Re: My 78 K15 High Sierra build - Fish Tremble
 

Some of what I'd been staring at that just had to be dealt with. Didn't really capture all the rust in the cab floor at this stage of the build, but most of you have seen it yourselves. I'm getting close to being caught up to where I am on this build. These pictures were from around Christmas time last year. Heading to the shop to do some work on the truck rather than this thread.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Looks good! You'll be glad you did it when it's all done... That dolly is a good idea. I bet some 35's will look just right with your lift, if you're going to regear down the road anyway. There is always the granny low to get rolling ;) Keep up the good work.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Tonight's posts are not all in the order I progressed. These are before and after of the transmission and tcase. My daughter came home for a visit and decided she'd rather help me clean parts than go shopping with mom, so she's helping scrape off the grunge.

Re: My 78 K15 High Sierra build - Fish Tremble
 

I don't have the tools or knowledge to rebuild these, so after we cleaned them up, they went to a drivetrain shop. First pic is after we cleaned them up, and then the "afters". At this point, I'm still debating whether to try to convert over to a hydraulic clutch from the manual setup you can see here. I'm sure it won't be any easier to do it after I get the truck further back together.

Re: My 78 K15 High Sierra build - Fish Tremble
 

While the transmission and tcase were out for rebuild, I worked on the fuel system. I wasn't able to start the engine, and when I pulled the fuel line off the carb and cranked, I got nasty orange stuff squirting out. I had a new fuel filter, so hopefully that crap didn't get into the rebuilt carb. Probably could have cleaned and relined the tanks, but found the Spectra Premium tanks (PN GM11A) on RockAuto for about $75 each and figured it was pretty cheap insurance to use new tanks. I'd seen a number of good reviews on Spectra Premium tanks on this forum and other places. Gas gauge was all over the map so got new sending units, also Spectra Premium (PN FG05B and FG05J for right and left) which cost almost as much as the tanks. Also got new straps.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Also redid the fuel line from the mechanical pump to the carb using my new tubing bender from Eastwood. I had previously tried to use a tubing bender I picked up at the local O'Reilly's parts store, but it got bent up worse than the tubing - total POS. This was a real challenge for me, but eventually got it where I was OK with it. The Eastwood bender worked great, the problem was figuring out all the bends. Also had to do a double flare on one end. We'll see whether or not it leaks somewhere later down the road.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Then came mounting the tanks onto the frame. All the donors I'd stripped down had some sort of padding between the straps and the tank. One had asphalt roof shingles, so I figured I'd use that as I had some stuck away. Big tip for anyone doing this. First mount the tanks without the padding. Tighten them down good and use a hammer to tap in the bends as you tighten to shape the straps. Then take it all loose and add the padding. As I discovered, you can spend half the day trying to mount a tank with new straps with the padding in place - there just isn't that much slack available! The shingle padding went in with the smooth bottom side against the tank.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Looks great Rick. Having spent a couple hours the past few days laying on my back cussing, my vote is to do the clutch linkage swap now if you are going to!
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Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks! I'm seriously considering it. Only thing is I've already got all new linkage for the manual clutch setup and haven't even tried it out yet. I've still got time to think on this.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Here are a couple of "befores" of the exhaust on the truck. I was impressed at how they reduced from the muffler output to the size of the tailpipe, and also the patch job:lol:

Re: My 78 K15 High Sierra build - Fish Tremble
 

Originally, I'd planned to get a muffler shop to do this job, but once the cab was off I figured if I can manage to weld together sheet metal, how hard can an exhaust be? Got some MagnaFlow 13215 XL Turbo Satin Stainless 2.25" mufflers and a Flowtech 52525FLT manifold back 2.25" dual exhaust kit from Summit Racing. About $245 for the setup, which I imagine is a good deal less than a muffler shop would have charged. The last bend is just clamped on for now until I get the bed back on and can set the height and cut for length to add tips.

Re: My 78 K15 High Sierra build - Fish Tremble
 

And some finishing up on the fuel system. Finally found some fuel filler hose with the right diameter and 90 degree bend from Classic Industries (PN G2663). These weren't cheap, but I wasn't having much luck finding a universal hose that would work. It was also a pain to find the little breather caps that are on the gas tanks, diffs, tranny and tcase. Having trouble finding the receipt for those to record in this thread, but I'll look a little harder if anyone is interested.

Re: My 78 K15 High Sierra build - Fish Tremble
 

And finally, hooking it all up. I re-used the hard lines mounted to the frame. The truck came with some manual gas tank selector valve mounted in the cab floor, so I didn't know where the original electric valve was supposed to go. I just made my own mounting plate and bolted it to the crossmember for the rear cab mounts. I wanted inline fuel filters between the tanks and selector valve, so spent a couple hours in a couple of part stores opening about 50 boxes to find a couple that came with mounting brackets. Found 1 each in 2 stores, but not exactly matching. They'll do for now. I hope all this works when I finally get a chance to try to fire the engine up again!

Re: My 78 K15 High Sierra build - Fish Tremble
 

I'm not sure I'd do the swap if I didn't need to to clear my shocks. My mechanical linkage always worked great. You will have a few hundred bucks in it when all said and done if you replace the master/slave and line.
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Re: My 78 K15 High Sierra build - Fish Tremble
 

I love this build. You are doing a great job. Fish will tremble once again!!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks for checking back in and for the advice Marcus. The guy who rebuilt my SM465 showed me that the input shaft was pretty badly worn and I'm thinking my clutch problems were the throwout bearing not moving smoothly on it. I don't really expect that once this restore is done, the truck will really be done so I'm sure I'll have opportunities to change things if I stick with the manual setup for now.

I appreciate the encouragement bilfman! It will still be a while before the fish are trembling as I still have all the bodywork and paint left. Then of course, I have to figure out how to rewire the truck and get the interior of the cab back together - that one has me worried!

Re: My 78 K15 High Sierra build - Fish Tremble
 

That's looking real nice!

Re: My 78 K15 High Sierra build - Fish Tremble
 

I haven't found a media blast company close by, so I decided to get my own pressure blaster. Says it is not meant for sand blasting, but got used with sand anyway. I will say that sand is abrasive enough that I've already had 2 blowouts in the media hose, and worn away a couple of tips just blasting my cab.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Here is the worst of the rust I need to deal with. Both floorboards and lower kick panels, couple spots around windshield, and in the firewall.

Re: My 78 K15 High Sierra build - Fish Tremble
 

With this post, I'm pretty much caught up with the highlights of my build so far. I work on the truck most weekends, but only occasionally during the week, so from here out my posts will show progress more in line with the majority of builds. Plus, spring has sprung in SE Texas so yard work chores have already begun, cutting into truck time.

Up next, rust repair on the cab. Also, the transmission I had professionally rebuilt leaks like a sieve when I put gear oil in, so I need to deal with that. I'll probably fix it myself since its already installed and it looks like most of the oil is coming from the side covers.

Last picture is a little engine bling I put on last weekend. Air cleaner is bigger than I expected, but I think it will grow on me if I let it stay;)

Re: My 78 K15 High Sierra build - Fish Tremble
 

Spring has Sprung!! I am jealous. Up here in the great white north we have record snowfall and the highways were closed for hundreds of miles, this was today :( Officially sick of winter.

Keep up the good work, looks great! Lotsa pride going to be in that truck, it isn't a rebuild, more like a ressurection.

Re: My 78 K15 High Sierra build - Fish Tremble
 

I always knew Texas was big, but had no idea it extened all the way to the rust belt! :lol:

Re: My 78 K15 High Sierra build - Fish Tremble
 

I was hoping to see that cab all welded up and back on the truck ;)
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Re: My 78 K15 High Sierra build - Fish Tremble
 

Nah, I'm not quite as young as you are and don't put the kind of hours you did into your resto:lol: I am working on it though. Knew I had a problem with the inner rocker on the passenger side behind the floor brace. Finally, after about 25 spot welds drilled out I found the extent of the problem. Also, the kick panel feeds into this corner and the lower inch of it is pretty rusted out. Trying to figure out how to cut this apart for repair without damaging the rocker, which go-figure, is pretty solid. Momma T's got me putting in raised vegetable beds with irrigation, so that is cutting into my truck time:waah:

Re: My 78 K15 High Sierra build - Fish Tremble
 

This is an amazing project. You sure came a long way from just wanting to get it inspected and putting it on the road. The frame and engine look like a million bucks. I like you patience for attacking all that rusted metal too. Sorry I can't help you with the foam but it made me laugh. Keep up the awesome work.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Tell momma T you'll be able to haul a lot more dirt with a completed truck :) you have a lot more work to tackle than I did. I know it will take a bit more time. Can't wait to see it cruising dow the road.
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Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks for the compliments quadzero! Yes, this project took a whole unexpected turn, but I consider this a practice project and decided I'm willing to tackle some things I would avoid if I were looking to end up with a perfect truck.

I'm ready to be driving it as well boynton. Perhaps you need to make more frequent trips to Houston to help out:lol: Doesn't look like your project gave you any practice at all on rust repair, and you barely scratched the surface helping me with my core support:lol:

Re: My 78 K15 High Sierra build - Fish Tremble
 

Haha you are right, I didn't get any practice with patching. I would love to come help, I'm just trying to find the time. You are going a great job though!!
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Re: My 78 K15 High Sierra build - Fish Tremble
 

The builds coming along nice the frame and everything cleaned up good

Re: My 78 K15 High Sierra build - Fish Tremble
 

Well, not a lot of progress to report for the last couple weeks on the truck. Spent a couple weekends building, plumbing and filling these vegetable beds. Did finish cutting out the cancer on the passenger side kick panel and floor. Placed an order for patch panels because there were more contours than I expected to find.

Decided to patch a relatively small area in the rear floor area where the patch panels I ordered aren't going to reach. Was going pretty well until right at the end when I burned out a big hole (typical for me:lol:). I'll probably cut all that back out and re-patch a larger area. Aren't you supposed to get better with practice???

Re: My 78 K15 High Sierra build - Fish Tremble
 

Are you done yet? :lol:

Re: My 78 K15 High Sierra build - Fish Tremble
 

Not hardly!! I did get around to cutting out a bit more floor and kick panel so the patch panels will be easier to fit today after yard work. Tomorrow is truck day, so hope to get at least one side of the floor done. Pics tomorrow evening (I hope):lol:

Re: My 78 K15 High Sierra build - Fish Tremble
 

Read your comment on Bompensteins build. It peaked my curiosity so I moseyed on over here to take a gander.
I see patch panels in your future. You can do it. I'll be watchin'
Subscribed.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks for checking in Bomp! Your crystal ball is apparently tuned in properly:lol: Spent pretty much the whole afternoon patching the passenger side kick panel. Spent about 1.5 hours just cutting and fitting the patch panel. 1st picture just has enough of it cut off to be able to lay it over the patch area. Then a couple of passes of trimming it down until it just overlapped the hole by about an inch. Since I couldn't trace the edge of the hole on the back of the patch, I traced the shape of the final patch onto the face of the kick panel. Cut that out and drilled a couple more spot welds, and had a patch that fit pretty darn well, if I say so myself:lol: Tacked it in, then took member DWCR's advice and rather than split the distance and tack again like I usually do, I started the new tacks slightly overlapping the edge of the previous tack weld. Worked much better. Ground the welds down, touched a couple of spots and grind some more. Ended up with still a few small gaps/holes, but I was afraid I'd blow them out if I tried to weld anymore. Any case, this is one of my better patches so far, and I'll figure out how to make it look better later.

By the way the cab is sitting on its back on a dolly, so these picture are actually taken from "under" the truck through the gaping hole I've cut out of the floor. I've got that patch, and it will be my next effort.

Re: My 78 K15 High Sierra build - Fish Tremble
 

As you have said, welding is practice, practice, practice. It also helps that you are working with the same material so you can hone your skills. I would suspect that your welder heat setting is too high or that you are holding it too long at the end of your welds. If you don't have a lower setting, try moving a little faster at the end or you can simply use spot-weld technique to patch in small areas. Good luck!:gmc2:

Re: My 78 K15 High Sierra build - Fish Tremble
 

Well, I've been slacking on the truck for a few weeks. My son finally graduated college and we've had family over so between visiting and yardwork not much truck time. I did get a little work done here and there though. Finished cutting out the part of the passenger floorboard I'm replacing. Getting the bad flooring out I've developed a unhealthy hate/hate relationship with spot welds. Every time you think you've got them all, you find more! Also, fitting a patch on 3 different planes is a pain. It's getting close, but I've ended up with some gaps that are going to be tough to weld. All in all, this has taken several hours and feels like very little done.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Congrats to your son for graduating.:metal:
I use Cleco fasteners or vice grips to hold the sheet metal nice and tight.
Before long you'll become more comfortable with spot welding floor patches into place. Sometimes I have to get the hammer to persuade the sheet metal into place. It takes time but the prize is the end result, not how quickly you got through it.
Keep at it your doing fine.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks for checking in and for the encouragement Bomp! Really proud of my son. He spent 6 years going through a 5-year architecture program, but also double-majored in history :metal: He's finally rediscovering what "free time" means now that he doesn't have to look forward to hours and hours of projects and model building night after night.

On the driver's side floor, I'll have to see if I can figure out how to use the clecos for this job. I've seen in your build (which I enjoy tremendously - and learn from by the way) how you use them and then cut both old metal and patch together for a close seam. On this panel, I needed the folded over edge and had to do a lot of cutting to even get the patch to lay in there. Unfortunately, after making some of the cuts which allowed the panel to lay better, it didn't lay quite where it had been and left me some wider seams than I intended. I may have to buy another patch and start over, not like this would be my first time doing that... live and learn :dohh:

Re: My 78 K15 High Sierra build - Fish Tremble
 

This build looks a lot like mine, which was supposed to be some repairs done to get Mustard back on the road to pull a horse trailer and ended up a frame off job by a beginner, too. Yours is looking really good, so far!

Congrats on getting your kid through school, too. Took me almost that long to get a 4 year engineering degree...
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Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks Nick! Took a look at your build and see a lot of similarities. I've been slowed way down and still working on my floor a bit here and there. Hope to post some pics tonight. Yesterday got to 106 in the shade here, so hopefully won't be as bad today. No AC in the shop.