Re: 1972 Blazer - 'Bullet' Project
 

I also found an 'easy' way to get rid of the spot welds where the outer rocker, inner rocker and torsion box meet.

I used a sacrificial set of pliers and a hammer to use as a 'sardine can' opener - rolling it along the bottom pinch weld - it came out pretty easy and in a few pieces...just some spot weld remnant grinding to do before getting to welds in this area now.

I was actually surprised how easy this was instead of drilling out all the spot welds (that and I don't own a spot weld drill bit - yet).

I was going to replace the torsion boxes but they are in really good shape now that I am able to see in there.

I will hit them with some rust prevention paint prior to closing them up for good to reduce future issues in this area. :)

Re: 1972 Blazer - 'Bullet' Project
 

For 5 bucks you can get a spot weld drill bit from harbor freight, i've found that if you're easy on them and use a little wd 40 or pb blaster you can get 30 or so spot welds before they break, I just buy 3 or 4 at a time.

Re: 1972 Blazer - 'Bullet' Project
 

If you are interested, we manufacture the Blazer "B" pillar, Blazer rear floor supports, blazer cargo to passenger step down area patch, and the Blazer rocker Box reinforcement plates. We also cary all of the other parts that I see in the pictures that are rotted away. WES

Re: 1972 Blazer - 'Bullet' Project
 

Just picked up a couple of spot weld drill bits and a LOT of patch panels for this project and the 70 2wd Blazer.

69-72 Blazer Rocker Boxes
69-72 Blazer Rocker Box Rear Support Panels
69-72 Rocker Box End Cap New
67-72 Inner Rocker and Floor Extension
69-72 Blazer Rear Cab Pillars
67-72 Truck and Blazer Front Cab Pillar Patch Panel
69-72 Blazer Lower Forward Bed Patch Panel

I got my welder back from my buddy and also picked up a 60 gallon upright air compressor today from Craigs List...that was lightly used in a shop for a few years.

So my arsenal of tools needed is dwindling - :)

Re: 1972 Blazer - 'Bullet' Project
 

OK - so about 2 hours in the cold garage - I now know that I am horrible at doing the patch panel thing...

My cab mount turned out horrible - wrong angle - huge gap...it is better just to replace the whole thing instead of cutting one down?

This crap takes forever...and I haven't even started to think about welding yet...yikes.

I did move my keg-o-rater CO2 tank over to the welder but the output on the regulator and input on the welder are different - so I need to improvise something to make it work [a reducer of some sort].

Anybody have any advice?

Re: 1972 Blazer - 'Bullet' Project
 

lks dcvn, I am in the same boat as you with this rust! Fortunately I have a solid windshield frame, but I have to do all the floor and rocker repairs you are doing. Good luck, I will be eagerly watching your progress.

Re: 1972 Blazer - 'Bullet' Project
 

I'd replace the whole support, no guess work on the angle. It definitely takes forever and a day to build one of these. Check out your local hardware store, not lowes or the depot but your local mom and pop store. Should be some brass fittings there to get you hooked up so you can start melting metal. Keep it up, just one step/job at a time and you'll knock it out. Keep in mind every single cut you make or spot you weld is a job. So after you do it you'll think "man I finally got something done", lol. Its a long road, but you can do it!:metal::5150:

Re: 1972 Blazer - 'Bullet' Project
 

I started off on the cab mount with a repop piece, too, but it didn't have the correct angle where it welds to the inner cab support, so I went with a used GM piece. I've seen pics where vt and jaros did what you're attempting to do, but it looks like a pita. I found that it was hard enough welding that cab mount when it was on the bench.... still in the truck would be near impossible for me. Remember: that lower A pillar patch is going to dictate how well and where your outer rocker is placed. Too high and the door will hit the rocker, too low and you'll have a huge gap. It's 26 3/4" from the front upper fender bolt (in the cowl) to the center of the lower fender mount hole (in the a pillar).

You asked if you'd be better off changing the whole cab mount or just patching it. I changed the whole mount because I had to... they were non-existent on my truck. To change the whole mount you have to: a) drill out all of the spot welds between the floor and the cab mount. b) drill out all of the spot welds between the reinforcement plate and the cab mount/inner cab mount and remove the reinforcement plate (this is easiest done when there is no floor in the way). c) drill out the four spot welds between the cab mount tabs/ears and the vertical section of the inner cab mount. d) drill out the four spot welds between the cab mount and the horizontal section of the inner cab mount (this is easiest done when that little spacer is not in the way). To make a long story longer, I think the way you're doing it is the best way if the rest of the mount is in ok shape, which is probably why vtblazer and jaros did their's this way. You may have to go thru a few of those mounts, though, to get the angle of your cut right. Hey, let's face it, if it was easy, our wives would be doing it. Kidding... just kidding.

Re: 1972 Blazer - 'Bullet' Project
 

I say hook that Co2 back up to the keg-o-rater and drink until it warms up outside...then get back to work on the Blazer, :lol: :lol:

J/K...You're doing great...one step at a time.

Re: 1972 Blazer - 'Bullet' Project
 

Yeah one step at a time. I'm about to be in the same boat, I know my B pillars are junk but I think my A pillars are decent so I can't offer you advice there but i've gotten some sheet metal welding experience recently and I can tell you that fitment is everything. I'd be tempted if I was you to start over cuz when you begin to weld it you want as little gap as possible. Even if the original metal you're welding to is in decent shape it's still gonna be tough to weld through and you can expect it to blow through if you have any gap at all. I would try to keep the gap to about the thickness of the welding wire if possible to minimize having any issues with it.

Hope that helps.

Re: 1972 Blazer - 'Bullet' Project
 

Dude you're makin some serious progress on the Blazer. Looks like your getting pretty good at this stuff. Come on down, I could use a hand. Ha ha.

Re: 1972 Blazer - 'Bullet' Project
 

I just got back from Key West for the holidays - and I don't go back to work until the 5th of January so I will have all week to get some stuff done on this thing (hopefully).

Re: 1972 Blazer - 'Bullet' Project
 

Way more progress today - :metal: And a few more questions...

I got the cab support dialed in - and then was curious to know where the inner rocker/outer floor extension fell in relation to the other parts...

Nothing is even tacked in yet - just making sure that everything fits together first.

I know that there will be some final trimming on each piece to get the best fit - but for now it all seems close.

Although - when I put the outer floor extension in - it appears to be off about an inch from the drain in the floor and the hump where the seat bolts in - that might just be some trimming along the way though...

More pix in the next post...

Re: 1972 Blazer - 'Bullet' Project
 

the inch difference in the floor patch [before any more trimming/alignment]

Re: 1972 Blazer - 'Bullet' Project
 

Excellent!!! Progress is progress!

Re: 1972 Blazer - 'Bullet' Project
 

Actually, I think VT picked up on that, (post #94) he cut a 1/2 circle around that depression so he could weld to the flat metal of the floorboard

Re: 1972 Blazer - 'Bullet' Project
 

Holy Iron Oxide Batman :lol:

That is one rusty Blazer. My hats off to ya for bringing something like that back from the dead.
Looks like you're staying busy with it. Enjoying the pics.

Re: 1972 Blazer - 'Bullet' Project
 

Firebird - for these parts - this thing is in great shape - it has only been in Ohio for 10 years or so - that is what happens to these things here...

Nothing a welder, a few patch panels, plenty of patience, some rust preventative paint and time in the garage can't fix.

Back to it in the morning...

Re: 1972 Blazer - 'Bullet' Project
 

Hey Tom good work. Keep it up. What patch panels are the outer floor? Where'd you get them? How much. I nee that piece with the hump on the edge. Does that also come with the inner rocker? Let me know. Thanks, Mario

Re: 1972 Blazer - 'Bullet' Project
 

Ya I lived in Ohio for nearly 40 years. Got tired of repairing rust a long time ago and started buying cars out west about 25 years ago and hauling them back.
Decided to just move out here a few years ago and save myself all the traveling :lol:

Well that and I got tired of the Ohio salt eating up all my rust free western cars :lol: Daily drivers would last 4-5 years and turn to dust, then back out west for another one :lol:

I can appreciate all the work you are doing though. I brought a few cars back from the dead. After 6-7 of those you start to really appreciate rust free sheetmetal :lol: It was worth the extra cost and traveling expense even after all those years.

Keep it up though. You are in pretty deep now. Probably too late to interest you in any rust free projects out this way huh??? :lol:

Just kidding, I'm sure it will look sharp when it's done.

Re: 1972 Blazer - 'Bullet' Project
 

Firebird - if you see any solid Blazer/Jimmy tubs - shoot me a PM since the 2wd I bought will need similar surgery down the road.

More progress today - I only take off Fridays in the 'nice weather months' here [June-Sept] to do work on my trucks - I am getting more done in the cold than I did over the summer...oh well.

Mario - the part you are referring to is the outer floor extension piece - it is the inner rocker and about 4 inches into the floor [no more front and rear parts to weld together - this covers the whole length of the truck rocker and floor - where the rust usually is.

I could not get mine to line up enough (on the drain channel and seat bump) so I cut the floor at the edge to butt weld on the original floor. I got it from a FS thread on the board here it has an outback truck parts sticker on it from your neck of the woods - but several vendors have them [TriPlus, Wes, GMCPauls] - run about $60. Here is a link to a pic of them:

http://www.gmcpauls.com/pictures/677...nnerrocker.jpg

I got everything lined up and I think tomorrow will begin my B-Pillar project to see how much I am missing and what I will need to build.

I stopped by my local hardware store and did find a few brass fittings that will be me up and running for welding.

I was going to paint the insides of the rocker boxes to protect them from any more rusting - but when I checked the can from www.nomorerust.com it mentioned not to use it below 35 degrees - I don't even think it hit that as a high today.

Well - nonetheless - here are my pix from today. I didn't get a shot of the trimming I did on the outer floor extension patch - but you can see it in the shot of the top of the floor/support...

After checking out the B-pillar I will bolt/tack weld everything in place then put on the door and fender to check for alignment to make sure that I am on track still.

Then take it all back off and adjust, if necessary, and then start my welding.

I think the other side should go a lot faster once I do one side - so I know what I am working with.

I have a new appreciation for people who do this stuff for a living and I hate anybody who lives in areas where this stuff isn't an issue.

Re: 1972 Blazer - 'Bullet' Project
 

I always have my eyes peeled and hit all the swap meets around Arizona, I'll keep in touch.

Re: 1972 Blazer - 'Bullet' Project
 

Easier to understand why a good body man gets $60+ an hour for that stuff, sure is fun eh??

Guess I better not post anymore pictures of rust free stuff out here if I want to stay on your good side. :lol:

Re: 1972 Blazer - 'Bullet' Project
 

It's looking good!

Re: 1972 Blazer - 'Bullet' Project
 

Hate is such a strong word. :lol:

Re: 1972 Blazer - 'Bullet' Project
 

Thanks dude. It's really looking good.

Re: 1972 Blazer - 'Bullet' Project
 

B Pillar Work...some before and then after fitting the patch panels together...

still no tack welding - I want to be sure that this stuff all fits before doing one weld.

I will need to create some of the floor and 'step up' area on the psgr side...

Cutting out the rocker box reinforcement plate was a good time let me tell you - 4 1/2" angle grinder on my back to get the remnants of that plate out was a PITA for the past few days.

Re: 1972 Blazer - 'Bullet' Project
 

few more pix...taking a break to thaw out and grab some lunch.

high of 23 today and I have been outside for 3+ hours already...brrrr

Re: 1972 Blazer - 'Bullet' Project
 

Way to go...nice work.

Re: 1972 Blazer - 'Bullet' Project
 

Looks good, it's coming along.

Holy moly it was a high of 23 and you're doing this outside??? :thud:

We had a high of about 58 here in Prescott Valley today. My body has adjusted quite nicely since we moved out here from cold country :lol:

Re: 1972 Blazer - 'Bullet' Project
 

Thanks Tim [ChevyMan]

I did about 2 more hours of work out there and then I was too tired of the cold to continue any longer...my knees and back are shot.

I am now working on the B pillar patch and the rear front quarter patch - more fun to follow as I am off work tomorrow as well.

I am working in a non-heated garage with a propane heater next to me and a 500 watt halogen light assisting with the crappy lighting in my garage.

I plan to build a well illuminated, heated multi-bay shop in 2011. I am heading to Alaska in 2010 so that will soak up my garage fund - but it should be worth it - :)

Re: 1972 Blazer - 'Bullet' Project
 

Nice work! Thanks for the pics...they will help me when it's time for me to start on that section of my truck.

Re: 1972 Blazer - 'Bullet' Project
 

Alaska, you can't get enough of the cold can you? I'm sure that is gonna be a great vacation Tom. I'm digging the progress on the Blazer. Can't wait to see more pics. Mario.

Re: 1972 Blazer - 'Bullet' Project
 

Wow that's dedicated.

Are you hand fabbing those floor pans?? Doesn't anyone repop the floor pans for these trucks??

Re: 1972 Blazer - 'Bullet' Project
 

hand fabbing floors - not yet. I have used all the patch panels I can so far...

I did some more work on the b pillar yesterday and neglected to get pix before I came back in the house.

I got it back to solid metal so I could see what I needed to do. Today is my last day of vacation so I would like to get some more done.

Re: 1972 Blazer - 'Bullet' Project
 

Today's progress - more bone chilling time in the garage - high of 28 today - :(

I ordered a set of the floor supports from GMCPaul today [Pic 1] - hopefully they show up by the weekend so I can see how they look mocked up in position - they support the floor area under the corner of the floor where my rust hole is.

I also need to pick up some weld through primer tomorrow/this week since the paint place was closed today by the time I thought of it.

Pix of the progress.

[Pix 2 & 3]

I cut out the floor to test fit the inner rocker patch - came out pretty close. I then mocked up the B Pillar patch and got it cut down close enough

[Pix 4 & 5]

I then wanted to see how the outer rocker looked mocked up so I put it on and got a few pix to show it on the truck...

Re: 1972 Blazer - 'Bullet' Project
 

I also needed to see how bad the rear quarter was so I did some trimming on that to resolve a crappy fix from one of the previous owners [old pix from late fall are the first 2] - interesting fix that they did here [pic of inside of quarter included] - looks like they never even ground the welds down afterward on the outside - just slapped on some filler and then painted it.

I went out to clean, unbent, non-rusted metal and cut from there...

Re: 1972 Blazer - 'Bullet' Project
 

Then I did some hanging of the rear quarter - I haven't trimmed it down yet...

and then a picture from when it was warmer out before I started this project...

I hate cold weather - :(

Re: 1972 Blazer - 'Bullet' Project
 

looking good. Keep at it.

Re: 1972 Blazer - 'Bullet' Project
 

Got my patch panels last night from GMCPaul - I got dinged on the shipping [$17 and it shows up in a $5 small flat rate box] - :( - oh well.

They seemed smaller than I had imagined - but I bolted one up to see how it looked. I didn't take a picture - I was too cold to stay out there too long.

One of my buddies let me borrow his propane heater for the winter - and the thing is terrible - don't get me wrong - it can warm you up if you are standing next to it, but for me to put on the rust paint and the weld through primer I need some warmer temps in the garage.

I just picked up a 125k forced air heater that is propane driven so that should put a bit more heat into the garage for me to work in. I should have that this weekend.

I will give by buddy his heater back with a 12 pack of beer for the 'rental fee' - :)

One day [hopefully before retirement] - I am moving just to be warm year round...I wish my job were portable.