Re: My new build thread: Stage 4!
 

Caught John at the CHAOS shop this afternoon. He is off work for a little while and making some progress on stuff! Gonna get my steering knuckles reblasted tommorrow and start finishing the assembly! Should be able to get the K5 up there real soon and get up to 1 ton status! Can't wait!

Re: My new build thread: Stage 4!
 

Anybody got some pic's of the seals for the top to bedside seals?Double wall vs single wall would be great. Double wall top here, but single wall pic's would help also. Bought a set from a member here, and just want to make sure they are for a double wall top. These came from Brothers P/N 617618. Mine never had any seals there when I removed the top way back once, so I used a 1 sided sticky 1/4" thick x 1" wide rv tape. Didn't really work ! I want it right the next time I do it. Thank's!

Re: My new build thread: Stage 4!
 

Ok, a glimmer of hope today!I caught John at the CHAOS shop today. Had a good chat about what's going on and my project. He is layed off from work now, and looking at renovating the shop. The weather is getting better here and looking at doing some additions to the shop. All the ice and snow are finally melted from in front of my pole barn door so I can get the K5 out. He has my front disc brake brackets painted and ready to go. Also had my front steering knuckles reblasted and primered up. Still going to paint them chevy orange again, this time with the right paint. Working on cleaning out the shop again to get my K5 in there. Can't wait man! Plan on actually getting some progress done on this project soon. John said he is willing to give me a key to the shop so I can go in and wrench when he is not around. I cannot wait to get going on this and finally get these 1 ton axles under this K5 and drive it again!

Re: My new build thread: Stage 4!
 

Ok, a glimmer of hope today!I caught John at the CHAOS shop today. Had a good chat about what's going on and my project. He is layed off from work now, and looking at renovating the shop. The weather is getting better here and looking at doing some additions to the shop. All the ice and snow are finally melted from in front of my pole barn door so I can get the K5 out. He has my front disc brake brackets painted and ready to go. Also had my front steering knuckles reblasted and primered up. Still going to paint them chevy orange again, this time with the right paint. Working on cleaning out the shop again to get my K5 in there. Can't wait man! Plan on actually getting some progress done on this project soon. John said he is willing to give me a key to the shop so I can go in and wrench when he is not around. I cannot wait to get going on this and finally get these 1 ton axles under this K5 and drive it again!

Re: My new build thread: Stage 4!
 

OOPS, double post-sorry!

Re: My new build thread: Stage 4!
 

Well after a bunch of searches, I am confident I bought the right top to bedside seals. Figured out Brothers has their info wrong on the site. By looking at all the pic's I could find, I have the right seals for a double wall top. Drove by the CHAOS shop today and John has a military 6x6 on the trailer out front!

Re: My new build thread: Stage 4!
 

Looking at replacing all my weather stripping for my doors and topper. Have allready got some here, but really don't want to go LMC on the important stuff. Got a real nice set of front door drip rail deflector seals today from Metro moulded parts. Anybody got any pics of this area with new seals installed?

Re: My new build thread: Stage 4!
 

Worked all day on the pole barn. Lots more work to do! Gotta get a hold of John and get going on the 1 ton axle swap.

Re: My new build thread: Stage 4!
 

Really looking at the drip rail deflector seal area. Got a new set of drip rail seals, and it looks like my K5 has never had them installed. I may be wrong, but this is a very interesting area.Anyone have some pic's of these seals installed?

Re: My new build thread: Stage 4!
 

Attachment 1100456Ran into John tonight at the local Eagles club for burgers. Stopped up to the shop after to check on progress of my axles. Front axle is almost complete. Ballistic high steer arms, steering knuckles painted chevy orange, DOM crossover tie rod ends welded and mocked up, spindles w/bearings packed, looking real good! Front diff carrier reinstalled also. Rear 14 bolt with the GOV-LOC also reinstalled! Rear has the disc brake brackets done and the guardsman yoke protector installed. Yeahh!!! Looked out back at the shop for some spare driveshaft parts, as in yokes and spline shaft stuff-more than enough to get her rolling once we get the axles under to get some angle and etc measurements. My camera sucks, but I got one pic anyway! Talking about driving the Blazer up there on Sunday! Here's my one crappy pic!

Re: My new build thread: Stage 4!
 

Checked in at CHOAS off road today. Looking good , seals installed. Spent time helping John with much needed cleaning in the shop after work. Next day or so there will be room for my K5! Some pic's!Attachment 1101331

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Re: My new build thread: Stage 4!
 

Couple more pic's!Attachment 1101344

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Re: My new build thread: Stage 4!
 

Oh yeah!! It's official, my 1 ton swap starts tommorrow. Drove the K5 up to CHAOS off road today. John will get started on it tommorrow. Gonna start with installing the Dana60 front axle. Set that up and move on to the rear 14 bolt. Then swap in the NP205 tranfer case after twin sticking it. Very excited to finally get this next step going! I will stop in to the shop tommorrow after work and help as much as I can. Here's some pic's froAttachment 1103096

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Attachment 1103124m today's move!

Re: My new build thread: Stage 4!
 

No new pic's today. Gotta gather some seals for the NP205 swap. Gonna reseal it and put on some paint before swapping it in. Dana20 to NP205 swap! Pretty sure I have all the necessary needed crossmembers gathered for this swap. Anybody else done this transfer case swap lately? Pic's?Attachment 1104139

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Re: My new build thread: Stage 4!
 

John's got the NP205 case all power washed. Gonna take the front and rear output yokes off and replace both seals tommorrow, followed with a coat of primer and paint! Replacing the seals in the adapter also. Looking real good. Also, almost done modifing one of my new ORD front upper spring shackles, I had a clearance issue with my headers there. I am using ORD's upgraded FUSH kit to replace my wimpy stock bushing setup that has never been replaced. I am very happy this is making progress, and even happier that John is doing all this work in his "spare" time and not charging me for labor. Good to have friends! I'll get some more pic's soon! My theme is turning out to be--BUILT-NOT-BOUGHT!

Re: My new build thread: Stage 4!
 

Spent some time in the shop today after work. John worked on the twin sticks and in mocking it up, found that the hole in the t-case adapter for the shifter bolt is too small. Wrong adapter, thank goodness I had bought another one that will work perfect! Could have drilled and tapped the one out, but easier to clean up the other adapter. Got it all cleaned up, John pulled both yokes off, knocked the seals out of the new adapter. Will pick up new seals tommorrow and should be ready for paint! John also has some yokes to upgrade to bigger u-joints, project is moving along!

Re: My new build thread: Stage 4!
 

Spent some time in the shop today after work. John worked on the twin sticks and in mocking it up, found that the hole in the t-case adapter for the shifter bolt is too small. Wrong adapter, thank goodness I had bought another one that will work perfect! Could have drilled and tapped the one out, but easier to clean up the other adapter. Got it all cleaned up, John pulled both yokes off, knocked the seals out of the new adapter. Will pick up new seals tommorrow and should be ready for paint! John also has some yokes to upgrade to bigger u-joints, project is moving along!

Re: My new build thread: Stage 4!
 

OOPS, double post again.

Re: My new build thread: Stage 4!
 

Glad you're really getting going on this thing! Looking forward to following the progress!

Re: My new build thread: Stage 4!
 

Thank's VA! I am really stoked about getting started on this, and my friend John is the key here. He has time on his hands right now and just really wants to help me get my K5 wheeling again. I have gathered up a lot of parts getting ready for this, and now is the time to get going on stage 4! I will post up some pic's asap!

Re: My new build thread: Stage 4!
 

Rainy day here, spent some time indoors working on K5 parts. Reworked a pair of visors I picked up from Sharpie a while back. Visors were in good shape, but one had some issues, fixed. Original visors are still there, but these replacements are way better! A little glue, some paint, armour all, and 43 year old stuff looks real good again!

Re: My new build thread: Stage 4!
 

T-case painted, semi-gloss black, adapter also. Gonna leave the aluminum frt and rear output housings and the rear aluminum cover that way. Looking good, get some pic's asap. John said tommorrow is the day to start tearing out the original axles! YES!

Re: My new build thread: Stage 4!
 

Ripping has begun today! The Dana44 frt axle is out. Also removed the front leaf spring upper bushings and brackets to make way for ORD's FUSH kit. While we were at it took out the stock front spring bump stops, which where useless anyway. Got a lot done in about 4 hours this afternoon. Pulled the 1972 4x4 steering power steering box off, making way for the rebuilt Brothers quick ratio 2wd box. Also completely rebuilt the steering rag joint to go back in. Wow! Pumped to see some actual progress! Here's some pic's!Attachment 1107441

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Re: My new build thread: Stage 4!
 

Nice progress!
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Re: My new build thread: Stage 4!
 

Good for you! It's been a long time coming!

Re: My new build thread: Stage 4!
 

Thank's Turp. Things are looking up here, starting to make some progress, taking advantage of Johns time off. Should make some major advances by the end of the week. Have a bunch of parts stashed for this ready to go. Thank's guy's!

Re: My new build thread: Stage 4!
 

Good day today! Dana60 is under the front of my K5! New steering box with rebuilt rag joint installed. Crossover with high steer mocked up and ready to finish welding the DOM pieces. ORD's Fush kits installed for the front upper spring bushings. Just need to weld on the driver side spring mount to the axle housing and tighten down the u-bolts! Very happy, John really got a lot done today and it is looking really good! Here's some pic's!Attachment 1108231

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Re: My new build thread: Stage 4!
 

Looking good....and tough!
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Re: My new build thread: Stage 4!
 

You say you have to weld on the driver side spring pad? Did you have to replace yours? If so where did you get the replacement?

Josh
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Re: My new build thread: Stage 4!
 

Thank's VA! Litebulb, I think I got it from DIY, But I'll check my records. Way pumped on getting going on this! John is really ripping on my project the last couple of days, wanting to get it be a rolling chassis again! This is what I have been waiting for a real long time!

Re: My new build thread: Stage 4!
 

Yes, liteb, I got the dana60 single front spring perch from DIY4X. Back in 012 it ran me about $26.00 shipped. Yes, John cut the original mount off, and getting ready to mount the new one exactly where it needs to be for my 8" superlift front springs.

Re: My new build thread: Stage 4!
 

Looking at my setup today, I am going to have to remove the dual front shocks. Not going to be enough clearance for the second shock to mount without hitting the brake calipers. No problem, gonna upgrade to some better shocks after the axle swap anyway. Next step to figure out is the 1 ton brake booster upgrade, no real problem, just need to make room. Parts are here and ready!

Re: My new build thread: Stage 4!
 

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Attachment 1108960Yes! Great day today. Dana60 is 89 percent done. Got the dual shock mounts off, just need to remount a pair of shocks and clean up the u-bolts. Also got the crossover DOM welded up, going to get it blasted and painted before final install. Got all that done , and moved on to the rear. Ripped/cut the 12 bolt rear end out. Torched out the rear shackle rivets on both sides and removed them also. Going to have to drop the rear of the fuel tank to install the DIY4X4 shackle flip brackets, but that's no big deal. Got the GM14 bolt mocked up under it to see where John needs to weld on the new spring perches. I also changed out my tall valve covers for some short ones to make way for my 1 ton brake booster upgrade. Very, very, happy to get this much done. Here's some pic's!

Re: My new build thread: Stage 4!
 

It feels good when you start making great progress! With all the parts you have saved up for this you should be able to really continue to move on it!

Re: My new build thread: Stage 4!
 

Right on! Thank's VA! Hoping to have it driveable real soon. It really is nice to see some of these parts that I have had for so long getting installed!

Re: My new build thread: Stage 4!
 

Thanks. I will give them a call tomorrow. Glad to finally see some progress. Really looks like your doing it up right.
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Re: My new build thread: Stage 4!
 

Thank's Litbulb. Off topic. but shot some pic's of a real nice C10 Custom today at the park next door to my house. Owner said okay to snap some pic's, tried to get the women to pose also-but no luck! 1969 C10 LONGBOX, REAL NICE!Attachment 1109259

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Re: My new build thread: Stage 4!
 

U-bolts ordered for the rear today. Should be ready tommorrow, maybe day after, local pickup. Gonna stop after work and pick up a 5 gallon jug of 85/140 gear oil to fill the front and rear diffs. Hopefully be enough to do the t-case and 465 transmission also! It's coming faster than I thought it would, but that's good!

Re: My new build thread: Stage 4!
 

Got the 14 bolt u-bolts today, look real good. Also picked up a gallon of ATF fluid so we can flush out the power steering pump and lines before hooking up the new steering box. John decided he needs to fab up some reinforcing plates/brackets for the rear frame to tie the DIY4X shackle flip brackets into the rear bumper mounts. You guys know there is not much steel there to begin with, and my K5 has had a few rear bumpers mounted on it. A lot of holes in what is left there, and it needs to be beefed up for the rear bumper John is going to build for me. That way we only need to drop the rear of the fuel tank once, instead of a second time when we install the new rear bumper. John is heading out camping tommorrow for the holiday weekend, but his youngest son will be at the shop, working on his rollcage setup. I'm going to spend some time there grinding the frame in places to clean it up and do some primering and painting of the frame and parts. Oh, almost forgot-John got the crossover and high steer setup blasted, painted and installed today! Looks great!

Re: My new build thread: Stage 4!
 

Not much done here today. I did dig the gas tank skid plate out and clean it up real good. Got it powerwashed and I will primer and paint it tommorrow. Skid plate and tank are both out of a 1972 Suburban I picked up for parts years ago. Tank is the same for a K5, except I cut the fill neck off shorter. No problem there, been running it for years. Just wanting to get the skid plate ready to reinstall after we get the rear shackle flip and bumper bracket reinforcement finished.