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Re: 66 4x4 my sons new project
I decided to focus on the cab and bed today and take a little break from all the frame, suspension, powertrain work. Plus I have parts all over the place, and I need to start assembling them, just to be sure I don't accidentally give away, sell or scrap something useful.... it has happened to me already!
With help of my faithful assistant, Abby, I put the bed back on the frame. This is helping me remember why I started on this endless project to begin with. http://jase-ace.com/public/photo/196...0Abby%2001.jpg The bed is from a 62 donor truck, so the bed rails have the mount points set for the wider x-frame. I snagged the rails from the original truck's long bed before I sent the rest of the heap to the scrapper. The original bed wood and strips are long gone with just a couple sections of 3/4" plywood for a floor. For some reason the PO decided to put fifty thousand 5/16" carriage bolts down each bed rail, even though the perimeter bolts would have sufficed. Obviously I have been dreading this day as I knew that at least half of these little bolts would be rusty and not spin off. I was surprised that many of the nuts did come off easily, but as luck would have it, almost none of these were the perimieter bolts which are the only ones that I really need to come off. Bummer. The solution is easy though; I'll just cut a few lengths of 1"x1/4" bar and tack weld a whole row of bolts heads to it. Then I can go underneath and beak all the nuts off. Then zip the bolts from the 1/4" strip and start on the next section. Shouldn't take long. Then I had a decision to make: I have three cabs, all with one good feature that the other two don't have, and I have to choose one. - The first cab is on my old 64 2wd is a factory A/C cab, perfect dash, small back window, with barely any rust, but has some sheet metal damage from an accident in a prior life. The damage is not visible from the exterior, and you have to know where to look to see it, but it will always bug me, and isn't easy to fix. - The second cab came from an old PG&E service truck, has a perfect dash with no accessories whatsoever (clean slate), big back window, but has a lot of rot in the lower firewall, floor, rockers, kick panels, etc. - The third cab is of unknown origin. It has a clean straight dash, small back window, and some minor rust near the rockers in the usual places, but nothing drastic. I want a big back window for sure. I drove my 64 around with a small back window for the last 12 years and want to upgrade. So I'll cut the big window panel out and transfer it to one of the less rusty cabs. Now I also have always liked the uniqueness of the factory A/C cab. But I've never had functional air conditioning in my pickup, the center vent is just a showpiece. Moreover I despise the bulky stock HVAC components. The huge unit under the dash takes up a ton of space, plus the huge deluxe heater in the engine compartment is a bear to work around. So I think I'll probably just snag the center piece from my 64 before I sell it and stash it away for use later on. Ultimately I decided to use the third cab since is is the most solid base, convert the big back window, and keep the smooth dash for now, and use block off plates for the cowl and firewall vents. I'll probably use a thrift air setup I have from the 62 donor that has a small heater core and blower located in the cab. I have a set of deluxe heater controls I can swap in and adapt to control the thrift air. http://jase-ace.com/public/photo/196...20Cab%2001.jpg http://jase-ace.com/public/photo/196...20Cab%2002.jpg I really like to look of the smooth dash. An oddly enough I'm really digging the ash tray, since I've never had one before! http://jase-ace.com/public/photo/196...0Dash%2001.jpg http://jase-ace.com/public/photo/196...0Dash%2002.jpg http://jase-ace.com/public/photo/196...0Dash%2003.jpg I pulled the standard heater out, pulled the chopped up wiring harness out, pulled the pedal box out and started fresh. Installed a 20 gallon gas tank (but it has rust and needs to be replaced :( ) and the seat. Put the hydraulic clutch pedal and actuator from the 62 into a 66 pedal box. (More on this later once I get my adapter plate made for the firewall) Disassembled all the pedal pivot shafts and sleeves, cleaned and re-greased everything. Operates nice and smoothly now. Reassembled and mounted the box. |
Re: 66 4x4 my sons new project
Wise choice on the cab there young grasshopper. I like the look of the dash with the addition of a BBW.
When you go to box the frame box it from the firewall forward only and use x bracing from the trans to the rear. IMO . If you remove the bottom spring it will soften up the ride and give you a lot more spring flex. Every thing looks really good , you are doing a assume job. |
Re: 66 4x4 my sons new project
Maybe if I wait until tomorrow Santa will drop a rust free, big back window, A/C cab down the chimney!
Wishful thinking? |
Re: 66 4x4 my sons new project
Help! Someone has stolen my beautiful chassis and left this multicolored hulk in its place!
http://jase-ace.com/public/photo/196...0Body%2002.jpg Not sure which badge to use. I was all set on the 62 badge emblems, but now I kind of like the 66. What do you think? http://jase-ace.com/public/photo/196...0Body%2003.jpg Why on earth the GM engineers decided to make the front fenderwell opening so huge, and the rear opening so small, I'll never know. I have half a mind to grab some spare, rusty front fenders I have lying around and experiment with making a bigger fenderwell on the fleetside bed on my 64, to match the front. Has anyone ever seen this done? http://jase-ace.com/public/photo/196...0Body%2004.jpg http://jase-ace.com/public/photo/196...0Body%2006.jpg I put all the front sheetmetal on because its supposed to rain in so cal for the next week and I wanted to keep the water off of the motor and the chassis. These are all of the exterior panels I plan on using. I didn't get around to mounting the front panel and grill for now. The inner fenders are a test set where I cut away to lower section to give better access for the shock towers I'm tentatively planning to install. It also opens up easy access to the sides of the motor. This sure would make spark plug changes a whole lot easier! Eventually I'll use heavy rubber mat to make a removable curtain to cover the open area and keep water and dirt kicked up by the tire from getting to the motor. http://jase-ace.com/public/photo/196...ender%2001.jpg http://jase-ace.com/public/photo/196...ender%2001.jpg I pulled the steering column from the 64 and put it in the 66. I was so pleased when I bolted it to the column support under the dash and then went to the steering box and found that the column flange lined up perfectly. The column itself is a hybrid of sorts. I replaced the shaft of a 66 column with that of a 68. This resulted in a stock 66 style upper with the double "D" sleeved shaft lower with the breakaway pin. I didn't like the funky radiator support brackets that came on the 4x4 chassis because they never fit right and didn't seem to be at the correct height. So I robbed the pair from a spare 2wd frame and chopped the bottoms off so they'd fit above my front spring hangers. http://jase-ace.com/public/photo/196...acket%2001.jpg I also cut the fron frame horns off of the spare frame. I'll be using these to make a rear frame extension, similar to the suburban and panel trucks, on which I can mount the rear bumper. I'm doing it this way because the bumper on my 64 never seemed sturdy on the little bumper brackets. Whenever I stood on it to reach into the bed it felt like it was flexing. http://jase-ace.com/public/photo/196...Horns%2001.jpg The doors came off of my 64 as well. They're pretty sturdy with minimal rust, but unfortunately the PO cut big sloppy speaker holes in them. When I was in high school I made the carpeted wooden panels for the door bottoms to cover up the two big holes down there and make a nicer mounting place for 6-1/2" speakers. I have a couple of straight door panels to swap on, and I'll be putting an arm rest on both doors. http://jase-ace.com/public/photo/196...Doors%2003.jpg http://jase-ace.com/public/photo/196...Doors%2001.jpg Going to take a break for a couple of days. Visiting the fam tomorrow and going skiing on Wednesday. Happy holidays to all! |
Re: 66 4x4 my sons new project
1) the 62 emblem
2) I have seen threads where the rear wheel opening was stretch but not raised that looked good 3) Merry Christmas / have fun skiing |
Re: 66 4x4 my sons new project
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Re: 66 4x4 my sons new project
if you dont want the multicolor hulk send the hulk on over this way :D
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Re: 66 4x4 my sons new project
I know I have read it in here somewhere, but am at work, so don't have time to find it, but the longbeds have a larger opening for the rear fenderwell. They are close to the size of the front opening. For what reason... I have NO idea! LOL
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I believe the height is the same. |
Re: 66 4x4 my sons new project
Again My hats off to ya,your doing an excellent job,Btw in my earlier post I said I was lookin at a 64 3/4 4x4 350 4spd short-wide,Guess what I went on ahead and purchased it here's a pix,http://i1168.photobucket.com/albums/...psa0bfc288.jpg http://i1168.photobucket.com/albums/...ps2fa80983.jpgcan't wait to get started on it,it's sittin on a 1970 4x4 frame.
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Re: 66 4x4 my sons new project
I don't know if its needed but I would bend the slave cylinder bracket back a hair so the the rod comes out straight, and add a gusset coming off the the lower spacer.
BTW what year slave is that? |
Re: 66 4x4 my sons new project
1985-GMC,
This was my first prototype of the slave cylinder mount based on some rough measurements I had made. I already made a gusset as you suggested, but didn't weld anything as I wanted to check for fit before welding it. It turned out very close. but as you pointed out the rod angle could be improved. I was planning to cut a new plate that shifts the cylinder 1/2" closer in toward the bellhousing. I was also planning to replace my bellhousing at some point because the previous owner of the donor 73 K20 I pulled it from had installed a 6.2 detroit diesel and cut a hole in the drivers side of the bellhousing for the starter :mad: Luckily I found another member on here selling a factory hydraulic clutch bellhousing. This way I can kill two birds with one stone. I'll probably finish the bracket as is and either throw it in the spare parts bin or give it to someone on here who needs one. |
Re: 66 4x4 my sons new project
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That is sweet! Its kind of funny to me that you have a 64 sitting on a 70 frame, only because my dad has a 69 sitting on a 64 frame which is basically the exact opposite! Anyway, it looks clean! And already a 3/4 ton chassis! The front axle looks like an even later model open knuckle dana 44 in front. Does it have power steering too? Start working on that thing and make a build thread, dude! I also like the cab running lights. I have a set of 5 that I removed from a 71 1-ton and I've been debating whether or not I want to cut holes in the roof to use them. |
Re: 66 4x4 my sons new project
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Now I kind of wish I had saved the original orange long bed so I could experiment with adapting front fender openings onto it. |
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Re: 66 4x4 my sons new project
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Here is pops truck! Maybe we should swap bodies! I'm loving my sons project & I cant wait to take it for a test drive:ito: |
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Re: 66 4x4 my sons new project
Awesome build man!! I have a 65 4x4 i'd love to swap out the suspension kinda like yours......
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Re: 66 4x4 my sons new project
Ordered the steel today; 3/16" plate to box the frame, 2" and 4" square tube to make weld-in crossmembers. I guess I've committed to boxing the frame in this weekend. Wish me luck! Yikes!
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Re: 66 4x4 my sons new project
you know the drill , lots of pics
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Re: 66 4x4 my sons new project
Dang, 2'x10' pieces of 3/16" sheet are heavy. I got a good workout.
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Re: 66 4x4 my sons new project
Got sidetracked this week when the rear wheel bearing in my Bronco decided to crack its case, drop metal chips into the rollers and eat into the axle shaft far enough to develop a pretty healthy leak. I woke up to a big puddle of gear oil underneath my tire. What a pain in the butt.
I've only managed to get a few things done on the truck. Tore all the old bed wood and fifty thousand rusty bolts out of the bed, and got the framework bolted back together with the 63-66 rails and 3/4" spacers. I pulled the bed, cab, front sheet metal and powertrain back off the frame to get ready for the frame boxing. All I've managed to get done on the frame are the rear frame extensions for the bumper and hitch mount. I cut the center sections out from a donor frame to make the extensions. I wanted to get these welded on, and get several nuts welded to the inside of the frame so that I can get the plates cut. http://jase-ace.com/public/photo/196...Extensions.jpg |
Re: 66 4x4 my sons new project
The forecast for today was rain, but it stopped early in the morning. It felt good to make some significant progress today.
I finished welding on the rear frame extensions. http://jase-ace.com/public/photo/196...s%20-%2001.jpg Then I put some bracing bars on the frame at the back and the middle, and pulled out the crosmembers. http://jase-ace.com/public/photo/196...e%20-%2001.jpg Then I lifted one of these heavy a** sheets of 3/16" plate up into the frame. http://jase-ace.com/public/photo/196...l%20-%2001.jpg And clamped it to the right frame rail to scribe the outline of the shape. http://jase-ace.com/public/photo/196...l%20-%2002.jpg Then I flipped it over to the left frame rail to scribe that side. http://jase-ace.com/public/photo/196...l%20-%2003.jpg Then I painstakingly cut one of the sides. I must have used a half dozen, 6" cut-off wheels, took about an hour to cut the one 10' length. Does someone want to loan me their plasma cutter??? Please! http://jase-ace.com/public/photo/196...d%20-%2001.jpg http://jase-ace.com/public/photo/196...d%20-%2002.jpg It needs to be ground down slightly in a few spots but it almost fits right in. It is actually nice doing these long lengths. I'll only have one splice in the middle of each rail. I positioned the seam so that the new transmission-transfer case crossmember will straddle the seam. The front sections will be about 5' each, but will be more tricky because of the contour of the rails up front. However it seems that the rails have four distint bends in them. Still working on the plan of how I'm going to get those scribed and bent precisely. |
Re: 66 4x4 my sons new project
are you planning to stitch weld the boxing
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Re: 66 4x4 my sons new project
The plan is to tack the plate in, on top and bottom, all along the frame. Then I'll weld medium-length beads, skipping around so as not to generate excessive heat in any one area. In the end the plate will be fully welded along the top and bottom joints with the frame rail.
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Re: 66 4x4 my sons new project
Really impressive Jason!!! :metal::metal::metal: Keep up the good work! :chevy:
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Re: 66 4x4 my sons new project
Well it turns out I will be moving in a couple of weeks :dohh: and won't be able to work on my truck at the new location. Soooooo I'm going to try to get the truck together as completely and quickly as possible in the next two weeks and hopefully make it driveable.
As a result I'm abandoning the boxing of the frame for now :(. I put all the crossmembers back in, re-torqued the frame and put the engine, transmission and transfer case back into the frame. I also swapped out my old cut up bellhousing with the factory GM hydraulic clutch bellhousing that I picked up from DirtyLarry. Then today I welded on brake hose mount tabs, installed the custom brake hoses I had made over at G&J, then bent and flared all my new stainless lines. I put my fuel line in too. I pulled everything back out to paint the new tabs I had welded onto the frame. http://jase-ace.com/public/photo/196...s%20-%2001.jpg The front and rear circuits end at this bracket, where they convert to flex hose, and will connect to a similar type of bracket on the bottom of the cab, then hardlines will run up the firewall to the master cylinder. Same for the clutch hydraulic line. Sorry for the bad pics, it gets dark too early these days. http://jase-ace.com/public/photo/196...s%20-%2002.jpg At this point I'm just about done with the frame. Left to do is fabricate a crossmember for the rear shock mounts, mount the bumpstops, and cut the rear frame extensions to mount the rear bumper. The original painted bumper I picked up from my uncle (C/10 King) is very clean but was bent and twisted on one side. Last weekend I welded the bumper to some steel beams and bent and twisted it back straight, or at least pretty darn close. So it is ready to go back on once the frame is ready. I'll spend the next few nights this week doing some minor fab in the garage after work to make the firewall adapter plates for the hydroboost unit and the hydraulic clutch master cylinder. And I need to stop into the Truck Shop over in Orange to pick up a whole list of minor things I need for the cab. |
Re: 66 4x4 my sons new project
Nice work, Jason! That is what I call progress...
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Re: 66 4x4 my sons new project
I'm sure you'll get it done.
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Re: 66 4x4 my sons new project
You are awesome son!:ito:
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Re: 66 4x4 my sons new project
Very impressive work. Wish I can learn to weld like that one day.
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Re: 66 4x4 my sons new project
All I can say is wow! Sorry to hear that you can't work on the truck at the new place, but you can come work on mine up here anytime! LOL. Awesome progress and cool project!
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Re: 66 4x4 my sons new project
Did a little work this afternoon. Put the cab and bed back on. Made a plan for my firewall brake line bracket location, and a tentative plan for my exhaust routing. I also modified the firewall, finished the brackets to mount my clutch master cylinder and flipped hydroboost unit.
Here is an excessive amount of photos showing what I did / how it turned out: http://jase-ace.com/public/photo/196...s%20-%2001.jpg http://jase-ace.com/public/photo/196...s%20-%2002.jpg http://jase-ace.com/public/photo/196...s%20-%2003.jpg http://jase-ace.com/public/photo/196...s%20-%2004.jpg http://jase-ace.com/public/photo/196...s%20-%2005.jpg http://jase-ace.com/public/photo/196...s%20-%2006.jpg http://jase-ace.com/public/photo/196...s%20-%2007.jpg http://jase-ace.com/public/photo/196...s%20-%2008.jpg http://jase-ace.com/public/photo/196...s%20-%2009.jpg I located the wilwood clutch master cylinder in the same location as a stock 62 clutch master cylinder. The firewall has little divots in the location where the through holes go, so i drilled those out appropriately for the bolts and the master cylinder. Made a backing plate to spread the load. I also swapped in the brake pedal, pivot and pushrod from a 62. This should give me good alignment for the pushrod. For the hydroboost I made a simple plate for the hydroboost to attach to using the big nut. Then I can mount the plate to firewall. This makes it easy to remove and replace or service later on if I ever have to. I had to open up the through hole in the firewall so that it cleared the large mounting nut. Everything pretty much turned out just like I planned it. This isn't the brake master cylinder I'm planning to use. I'd love to put a nice aluminum wilwood unit right there to match the clutch master cylinder. We'll see if I can convince myself to spend the money. Otherwise a stock late 70s or early 80s corvette brake master cylinder will do. |
Re: 66 4x4 my sons new project
Hey Jason again,Awesome,I believe that's the same color green on your firewall that's the original color on my truck.....
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Re: 66 4x4 my sons new project
Any updates,The weather here has been well winter,so I haven't got to do very much other than take the lockouts from the 3/4 front and put them in the 1/2 ton front.they went right in.so that saved me from lookin and some cash....once I get them switched out then I can start on the body.
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Re: 66 4x4 my sons new project
Whew! Been spending some long days working on the truck, but it seems like when I stand back and look at the thing I can't even tell what I've done! Actually thought I have made a lot of progress.
Brakes I got all the mounting clips for the lines and hoses hooked up so things are looking tidy. I also finished my hydroboost mount plate, and mated up the new hydrobost unit and (from a 79 K30) with a new brake master cylinder (from a 79 Corvette). The master bore diameter is 1.25" which goes well with the ~3" bore diameter "1/2-ton" sized front calipers that I have. http://jase-ace.com/public/photo/196...h%20-%2001.jpg http://jase-ace.com/public/photo/196...h%20-%2002.jpg I still need to cut and shape a new hydroboost-to-master cylinder rod as the Corvette MC requires a shorter pushrod. I resealed my power steering pump and picked up fittings and some dual braided hose from G&J to make the hydraulic lines for the power steering system. http://jase-ace.com/public/photo/196...s%20-%2001.jpg I also picked up a set of these little guys, because I finally ran the numbers and realized there was now way to get the correct front to rear brake bias i wanted while utilizing same size calipers front and rear. The Wilwood B52s are the small bore for the rear. I'd like to use the large bores for the front, and also use a Wilwood aluminum MC to lighten the load on the firewall. but thise will be little upgrade projects for later down the road. http://jase-ace.com/public/photo/196...r%20-%2002.jpg I also have this arrangement of hoses and brackets to connect my firewall hardlines to the chassis hardlines for brake and hydro clutch. I still have to plumb the hardlines from the masters to these hoses. http://jase-ace.com/public/photo/196...s%20-%2001.jpg http://jase-ace.com/public/photo/196...s%20-%2002.jpg Suspension I spent half a day fabricating this stupid little crossmember for the upper damper mounts, and putting the tabs on the axle. I don't know why it took so long but now I have all the Bilstein 5125 dampers mounted, so suspension is basically done. Just need to paint the crossmember and torque down all my u-bolts once I decide I'm happy with the ride height. I also may cange the damper mounting later. This setup has about 8.5" compression travel and about 5.5" extension travel. I think that should be enough? I probably need to look into limit strap and bump stops if I think the leafs will even let it flex that much. http://jase-ace.com/public/photo/196...s%20-%2001.jpg http://jase-ace.com/public/photo/196...s%20-%2001.jpg Chassis Not much going on here. Really, really, really wished I had been able to box the frame. Oh well. Here are a few shots of the frame extensions for the rear bumper once they were done. http://jase-ace.com/public/photo/196...r%20-%2001.jpg http://jase-ace.com/public/photo/196...r%20-%2001.jpg http://jase-ace.com/public/photo/196...r%20-%2001.jpg http://jase-ace.com/public/photo/196...r%20-%2006.jpg http://jase-ace.com/public/photo/196...r%20-%2007.jpg Body I drilled out the spot welds on the two little feet that mount the rear bed sill to the frame and moved them inward. My bed came off of a 62 so the mounts were such to accommodate the wider early 2wd frames. http://jase-ace.com/public/photo/196...s%20-%2001.jpg I actually have a new repop rear sill, but I can't install it because I found out my bed took a nasty hit to the back right corner. When you pull the taillight you can see that the inner tub below the stake pocket, where the tailight housing mounts to, is smashed in. Consequently the rear sill is tweaked and the bottom where they bolt together. There needs to be some serious body work done in this area to make it right, but for now you can't really see it from the outside unless you're looking for it. I trimmed the transmission opening in the cab to accept the manual trans and the new high hump cover. Just waiting for the new, unmolested high hump to arrive in the mail, then i can cut it a fresh opening for the NP205 shifter. I also had the joy of getting out a half dozen seat bolts that were sheared off. Ended up welding new bolts to the sheared ends, then pulling them out. The heat of the weld helps loosen them up a bit too. I tried welding on the bottom at first, but upside down with barely any threads exposed was a main in the ass. There is one I just couldn't get out, so I said forget it and called it good. Heater I cleaned out the recirculating heater from a 62 that I plan to use on the truck. I swapped the hose outlet section with one from a later year deluxe heater so that the hose outlets match up. I also plan on using the deluxe heater controls and just leaving an extra dummy lever for the one I don't need to adjust airflow from the cowl. DO they just put the speed adjustment resistors in here so that the air flow will cool them down? I can't see any other reason for it. http://jase-ace.com/public/photo/196...r%20-%2002.jpg Then I got to thinking though, that perhaps the wimpy little fan blower wonm't be adequate for defrosting and heating the cab when it is really cold out. With the later model deluxe and thrift heaters, once you get up to speed the air pressure form the cowl pushes through the heater core so that the blower isn't really doing much. So I'm going to save the deluxe heater box and parts that I have to that I can convert later if I thin it is necessary. I was just really hoping to get away from the huge box hanging in the engine compartment. Oh well. Does anyone know if there is supposed to be a cover or a louver that mounts on to the deluxe heater tube right here? http://jase-ace.com/public/photo/196...r%20-%2001.jpg Cooling Picked up a new griffin radiator and worked a little last night on mounting it to the radiator support. Six 5/16" mount bolts with standoffs and rubber gasketing should do the trick. http://jase-ace.com/public/photo/196...r%20-%2001.jpg I had some new helpers this weekend too. http://jase-ace.com/public/photo/196...s%20-%2002.jpg http://jase-ace.com/public/photo/196...s%20-%2004.jpg Some little snails that mush have moved into my inner fenders while they were on the ground in the rain. Plus my usual furry friend, Abby. She couldn't wait to ride in the pickup, so the other day when the door was off she tried to jump in. Well, I think she underestimated either the height of the cab or her vertical reach, because she didn't quite make it, got the "Oh ****!" look on her face and I tried to catch her as she fell backwards and rolled onto the ground. Silly pooch! http://jase-ace.com/public/photo/196...r%20-%2001.jpg |
Re: 66 4x4 my sons new project
Looks real good Jason. Excellent craftsmanship. When I was measuring for my front shock mounts, I think I actually had more droop in the front end then compression. Is that up and down travel measurement at the shock? 14" is quite a bit. I think I have the 10" version.
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Re: 66 4x4 my sons new project
Marcus, you are right, 14" is a lot of travel. I should have been more specific. The rear has the capability to cycle 14" based on the geometry of the shock. Whether the leafs will actually flex that much is another question. Plus, having my dampers at such a shallow angle reduces the effective damping when the suspension cycles linearly up and down. All my dampers have 10" of axial travel.
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Re: 66 4x4 my sons new project
Made some progress on the brake, clutch and fuel lines tonight.
A few pics: http://jase-ace.com/public/photo/196...s%20-%2001.jpg http://jase-ace.com/public/photo/196...s%20-%2002.jpg http://jase-ace.com/public/photo/196...s%20-%2003.jpg http://jase-ace.com/public/photo/196...s%20-%2004.jpg http://jase-ace.com/public/photo/196...e%20-%2001.jpg http://jase-ace.com/public/photo/196...e%20-%2002.jpg I still have some ends to flare on the brake lines. I hope to be able to make all the power steering and hydroboost hoses tomorrow night. |
Re: 66 4x4 my sons new project
Very impressive updates. The brakeline work is very professional. Even the snails are too cool.
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