Re: Left for dead: 72 2wd blazer build
 

Well I knew it had been a while since I updated but I didn't know it had been almost 2 and a half months! Im sure some started thinking the blazer really had been "left for dead". The reason why I had not done much updating is because I got a new job that allows me to spend alot less time with the truck but a whole lot more time with the family (which is fine with me). Below are a few things I have done to the blazer since late March.


I pressure washed all of the grease and grime off of the firewall so I could start sanding the area down for primer once the metal work on the firewall is done.
http://i848.photobucket.com/albums/a...r/IMG_3517.jpg


The after shot picture once the firewall was pressure washed. As you can see some of the factory paint was knocked off leaving the factory oxide colored primer.
http://i848.photobucket.com/albums/a...r/IMG_3522.jpg


There was a TON of grime on the frame. Even though the engine was missing when I got the blazer I can assume it was completely worn out.
http://i848.photobucket.com/albums/a...r/IMG_3518.jpg


There is still a little grease here and there that needs to be cleaned off before primer goes down, but everything is much cleaner now.
http://i848.photobucket.com/albums/a...r/IMG_3521.jpg

Re: Left for dead: 72 2wd blazer build
 

Looks much better. I see you had to use the finest setting on the washer to get some of it off...I had to do that on my frame and liked the lines it left all over...

Re: Left for dead: 72 2wd blazer build
 

Looking good! Were you able to find any parts out at pate for it?

Re: Left for dead: 72 2wd blazer build
 

I didn't take any pictures to show on here but I also spent an entire day grinding down welds. It is not a glamerous step of the restoration process but it needed to be done. I also spent a day sanding down my front fenders down to bare metal and coated them with base primer.

Before I finished out the drivers side rocker box replacement I wanted to address the pitted and rusted toe board (Drivers Side).
http://i848.photobucket.com/albums/a...r/IMG_3560.jpg


I know everyone has seen the body shell of the green 72' donor suburban that has been helping this project out. This is a picture of a white 72' suburban shell that has given up some of its parts for the cause as well.
http://i848.photobucket.com/albums/a...r/IMG_3563.jpg


The donor toe board that was removed from the white parts suburban body.
http://i848.photobucket.com/albums/a...r/IMG_3564.jpg



A view of the removed rotten toe board in the 72' blazer.
http://i848.photobucket.com/albums/a...r/IMG_3562.jpg

It isn't welded in yet but this is a shot of the donor panel set into the 72' blazer.
http://i848.photobucket.com/albums/a...r/IMG_3566.jpg



I know it is not alot of work for over two months of time, but the time I have been able to spend with my wife and two boys over the last couple of months has been priceless. I am going out to my dad's tomorrow to work on the blazer some more, and I am bringing alot of parts home to work on at my house to help keep progress going. I will update again as soon as I have more progress to show.

Re: Left for dead: 72 2wd blazer build
 

VA72C10, Thanks! The pressure washer was definately dialed down to a small diameter! I think I used about two gallons of grease remover on it as well. I think about 1/3 of the grease that came off of the blazer ended up on my face and in my hair. :lol:

Shane, Thanks for the comment! I found alot of cool stuff at Pate, but the only things I picked up for the blazer were items that I had bought on the forum and simply picked up at Pate. I am already looking forward to next year.

As you can see my dad and I are putting both of the suburban body's we got from you to good use. You might now want your son to see this thread. He might not like what I have done to his suburban. ;)

Re: Left for dead: 72 2wd blazer build
 

That frame and firewall look soooooo much better. Don't ya just love a clean frame? Nice job...

Re: Left for dead: 72 2wd blazer build
 

looks like a good project

Re: Left for dead: 72 2wd blazer build
 

What is your target date for finishing the passenger side of the floor and rocker?

Re: Left for dead: 72 2wd blazer build
 

1949gmc, Thanks I wish the body wasn't in the way so the rest of the frame could look as clean!

trenz68, Thanks! Its getting there.

Muleman100, It shouldn't take any longer than it does to re cover the seats to a 1966 suburban!:devil:

I wen't out to my dad's on Saturday to work on the blazer. It was a pretty uneventful day. We only got the following done.

- Welded in the donor toe board
-Completely welded in the donor hat channel (previously blocked by rocker box)
-Bolted both aftermarked blazer rienforcement plates into place
-Drilled out front fender to body mount holes
-Installed rienforcement place in F. fender to body mount
-Tacked the bottom of the rocker to the bottom of the outer floor panel
-Bolted D/S seat into place and got all of the mounting holes drilled and brackets welded into place
-Removed the remnants of the old rocker box
-Test fit the replacement focker box into place


Okay I had some pictures to show but Photobucket wants to be a pain in my @$$ like always so I will post them when it decides to work properly again.

Re: Left for dead: 72 2wd blazer build
 

Here is a before pic from February of the drivers side rocker area!
http://i848.photobucket.com/albums/a...IMG_3183-1.jpg


This is a shot of the rebuilt drivers side rocker area as of June 6.
http://i848.photobucket.com/albums/a...r/IMG_3597.jpg

Same area just looking forward.
http://i848.photobucket.com/albums/a...r/IMG_3598.jpg

This is a shot of the rebuilt underside of the drivers side rocker area. This is before the remnants of the old rocker box were removed from the vehicle, and touch up paint was applied.
http://i848.photobucket.com/albums/a...r/IMG_3595.jpg

Re: Left for dead: 72 2wd blazer build
 

nice progress!

Re: Left for dead: 72 2wd blazer build
 

VA72C10, Thanks! It feels good to see one part of this tub that doesn't have rust holes in it.

Re: Left for dead: 72 2wd blazer build
 

Looks great. The more pictures the better. I will be doing a lot of this same stuff

Re: Left for dead: 72 2wd blazer build
 

WOW MAN! A month ago I woulda looked and said cool. I started on this and im AMAZED! Your doing WORK! I wish you could come give me some pointers! Looks great how long has all this taken you? Thanks keep up the AWESOME work!

Re: Left for dead: 72 2wd blazer build
 

JimmyFloyd, Thanks! I will definately keep posting as many pictures as I can.

Oldblue1968chevy, Thanks for the recognition! It has definately been some work.

Re: Left for dead: 72 2wd blazer build
 

I got a chance to work on the blazer a little today. I spent most of the day tearing out all of the rotten panels in the passenger side door area. I belive there was about 20 pounds of rust and dirt that came out of the truck today; and one rats nest.


I got the drivers side rocker box set into place, but my dad threw his back out so we were unable to weld it in today.
http://i848.photobucket.com/albums/a...r/IMG_3602.jpg


It felt so comforting to complete the metal work on the drivers side door and rocker area. Then it felt very deflating to start it all over again on the passenger side. Here is a shot of the passenger side before starting. It was much better than the drivers side when I started on it.
http://i848.photobucket.com/albums/a...r/IMG_3608.jpg


After taking off the rotten rocker panel I was left with the typical rotted out lower door pillar.
http://i848.photobucket.com/albums/a...r/IMG_3610.jpg


At least on this side I was left with enough metal to take pictures for references.
http://i848.photobucket.com/albums/a...r/IMG_3611.jpg

Re: Left for dead: 72 2wd blazer build
 

I was able to get the outer section of the old floor out today and cut the reproduction outer floor section down to size. I would have been able to get it tacked in today if it weren't for my dads bad back and a rotten hat channel.
http://i848.photobucket.com/albums/a...r/IMG_3613.jpg


Since I couldn't tack any new metal in I continued cutting out rotten metal. I tore down to the 1/4 panel brace. I was hoping it would be in good shape but it was rotten as well. So I cut it out to use as a template on making a new one.
http://i848.photobucket.com/albums/a...r/IMG_3615.jpg


I was thinking I might be able to keep the original rocker box in place and just patch it but it is pretty pitted so now I am thinking it will be replaced. I know this doesn't sound like alot but that was a days work! Hoping to make more progress soon. Here is a parting shot of the way she looked when I left her today.
http://i848.photobucket.com/albums/a...r/IMG_3616.jpg

Re: Left for dead: 72 2wd blazer build
 

Thumbs up for taking on a project most guys would have probably sent to the crusher or stripped for parts...

You do great work, especially the repair work you did on the rusty cowl, nice....

Re: Left for dead: 72 2wd blazer build
 

68,69 K20, Thanks for the compliment! It's been alot of work so far, but still alot of fun.

Re: Left for dead: 72 2wd blazer build
 

WOW! I just stumbled across your build here, and dang you sure are going the extra mile on reviving that Blaze! Very interesting to read, and see all of your progress photo's.

Keep up the good work, and I can't wait to see it all come together now!

Subscribed :)

Re: Left for dead: 72 2wd blazer build
 

Vectorit, Thanks! I am trying to show as many pictures as I can for both information and entertainment value. Whenever I am done with the blazer I plan on starting on my 72' suburban. It should be a cakewalk compared to this old girl!

72' Deluxe, with factory 402 big block. A spectator at the local cruise night called her "The Battle Wagon". I liked the name so thats what I now call her.
http://i227.photobucket.com/albums/d...n/IMG_1060.jpg


Not much in the way of rust. A little over the windshield, but that is it. Those specs you see aeren't small rust holes but little tar balls. They come from Texas asphalt roads that get so hot in the summer they make your tires sling up tar goop.
http://i227.photobucket.com/albums/d...n/IMG_1061.jpg

Re: Left for dead: 72 2wd blazer build
 

I got back out to the shop this weekend and made more progress! The first thing I did was get rid of all the rot in the rear door panel. As you can see it did not leave a whole lot left. I'll admit at this point I was wondering where to base dimensions on how to place things back into place.
http://i848.photobucket.com/albums/a...r/IMG_3627.jpg


I figured the piece that would be the hardest to screw up would be the vertical flooring, so I started the rebuild process here.
http://i848.photobucket.com/albums/a...r/IMG_3645.jpg


Next I started the long task of rebuilding the 1/4 panel to door jam brace. It is no where near as pretty as the repro's (or the D/S one I made) but I really need to put that money in other parts of the blazer.
http://i848.photobucket.com/albums/a...r/IMG_3626.jpg


After getting the 1/4 panel brace welded in I got the rear door pillar patch welded into place.
http://i848.photobucket.com/albums/a...r/IMG_3646.jpg

Re: Left for dead: 72 2wd blazer build
 

While the blazer has come a good ways I still feel that everywhere I look there are rust holes. Here you can see rust holes in the front floorboard area where the hat channel goes.
http://i848.photobucket.com/albums/a...r/IMG_3647.jpg

Fortunately I still had the donor flooring left from that old truck cab and it was in good shape. It also had a solid hat channel on it so I replaced both pieces at once.
Here is a shot of the blazer floor once the rotted hat channel and flooring had been removed.
http://i848.photobucket.com/albums/a...r/IMG_3648.jpg


The blazer now has a solid P/S floorboard and hat channel once again.
http://i848.photobucket.com/albums/a...r/IMG_3649.jpg


After I got the hat channel in place I trimmed down the outer floor patch panel and got it tacked in. Once I got this far along I really started noticing that this side of the blazer was really going back together much smoother and with better fitting than the drivers side panels had. I am attributing it to leaving the rocker box in on this side. It is working great as a reference for where the place all of the donor/ patch panels.
http://i848.photobucket.com/albums/a...r/IMG_3650.jpg


Before I called it a day I had just enough time to trim down the kick panel patch and tack it into place.
http://i848.photobucket.com/albums/a...r/IMG_3651.jpg



I was really pleased with the amount of work that got done this weekend. Next time I work on the blazer I am hoping to finish all of the rust repair around the door area and am hoping to finally get the top off of her and see what the windshield frame really looks like.

Re: Left for dead: 72 2wd blazer build
 

nice work on the rust repair...and that burb looks like an EXCELLENT start!!!

Re: Left for dead: 72 2wd blazer build
 

VA72C10, Thanks! I will be glad when I am done doing rust repairs in the door and rocker areas. I feel like I have been working on this part of the blazer for ever. I am not sure how eager I will be to start on the suburban after the blazer is done, I might need a break by then!

Re: Left for dead: 72 2wd blazer build
 

You might be surprised. You may find yourself getting revved up to work on something different.

Re: Left for dead: 72 2wd blazer build
 

You have a break every other weekend.

Re: Left for dead: 72 2wd blazer build
 

hgs_notes, I hope that is the case. I do find myself thinking about things I want to do to the suburban even though the blazer is no where near completion.

Muleman100, HA! I think you forgot how "relaxing" it is when you have 2 under 2 at home!

Re: Left for dead: 72 2wd blazer build
 

your work looks great

I did the same thing to my 67 short box. My only mistake was not aligning the doors on the cab first and then welding the rockers on. If you dont make sure the door fits and has a nice vertical line against the 1/4. Then hanging the rocker horiziontal to the bottom of the door the gaps are really hard to get looking right.

Re: Left for dead: 72 2wd blazer build
 

72MARIO, Thanks! I am definately concerned with what the door gaps are going to look like. On the drivers side I bolted the blazer door on while welding the rocker panel on. Unfortunately the original door is completely rusted out and I am not using it. For the most part it all fit up okay. There was a little rubbing of the door and rocker at the very front. I just hope that the door that I am going to use (cut down truck door) fits up at least as good if not better than the original door. I should find out the next time I work on the blazer.

Re: Left for dead: 72 2wd blazer build
 

I got more work done on the blazer this past weekend. I finished tacking in all of the patch panels on the passenger side of the blazer and got the rocker panel to line up beautifully with the door. Unfortunately I did not get a picture of the finished door jamb area by itself, but here is a picture with the original door in place to help me guide the placement of the rocker panel.
http://i848.photobucket.com/albums/a...r/IMG_3699.jpg


After getting the rocker panel lined up I tossed the original rusted out door to the side, and took the doors off of my factory big block parts truck. Here is a picture of the parts truck door before going under the knife.
http://i848.photobucket.com/albums/a...r/IMG_3700.jpg



I got the doors on the blazer without too much of a problem. However the drivers side door does rub on the rocker panel so I will have to do a little shaving there. Also I still have to convert these doors (70') into 72' doors and I have to put all the blazer hardware onto them. Here is a picture of the former truck doors on the blazer.
http://i848.photobucket.com/albums/a...r/IMG_3701.jpg

Re: Left for dead: 72 2wd blazer build
 

After getting the doors bolted into place I started the task of taking the top off. I have been eagerly anticipating this so I can see how much rust I need to fix in the windshield frame area. I was pretty nervous since every other part of the blazer has had an above average amount of rust.

For once I was happy to see an unexpected lack of rust! I didn't even find one pinhole on the top of the frame. This part of the project should be a breeze to repair.
http://i848.photobucket.com/albums/a...r/IMG_3705.jpg


I was expecting to find quite a bit of rust hiding out under the top on the bedsides. Again I was happy to find only one problem area. It is a good size rust spot but I will repair it with a donor section from a truck bed.
http://i848.photobucket.com/albums/a...r/IMG_3708.jpg


Thats all I got done this week. Below are some pictures of the blazer with the top off. My dad said taking the top off made it look even shorter.
http://i848.photobucket.com/albums/a...r/IMG_3704.jpg

http://i848.photobucket.com/albums/a...r/IMG_3711.jpg

Re: Left for dead: 72 2wd blazer build
 

Wow, It's start to shape up. I wish the po would have had the doors on before he welded the rockers on my Jimmy. They don't even come close. The front of the rocker sticks in at least an inch in front of the doors. Nice work. Looks good.

Re: Left for dead: 72 2wd blazer build
 

Big Block, Thanks for the comment! These definately aeren't concours quality gaps, but for as much metal as I had to remove and build back I am extremely happy with the way it all turned out (even though I have a little aligning left to do).

Re: Left for dead: 72 2wd blazer build
 

I got out and worked on the blazer some more last week on Labor Day. As everyone that has followed this thread knows I have practically replaced all of the metal in the floorboards. Once I got the passenger side rocker panel in I figured I could count everything in that section of the truck done as far as metal work is concerned. As I was sitting back, looking at my achievement I noticed a small quarter sided hole in the bottom of the firewall. I am starting to think the rust is growing faster than my cutting wheel!

The small section cut out of the bottom of the firewall.
http://i848.photobucket.com/albums/a...r/IMG_3796.jpg


The donor piece from a parts suburban trimmed and fit into place waiting for the welder.
http://i848.photobucket.com/albums/a...r/IMG_3810.jpg

As simple as that was it was just the warm up for the most critical challenge in this build. The repair of the dreaded blazer windshield frame! Overall mine wasn't in too bad of shape but it still needs plenty of patching. First step. Go back to the donor cab that I cut the floor out of.
http://i848.photobucket.com/albums/a...r/IMG_3813.jpg


It was a little harder to cut out than I thought because without the floor the cab immediately buckled but I got the needed section out!
http://i848.photobucket.com/albums/a...r/IMG_3815.jpg

Re: Left for dead: 72 2wd blazer build
 

I feel bad destroying a cab that still had/has so many good panels in it but I know its all for the best. Heres the rest of the rest of the cab parts cast out to the boneyard with the rest of the parts vehicles.
http://i848.photobucket.com/albums/a...r/IMG_3814.jpg

The next thing I did was cut out all the areas of the passenger side windshield frame that had rust holes or any weak metal. My plan is to cut out a donor panel from the truck cab and weld it into the blazer as a single piece.
http://i848.photobucket.com/albums/a...r/IMG_3817.jpg

Heres a shot of the back side of the trimmed down windshield frame.
http://i848.photobucket.com/albums/a...r/IMG_3818.jpg

It took the rest of the day but I got the donor piece cut out. It needs slight trimming to fit into the blazer perfectly but it looks like its going to do a great job of repairing the blazer. Unfortunately by the time I got this far along the day was over. I am very eager to get this piece in so expect another update soon.
http://i848.photobucket.com/albums/a...r/IMG_3819.jpg

Re: Left for dead: 72 2wd blazer build
 

Keep up the good work!

Re: Left for dead: 72 2wd blazer build
 

It's gotta end some time!

Re: Left for dead: 72 2wd blazer build
 

Good job saving your windshield . Thats not a job for the faint of heart. keep up the good work.

Re: Left for dead: 72 2wd blazer build
 

VA72C10, Thanks! I will definately keep on keeping on!

PHAT TONY, Thats what I keep telling myself! I have seen others on here take on worse and end with show winners. That always helps me to stay motivated.

SOON2BLAZE, Thanks! I will admit this is the part of the project that has been on my mind the most. I think if I can repair this the rest of the metal work will be a snap.