit so far.

http://i1329.photobucket.com/albums/...ps1rvlrkkl.jpg

I guess I didn't upload a whole side view with the rocker clamped on. I will get one uploaded later.

Re: Rustbuket 67 build "Georgia"
 

I'm still working just real slow.

Thanks Wade, I though it turned out pretty well for a first timer. I probably should have cut a few small sections to practice welding on before jumping right in. Some of my exhaust welds are what I would call a "dead worm" laying on pipe. The mufflers are IMCO race muffler, a flowmastercknock off that I pulled of a truck I scrapped a few years ago. The were pretty new when I pulled them and had a nice tone. I intentionally flanged the mufflers incase they are too loud or I'm getting too old. That way I could weld flanges on a quiet set and swap them out if needed.

Mostly working, raising kids, and I spend most of my free time in the gym nowadays.

Re: Rustbuket 67 build "Georgia"
 

I have other updates but let's stick with getting the cab squared away first before getting back to the drivetrain.

Re: Rustbuket 67 build "Georgia"
 

Dan, rust repair is a bear, but you are doing a great job. Will look just like new when your done...Jim

Re: Rustbuket 67 build "Georgia"
 

Glad to see some progress, if you want some help you know how to get a hold of me.

Re: Rustbuket 67 build "Georgia"
 

What's up Dan? Good to see you still have Georgia. Nice work on the rust repair.

Re: Rustbuket 67 build "Georgia"
 

Well, it's good to hear from you. Looking forward to hopefully seeing some updates sometime soon. Glad you are doing well.