Re: My 78 K15 High Sierra build - Fish Tremble
 

Closest thing I could find to replace the rubber boot on the steering shaft coupler was a kit from Quadratec for a CJ Jeep. It came with new stuff for inside the coupler (I'm guessing that's what this is called) and it all fit fine. Jury is still out on the boot itself as I bent up the seat plate of it trying to get it onto the shaft. Also got a boot listed for a 70-81 Camaro for the clutch rod. I originally mounted it on the engine bay side of the firewall, but the resting position of the pedal had the boot all scrunched up. I think it will work much better mounted inside.

I hunted and hunted for both these boots listed for the truck but no luck. I think these will both work ok.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Any case, the column is all back together and no spare parts. It did require quite a few trips inside to look at pictures, and a fair amount of head scratching but I think its going to work out fine. I'm guessing that the horn cover didn't come from the factory with screws holding it to the wheel, but its the way it came in this truck. May look for a replacement at some point.

Nice to be able to steer this thing a bit without having to muscle the front tires back and forth :lol:

Re: My 78 K15 High Sierra build - Fish Tremble
 

That worked out great. You should be on the road by next Tuesday!

Re: My 78 K15 High Sierra build - Fish Tremble
 

You funny :lol: :lol:

Re: My 78 K15 High Sierra build - Fish Tremble
 

Power steering is pretty nice, good job!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks Brett! You are SO close to having a roller.

I haven't posted in a couple weeks, but I have been busy. Finished sanding/cutting on the hood and buffed out 1 side. Confirmed what I was afraid of - I have paint stripes. Hard to tell in pictures but they are there and I'd be staring down the length of them when I'm in the truck. I'm going to repaint the hood as well as the fender that the wind blew over. I've got extra paint, just need to get some more clear.

Re: My 78 K15 High Sierra build - Fish Tremble
 

I've been busy on some reassembly stuff as well. I did not clean and paint parts when I did disassembly, so having to do it now and that takes time. Got the hood latch cleaned up and installed with the cable and interior handle. There must be some part that holds the end of the cable. Going to have to find a replacement because I can't find my original part.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Also cleaned and painted the wiper stuff. I bought the wiper motor new before I decided to tear this whole truck down, but it was already rusting. All cleaned up, painted and reinstalled.

I haven't installed the wiper arms yet because the windshield is going to have to be replaced again. Got a crack in one corner. My glass guy said its because the new windshield gasket/rubber is too stiff. Said that all of the brands of new windshield rubber (with corroboration from other installers he knows) are too stiff. Advised never to get rid of the old gasket if its not torn up. They can be cleaned up and reused and are a lot better than the new ones. He got an original used one from a salvage yard to clean up and re-use and said he'd work a deal with me on the next, new glass and install.

Re: My 78 K15 High Sierra build - Fish Tremble
 

I have also been cleaning up and painting all the driver's side door parts. Decided to only do one side at a time so I can use the other side as example of how to reconnect things. I'll show pictures of that when I start reassembly. I forgot to get new gaskets for the exterior door handles and lock, so hopefully that will be next week.

I bought all my new door rubber from GMCPAUL's, a supporting vendor. It's made by Precision. Got the door weatherstrip on. Took all of about 10 minutes to do both sides. No glue required, and holds the mounting lip really well. I hope that the rest of the rubber fits and installs as well as this weatherstrip.

I got myself a good set of wire crimpers, and have ordered split loom and whatever you call the little rings/whatever to mount it to the frame and body panels. Hasn't come in yet, but I won't have any excuse to keep procrastinating on the wiring much longer. For whatever reason, that job is intimidating to me.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Looks great! Wiring isn't too bad, just take your time.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Its all coming together nicely!

Re: My 78 K15 High Sierra build - Fish Tremble
 

I agree slow and steady is the key here.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks for the encouragement guys. I know that once I dive in, it likely won't be any worse than half the other stuff in this build. Just have to quit putting it off - but there are SO many other things that also need doing:lol:

Re: My 78 K15 High Sierra build - Fish Tremble
 

Hahaha. I hear that but trust me you don't want to wait too long because things start to get in the way.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Sucky deal on the windshield Rick. So what is the electrical plan you going to get one of those you build it type kits or? I've always bought the pre built factory type harnesses as replacements for the ones I couldn't or didn't want to repair.

Re: My 78 K15 High Sierra build - Fish Tremble
 

I got an American Autowire kit, which should be mostly plug-n-play, but not entirely. So most of it should go pretty smoothly.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Good stuff! I'll be back on mine when my kitchen remodel is done!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Good luck with the wiring Rick. I also procrastinated on mine, but once I finally gave in and started, I found it to be enjoyable. AAW lay it out so well it makes life pretty easy. My install was far from stock with the LS/non-factory air and other improvements and turned out just fine. Even added some weather pack connectors in places I thought needed a little upgrade. You will be just fine. These trucks really don't have much going on compared to today's cars.

Chris

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks for the encouragement Chris. I realized this past weekend that it wasn't the wiring itself that intimidated me - its that I am not the contortionist that I used to be and I've never been flexible :lol: I did get started though.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Getting it wired and everything working your in the home stretch Rick!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Hilarious! Well after back surgery I wasn't exactly thrilled with the idea of hanging upside down in the cab with my head under the dash and feet hanging out the rear window hole. Somehow, little bit at a time, it was done.
Chris

Re: My 78 K15 High Sierra build - Fish Tremble
 

Well, I've been having loads of fun figuring out where the random brackets and switches go that are tied into the pedal assemblies. Finally think I got the brake light switch mounted right. I'm hoping that it activates the brake lights when the plunger is released by pushing the pedal. As you can see, I've started wiring under the dash as well.

Re: My 78 K15 High Sierra build - Fish Tremble
 

And during disassembly, I found part of a switch (on the left) hanging from the wiring. After looking online for what seems like hours, I'm pretty sure this is a safety switch that keeps you from starting the truck without pushing the clutch pedal in. Ok, so found one and ordered it. Now where does it mount??? More hours online didn't turn up anything. Finally pulled out my 5" thick Assembly Manual with the illegible index this afternoon. After looking through about 1200 pages of it, I found this diagram.

Turns out the little 'j' hook thingy on the end of the plunger doesn't actually hook to anything. It's a spring loaded thingy that is intended to be pushed through a hole on the clutch pedal. Then the switch bolts through the square hole above and to the right in the picture. Looks like it needs a special plastic bolt. Found one online that matches the part number in the assembly manual but says its for 79-84. Hope it works - for $10.00 I went ahead and took a chance and ordered it.

The bracket was a whole other mystery. Turns out is is 1 of 2 of these brackets and mounts where the steering column collar bolts to the pedal assembly bracket. Allows you to bolt the dash sheet metal to it to stiffen the dash face. Had to drop the column again and loosen the brake booster in order to get it installed.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Since I'm having to order small parts every time I turn around, I'm working on more than 1 thing at a time. Been working on the driver side door. Figured out how to reattach all the rods to get the latch, lock and handles to work. Also got the regulator and window in. Little stiff closing the door with the new weatherstrip, but I think it fits well.

Messed up the piece of rubber that has to rivet to the vent window so had to order another. Otherwise, its close to ready to go in as well. I haven't started the passenger side yet in case I need to look at parts for reference.

One of my son's friends called these my "man cave curtains" :lol: Thought I'd share. Spread the old harness out so I could find the miscellaneous grommets, connectors, etc. in case I need them.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Good progress. I can't recall how that clutch safety switch is mounted, sorry.