Re: Project: 1966 Stepside LWB
 

I think if you tell me we can both fly, I will let you jump off the cliff first !!

Seriously though, I want to do the same thing, but I am keeping in mind that my truck came stock with a 292cid and I am dropping in a SBC 350, so I really wanted to look at how much lower it would sit naturally before I cut any springs....

Yeah I think I will tackle my front end this weekend, maybe starting tomorrow.
With 20 hours of daylight, there wont be much fireworks going on around here anyways .......

Re: Project: 1966 Stepside LWB
 

Ok, so this may be your answer, McMurphy :)

I got really motivated and decided to do the passenger side this afternoon. It took all of Saturday for me to do the driver's side, and I did the passenger's side in about 5 hours! Woot!

First, I removed the brake line, the tie rod, and loosened the nuts on the ball joint shafts. Notice that I haven't used a pickle fork yet to break the mechanical welds between the spindle and the ball joints. You can still see that the spindle hasn't engaged against the top nut.

Re: Project: 1966 Stepside LWB
 

Here they are after I have used a pickle fork to break the mechanical welds. The spring is pushing the upper and lower control arms apart, and taking up slack on the ball joint shafts up to the nut.

You can remove the whole assembly now. No need to mess with anything inside. I wish I would have been thinking last time. This would have saved me some time.

After this, I changed both of the ball joints. The tops is done by cutting the 4 factory rivets and using an air chisel/hamer to knock them out. Grind the tops off if you can't chisel the tops off (I couldn't). Then the lower ball joint requires a press. This is seriously tough if you don't have the right tool. I even had the tool (harbor freight, admittedly) and I spent a long time trying to get the new one pressed in without getting it started crooked.

Re: Project: 1966 Stepside LWB
 

So, I wanted to drop the front about another inch to inch and a half. I did a bunch of reading and I saw that cutting one coil would drop the front about 1-1.5 inches. Well, I decided to go for it and cut a coil out of my springs.

Re: Project: 1966 Stepside LWB
 

And it dropped about 2.75"! :-O

From fender wheel well to center of hub, I'm right at 14 inches now. I wasn't quite trying to go this low, but I don't regret it. It will look pretty slick when I get the back lowered a little also.

Re: Project: 1966 Stepside LWB
 

Man that is totally awesome !!
I like the stance !

I am actually taking today off from my build, but I have the next 4 days to work on it straight...

I like your work man.

Re: Project: 1966 Stepside LWB
 

Ok, it's time to show off all the progress I've made and hidden over the last month!

First, here's a picture of the drop spindles with the 6 lug hub/disc setup that I went with. I didn't add good pictures of this before, but this is what's hiding under those wheels.

Re: Project: 1966 Stepside LWB
 

Here are the drums and spindles that I pulled off. I sold them (for barely anything) to a 15 year old kid a town away that just got his dad's old Chevy. He was super excited to get some brakes, as he was missing a lot of parts. It felt good giving a little bit back to the community.

I also got a shim for my top radiator hose. I was having trouble because my top radiator inlet was 1.75" while my thermostat cover was 1.5", and I couldn't find a flex hose that would adequately adapt down. I put a couple of band clamps on there, but I was still getting a little bit of leakage. This was a gates #26391, and thanks go out to Markeb01 for sending me over the part number and recommendation.

Re: Project: 1966 Stepside LWB
 

I bought the Captain's brake booster bracket and fitted it up. Great quality, great product. Here are some pictures of it mounted to the firewall, in addition to some pictures of my booster/master cylinder setup that I bought complete with proportioning valve.

Re: Project: 1966 Stepside LWB
 

I fitted the booster up to see how I was going to connect it to the pedal. The booster rod was exactly 3.75" too short. I eventually took and cut the rod for the old master cylinder, and used it to extend the rod on the new booster. This allowed me to use the same hardware and setup that was in there originally with the new booster.

The first pic is of the new booster rod coming through the firewall where it would connect to the pedal. It's too short, and this is the piece that I extended.

Re: Project: 1966 Stepside LWB
 

Here I got the calipers and hoses mounted up to the new discs. It took a few tries to make sure that I got everything lined up correctly, but everything fit.

Re: Project: 1966 Stepside LWB
 

Next up, I spent some time getting power steering installed. I did this pretty quickly, and someone more equipped than me could probably do it in 3/4 a day. This took me about a day and a half, but it wasn't nearly as bad as I thought it was going to be.

I bought CaptainFab's power steering adapter plate, which is super quality. Seriously, did a machine make those welds? I've worked with professional welders who couldn't run puddles like these. The captain's kit comes with instructions and a template which is really helpful.

Re: Project: 1966 Stepside LWB
 

Next, I dropped the old power steering unit off. I cut the steering rod 1 3/4" after the existing flange, per the included instructions, just so I didn't have to fight with it while it was still installed. Remember to keep a ball joint separator (pickle fork) around to separate the pitman arm from the steering rack.

You can see in a couple of these pictures that I put new tie rod ends on. The old ones were pretty nasty.

Re: Project: 1966 Stepside LWB
 

I used the template that was included in the kit to mark where I was going to drill my holes for the new power steering box. I cut out the holes where the existing power steering box was mounted so that I could match the template up exactly where I needed and center punch the new hole locations. I also wire brushed the whole area and used some self etching primer to cover up the bare metal.

For one of the holes, it overlaps an existing hole by so much that I couldn't drill it. I used a round file to elongate the original to the point where I could get the bolts through where they needed to be. The kit comes with all grade 8 hardware to cinch everything down super tight.

Re: Project: 1966 Stepside LWB
 

I bought a PS box from a junkyard which was pretty dirty, so I took it down to the self-serve car wash and power washed it. It came out pretty dang good.

I started pulling off all the stuff that I didn't need from the new PS box, and I used my helper to do some of the heavy lifting :)

Re: Project: 1966 Stepside LWB
 

Back to the frame, I fitted the new adapter plate, flange and the PS box up. Everything seemed to fit right up where it needed to.

Re: Project: 1966 Stepside LWB
 

Some more pictures of fitting everything up, and the quality of welds here. The pitman arm that was on the new PS box was in the correct position, so I didn't even have to mess with pulling it off. I was pretty happy about that.

When I bought my engine, it came with a power steering pump and all of the brackets. I don't have pictures of this part, but I put those all back on and put the PS lines on. Everything fired right up, and after some bleeding, I had a really solid PS system. Also, I put a grade 8 bolt through the steering rod to hold the new flange on. I will have it welded up in the near future, but I couldn't wait to try this out. I can steer with one finger now, and it's great!

Overall, this is one of the best upgrades I have done. I definitely recommend that everyone do this if they have even the slightest urge.

Re: Project: 1966 Stepside LWB
 

Back to the disc brakes, here are some pictures of the brake booster rods that I had welded together. I really need to break down and just buy a welder, but I haven't done it yet.

I extended this by 3.75" which put the rod, at full rest, exactly where the bolt hole is on the pedal.

**Question - Do I need to pre-load the brake booster at all? In other words, should I have made the rod extra long to put a pre-load on the booster/MC?

Re: Project: 1966 Stepside LWB
 

I fitted the brake booster on, connected the linkage, installed the MC and new brake lines, and gravity bled all of the lines. I fired everything up and I have front discs now!

So, when I push on the pedal, I was able to push it all of the way to the floor, so I spent another couple evening bleeding and re-bleeding the brake lines. The pedal got a little stiffer, but I am still able to push the pedal all the way to the floor when I really stomp on it. With the motor off, the pedal is really stiff and I am not able to put it all of the way to the floor, but with the booster's help, I still can.

I took it down the street for a test drive (with one hand on the E-brake), and I am able to lock up the tires at about 2/3 pedal, so I have good stopping power, but I am still not comfortable being able to push the pedal to the floor. Any ideas?

Re: Project: 1966 Stepside LWB
 

After I took the truck around the block, I grabbed my helpers (the ones who can walk) and we brought it out to more level ground in the cul-de-sac to get some pictures of the current stance.

Re: Project: 1966 Stepside LWB
 

I'm glad you went with Captain's kit.
He helps out so much in these forums.

Re: Project: 1966 Stepside LWB
 

Yep, I could not agree more. I didnt even consider another kit, and I am glad I didn't. The fit and quality is really good!
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Re: Project: 1966 Stepside LWB
 

I'm glad the PS and PB install went well for you Kevin. Also thanks for posting the pics of your progress, and for the compliments.

As for the brake issue, you might try bleeding all 4 corners once more. You also might try adjusting the pushrod between the pedal and booster out just a little and see if that helps.

Re: Project: 1966 Stepside LWB
 

Kevin that is just awesome!!
I installed my PS pump this weekend too...coincidence is a funny thing LOL.
Looks like your helpers get to enjoy your truck almost as much as you do !!

Good times, those are photos that both those children will cherish later in life for sure!
Looking real good man, real good !!

Re: Project: 1966 Stepside LWB
 

Thanks Captain, I think that's going to be my next item to try. I've already bled the brakes out 3 times, but I may as well go another if it gives me better brakes. I wonder if I moved the brake rod out a little (or a lot), if it would allow for more travel, and thus give more pressure, and a better brake feel.

Thanks again for stopping in, McMurphy! Yep, the kids love to ride around in "Mater" when they get a chance. Glad you got your PS in there. It makes a huge difference, and it was one job that was easier than I thought it would be.

I am in Dublin on business travel right now, so unfortunately all I can do is look at threads on here for the next couple of weeks.

Re: Project: 1966 Stepside LWB
 

I used Captain Fabs plate too, and you are right it was one of the easiest things I have done to the truck so far!! Enjoy Dublin .... especially if you are in the Ireland one .... LOL

Re: Project: 1966 Stepside LWB
 

Haha, thanks! I am in Ireland. Back home to Bellevue, WA mid-month.

Re: Project: 1966 Stepside LWB
 

Man, I've been looking at some of the work that is done on some of the build threads here. When I started this project, I didn't even think of pulling the cab off and blasting the frame, etc. I was so focused on just getting my truck drivable. Now I am thinking that I may do this down the line when I get a lot of the upgrades in that I want, and I have a little more room that I can work with. I also really like the 55-59 body styles, so I may pick one of those up as well. See what you guys are making me do?

Re: Project: 1966 Stepside LWB
 

Did you ever get your brakes worked out.
Did adjusting the rod as Captainfab suggested help?
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Re: Project: 1966 Stepside LWB
 

x2

Re: Project: 1966 Stepside LWB
 

I built my own bracket, and mounted the stock 77 burb booster and MC on my 66 - it all came from the Burb and I have the same Issue - they work but can be pushed all the way to the floor, I have just enough slack so I don't wnat to lengthen the rod and open the MC.

I am going to drill a new hole below the facotry hole - it should give more travel for the same mount of push - Just like the old Nova and Camaros of the 60s 70s they had 2 holes, one for manual brakes one for power - I will post my results here and on my build

Re: Project: 1966 Stepside LWB
 

Hey guys, just wanted to let you know that I have the brakes working just fine. I just had to adjust the stud out and now I have great braking pressure. Bleeding like 6 more times may have had something to do with it also :). I now skid to a stop anytime I want to. I also took some time to readjust the rear drums and ensure that they're engaging fully, so brake problems are no more. I have learned a ton!

Thanks Captain again for the sage advice.

Re: Project: 1966 Stepside LWB
 

It's with a heavy heart that I am announcing that I am selling my truck. I have put a ton of work into it and have learned even more, but some things have changed and I am looking to part with it.

Don't be sad, this is not goodbye. I will do another in the not too distant future, and I am sure I will be back begging for more advice at that time :)

Please PM me if you have advice regarding how I should go about selling this.

Re: Project: 1966 Stepside LWB
 

I struggled with my brakes exactly as you.

The solution was also found exactly like yours.

I also adjusted the rod (stud) to engage the booster sooner.

I honestly think all the bleeding I did just wasted a bunch of fluid. :(

oh well,
All is good now.

Re: Project: 1966 Stepside LWB
 

sorry to hear that you have to part with your truck, I wish you the best, and hope to see you hang around

P.S. I am out in the garage tomorrow morning to start stripping off the front suspension, I thank you again for posting your experience, that helped me a lot with deciding to take the leap with my front suspension.

Re: Project: 1966 Stepside LWB
 

I'm sorry I missed your post of having to sale your truck. But like you said, you'll be back.
Once these trucks get in your blood, you'll always have an aching for one.

Thanks for sharing your time in these forums.
I've enjoyed reading what you've posted.
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Re: Project: 1966 Stepside LWB
 

Wow, what a complete bummer.
I was just thinking of you this past week too, and thought about dreging up your thread to see if we could get an update.

Good Luck Kevin, and thanks again for being an inspiration!

Re: Project: 1966 Stepside LWB
 

Well Kevin, this was a good read and a wealth of info. It was like reading a book with a sad ending.

I have a 1966 stepside short bed that I will be doing the 350 swap and brake booster. This thread has answered so many questions I had. I have a 1990 GMC suburban that I have decided to part out. I am keeping the engine and transmission and anything else I can think of that will switch over. Some of my stuff will have to be a little different because my truck is bagged. But the fact that recorded everything you did with such detail, my work will be much easier.

I too will be looking up capfab for the brake booster mount. Pretty cool how people on here can make these type of jobs so much easier. Best of luck to you and look forward to your next build.