Re: Sarge's rattle-can rebuild
 

If you don't have one already there are body files to shave the filler down before it completely sets. Makes shaping a bit easier.

Re: Sarge's rattle-can rebuild
 

Thanks! Yeah, that's what I was thinking. I'd rather be driving it than working on it, but if it's got issues better to know sooner than when they get worse.

I went to an auto body supply store Friday and told the guy what I was working on, and that I'd never worked bondo before. It'd been nice if he'd mentioned those. It worked out OK though.

Re: Sarge's rattle-can rebuild
 

Getting close. I picked up a small piece of 16 gauge steel from Home Depot to cut some patches out of. I was guessing the size needed and it turned out to be thicker than the damaged area. I used it anyway, can't see what it'd hurt. It probably kept me from blowing through more times than I did. Passenger side a-pillar first. It has one hold I need to tack.

Re: Sarge's rattle-can rebuild
 

This other area is in the drivers side cowl area. Is it just me, or does this rust hole look like a face that's laughing? Rust removed, patch cut, then tacked in. I think I was holding the trigger too long. It was late yesterday when I did this one and when I ground these smooth and went to make another pass around I blew through twice. I don't like chasing mistakes when I'm tired so I put my toys up for the day. I'll get back after it today and hopefully finish the repairs and prime/paint.

Re: Sarge's rattle-can rebuild
 

Nice job, one less worry.

Re: Sarge's rattle-can rebuild
 

Thanks FR. I made some progress today but didn't get as far along as I wanted to. I got both sides done then wiped them with bondo, sanded, and primed. I had hoped to clean and scuff the rest of the windshield channel for a fresh coat of paint but ran out of time. I'll get it this week after work, weather permitting.

Re: Sarge's rattle-can rebuild
 

What'd you use to make such a precise cut - dremel?

Re: Sarge's rattle-can rebuild
 

I used a 4" cut-off wheel on the cuts that follow the windshield channel, but it's too big to go across it due to the depth there. To connect the long cuts I used this bit in my die grinder. I forget what those bits are called, but they move a lot of metal, a bud gave me a handful of them a few years ago. I used the tip of this bit, low rpms, slow and steady.

Re: Sarge's rattle-can rebuild
 

Finishing up this repair, after welding in some patches and grinding the welds smooth I wiped some bondo over both spots to help smooth out the repair. Also, I had two other spots where the metal was solid but rust pitted. There wasn't any point cutting them out but I did want to stop the rust and repair the area best I could, so I treated them with rust converter and let them cure then wiped over them with bondo as well. Then the entire glass channel got sanded, primed, and painted.

Re: Sarge's rattle-can rebuild
 

Real, real happy with the way this turned out. Whoever said I'd rather be lucky than good said a mouthful. The new windshield should be installed today.

Re: Sarge's rattle-can rebuild
 

Like it never happened!

Re: Sarge's rattle-can rebuild
 

Thanks Art. I'm going to try my luck on the floorpans next, I've got three or four smallish rusty spots that need to be cut out and patched. The steel seems to be thicker there so hopefully it's a little more forgiving.

Re: Sarge's rattle-can rebuild
 

Nice work man. That turned out great.

Re: Sarge's rattle-can rebuild
 

Thanks Marcus. I thought I'd have the windshield in by now for the last repair pic but the guy is MIA. I'm ready to drive this thing again.

Re: Sarge's rattle-can rebuild
 

nice work man!

Re: Sarge's rattle-can rebuild
 

Thanks DJ. It's slowly coming around.

Re: Sarge's rattle-can rebuild
 

I just finished this. Not too bad coming out of a rattle can

Re: Sarge's rattle-can rebuild
 

Did you go with the Rustoleum satin black?

Re: Sarge's rattle-can rebuild
 

Hey John. i just glanced over your thread and something came to mind. I'm not sure if you know this or not, but that military green paint is a carcinogen. Be extremely careful when sanding that stuff, and wear a HIGH quality respirator. Just fyi.

Nice work on the truck!

Mike

Re: Sarge's rattle-can rebuild
 

Thanks Mike. I'd read that stuff was terrible bad but I still don't have a good respirator, I'm still shopping for one. I folded a scott's shop towel in half and put it over my mouth and nose with a cheapie dust mask over it and kept a compressed air nozzle at my side to keep the stuff blown away from me. I know that's not a good substitute, but it's what I had. I tried to stay away from the stuff.

I mentioned to you recently your old truck pops up on CL constantly, and I saw it again the other day. This time it's not for sale but it's parked next to a truck that is. That thing is like Waldo. Check out the ad, 2nd pic: http://montgomery.craigslist.org/cto/5577218861.html

Re: Sarge's rattle-can rebuild
 

Good eye! That's funny that you keep seeing it.

Re: Sarge's rattle-can rebuild
 

Yea I did. It worked out pretty good. I use it for every piece now. Will update pics soon

Re: Sarge's rattle-can rebuild
 

I like it too. It's got the right amount of gloss to look like it might have been or could have been factory. Did you use it on your frame too?

Re: Sarge's rattle-can rebuild
 

Lookin good John! Keep at it! :metal:

Re: Sarge's rattle-can rebuild
 

Yea. A little on the frame too. On parts of the frame where it'll be visible. So far so good

Re: Sarge's rattle-can rebuild
 

Thanks David. Now I get to try my hand at floor repair.

I used it under this truck, spent a weekend under it with a pressure washer and maybe a dozen cans of it. It's been a few years now but it still looks good and is holding up great.

Re: Sarge's rattle-can rebuild
 

I wish I could get under there and spray down there. The damn thing is too low. But it's not bad down there anyway. I'm starting to mock up the new tubs and radiator support. And get ready to to drop in the motor this weekend with a lil help from the buddies. Beer and wrenching today!

Re: Sarge's rattle-can rebuild
 

This may be one of my favorite Blazer projects yet. I've never had a good place for the top. The main criteria was out of the way, whether I'm using the top or not. This was simple and worked great. Big thanks to made2drag for stopping by and helping me get if off the truck and on the rack.

Re: Sarge's rattle-can rebuild
 

Bud that worked out great.

Re: Sarge's rattle-can rebuild
 

Thanks Jim. Added bonus there was no rust under the top. I was a little worried about that after finding some under the windshield gasket.

Re: Sarge's rattle-can rebuild
 

Alright now enjoy going topless! It's beautiful over here.

Re: Sarge's rattle-can rebuild
 

Good build. I like the, learn as you go, method. I look forward to doing that with welding at some point too. I also grabbed some hammers and dollies to start tapping out little dents. Completely understand your comment about reverse dents. Did you get some good summer use of of this rig?

Re: Sarge's rattle-can rebuild
 

Thanks, and I sure did. I drive this truck a lot, and I'm guilty of driving it around partially disassembled. Right now the dash pad and gauge bezel is off but I've driven it all summer like that. I figure it'll be ugly and obnoxious until I'm done, and then it still will be to most people anyway. So drive it, right? Here's a pic. I have worked a little at repairing the original dash pad and installing a switch panel into the gauge bezel, they will be ready to install soon, I'll have new updates then.

Re: Sarge's rattle-can rebuild
 

updates?

Re: Sarge's rattle-can rebuild
 

Unfortunately, no. All my free time so far this year has gone to other stuff around the house that needed attention. I'm caught up around the house though, I'll have some updates soon.

I'd planned to finish this truck this year but that probably won't happen now. I've got a new engine for my other K5 that has been sitting in my shop a few years now, I'll get that one running again so at least both trucks are driving.

Too many projects...

Re: Sarge's rattle-can rebuild
 

Hear that! Glad it is still kicking around.

Re: Sarge's rattle-can rebuild
 

truck is really cool glad to hear she will get some attention she deserves it! lol

Re: Sarge's rattle-can rebuild
 

Thanks guys, it's not going anywhere yet. I've got an SM465 I want to install and I've never done a swap like that. My rational side says to put a truck/RV shift kit in the TH400 and forget about it but I want a keeper with a clutch. I'm almost done with the home projects I want to do this year so I'll have time to play with the trucks again soon.

Re: Sarge's rattle-can rebuild
 

:metal: I'm still trying to find the other k5's build thread...... ;)

Re: Sarge's rattle-can rebuild
 

:metal: