Re: My 78 K15 High Sierra build - Fish Tremble
 

Nice install pics!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks y5mgisi - I aims to please. So here are some more. Finished testfitting the Vintage Air system this weekend. I had bought the nice chrome bulkhead connector dealy, but I could not find a spot for it that wouldn't require a) new fittings made or bought to point in the right direction from the evaporator unit, b) a lot of knuckle busting trying get wrenches into tight spaces to fasten connectors, c) trying to maneuver hoses over fittings only a few inches apart. I'm sure that a lot of folks have gone this route successfully, but it was smelling like a lot of aggravation to me!

So, I used the block off plate as a template to mark the hose holes originally intended by VA onto the firewall. I also used that plate to make sure my fittings were oriented correctly to go through the firewall holes when I fit the evaporator back in up under the dash. My wife was nice enough to pick me up a bigger step drill bit when she was in town because the one I had wasn't big enough diameter. Got things mounted up after making the holes and I think it will look just fine. That empty bottom hole will be for wiring to a heater valve. A grommet for it is include in the kit.

Re: My 78 K15 High Sierra build - Fish Tremble
 

I bought VA's bracket kit to move the alternator to the driver side so that I could mount the AC compressor on the passenger side and avoid having hoses run across the engine.

VA did us a big disservice on this bracket. I'm using original drop manifolds on my truck, as well as OEM brackets for the power steering pump. VA's instructions say that if you use the OEM power steering brackets "you may have to trim the front spacer". Doesn't say how much. Apparently they don't figure that the average Joe will have the OEM PS brackets and just include the correct length spacer in the kit. Well, I estimated I needed to grind about 3/16 off the spacer based on visual of the PS bracket. Tried to mount the new alt bracket which bolts into the 1st and 3rd manifold bolt holes. Wouldn't line up to start the bolt. Screwed with this for at least a couple hours. Drilled bracket holes bigger to give more slack (probably not needed in retrospect), ended up removing all the manifold bolts to get the front one to start (the problem one). Bolted the rest of the manifold back on and mounted the alternator. Was pointing way off at an angle. Figure out it was that spacer I ground down. Off it all comes... grind some more... back together... still not right... repeat a couple time! Finally, got the alt pointing forward. That bolt went in easier and easier the more I ground off. Why oh why couldn't they have just included the right length spacer??? I think that I ended up grinding off about 3/8 inch on that spacer when done. I'll have to measure when I pull it apart to paint the brackets. Enough rant for this post, it ended up looking pretty good.

Re: My 78 K15 High Sierra build - Fish Tremble
 

AC compressor went on a "little bit" better. The bracket that went into the manifold holes went on without a problem - no spacer grinding required. Picture in the instructions of the front bracket that bolts into the water pump was a bit misleading in my opinion. 1st attempt was backward. As you can see, the adjusting bolt had no place to go. Off came the compressor, flip front bracket around and all is good.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Time for the condenser. By this point, I'm starting to think I can't be trusted with wrenches anymore:lol: Mounted up the brackets and the dryer. Those with a discerning eye can spot my problem in the first picture. Took me mounting it and seeing it all caddywampus to figure out that the brackets actually do have an up and down (directions had good pictures, but no warnings for idiots like me:lol:). I hadn't even drank more than a beer or two at this point! Anyway, flipped the bracket and it mounted up better - whew, I thought my core support was jacked!!! Also, the grommet going through the block-off plate at the left of the core support would be much easier to put in from the engine side - not much room to maneuver from the front - trust me.

Last picture is a safety switch for the dryer. VA instructions had that as the last step. Why they didn't tell me to mount it on the dryer at the stage I was in my first picture beats me. Tough to tighten it down once the condenser is mounted in the core support.

Re: My 78 K15 High Sierra build - Fish Tremble
 

But all's well that ends well. Really, a few clarifications in the instructions could have saved me literally hours but in the end everything actually fit and looked just fine. I didn't bother with hoses (no AC hose crimper yet), electrical (no wiring in truck yet) or duct work (would all have had to come back out anyway and not anticipating cutting/drilling for those).

Pulled the evaporator back out from under the dash and packed up all the left over parts for final install. Next up, I've got to redo some bodywork on the firewall where welding those evaporator mounting bolts to the inside of the firewall caused filler/primer bubbling and I've got to redo the filler on the door edges where I "fine tuned" them a few weeks ago. Ordered some 2K Urethane primer/surface from Eastwood for the block sanding stage coming up. I'm actually kind of excited about that. Not the spraying and block sanding part, but knowing that after that I should be ready to paint:metal:

Re: My 78 K15 High Sierra build - Fish Tremble
 

What a hassle! Thanks again for sharing so that others might not share the same headaches! And congrats on getting so close to paint!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Looks good! I did the same thing you did and hung the brackets on evaporator/core support upside down on the first try.

I didn't have near as much drama with the brackets, but I used the serpentine belt setup. I did have a little trouble finding a belt that fit. I think the one I ended up using was listed for a Crown Victoria. :lol:

You have one more hole to drill in the firewall if you haven't done it already since your last pic. There is a drain tube for condensation from the unit under the dash. I used a level across the bottom of the unit and made a mark on the firewall. Then I went down about a 1/4 inch to give the drain a little fall and drilled a hole.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Hi, I have actually drilled for the drain tube. On mine, I drilled right at the top of the floor just before it joins the firewall. The firewall actually has about a 1" overhang there so you'll barely see the drain line from the engine compartment. This may provide more slope than necessary, but I believe it was only about an inch drop and keeps it mostly out of sight.

I've still got to find belts for both the alternator and the compressor. The VA instructions do provide suggested lengths and since my engine and accessories are otherwise stock I'm hoping this won't be an issue.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Ah, good idea.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Been a while since I've updated. Just noticed its almost a month. Made little progress in most of that time, but made up for it this weekend. I had redone the bodywork on the firewall (from AC test fit) and the door edges and got the truck shell reassembled again. This weekend started by getting the trim molding fit and drilled the holes in the aftermarket front fenders. Glad I did this before paint as I ended up filling a couple of the new holes when I wasn't happy with the fit.

Yesterday I scuffed the whole truck since the epoxy was well past the 72 hour window, cleaned with wax and grease remover and shot 2 more coats of epoxy. Then 3 coats of 2K primer. She's finally wearing a new color!:cf:

The 2K was setting in the cup almost faster than I could get it sprayed, and I was using a reducer. I literally had to mix enough for the gun, spray, clean the gun and repeat like 12 times. Took a LOT longer than I'd expected but its done.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Looking good! :metal:

Have you decided on paint color yet?

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks Greenlee! I'm still thinking dark camel which actually looks like a bright medium brown and was a color GM used in the late 70's. Got to admit though that flat black doesn't look half bad :lol:

Funny thing is (in kind of a weird way) while I was in the shop yesterday making this truck look nice, my 2002 Tahoe (current DD) was out in the drive just getting pounded by golf ball and larger size hail. Dinged the heck out of the hood and likely the roof.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Rick, that is looking so good! I bet it feels good to be making some forward progress!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Nice work! When do you think you will actually put "real" color on it? I think when (if) i get to that point on my 78, i just might faint from pleasure.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks Mike. Actually, after I finally got done Sunday I felt more like I'd been beaten with a bat, but now that I can stand straight again I am feeling pretty pleased with myself :lol:

Y5mgisi - thanks, I am hoping to be ready to start doing real color in a few weeks. I still have to block sand the whole thing. I am hoping that I'll be satisfied with 1 pass of 2K/block sand, but since this is my first project I guess that is a little unlikely. I foresee a battle to convince myself I'll be ok with a 10-footer and get on with paint.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Sweet! I want to try two things when i do mine. First is to use a product similar to feather fill. From what i gather its just an uber fill primer. The other thing is a random orbital long board. From my research, those to items combine to make the fastest work of the straightest body work.

Re: My 78 K15 High Sierra build - Fish Tremble
 

I've got a Hutchins 3800 Orbital Action Long Board Air Sander (shown post #131). It does work pretty well for fairly large, mostly flat areas. It's a bit of a trick to control though. Not so bad on a horizontal surface, tougher on vertical surfaces.

Re: My 78 K15 High Sierra build - Fish Tremble
 

For some reason i was under the assumption you could mix and refill a paint gun in the middle of a job without cleaning it, figured if the paint stayed wet in the gun you would be ok.. guess i was wrong huh... Nice work!

Re: My 78 K15 High Sierra build - Fish Tremble
 

With epoxy primer, I was able to do just that SwampRat. But this 2K primer was setting up fast enough that it would clog the gun. I do have to admit that after the first couple times I decided to sacrifice the paint cup and lid and just clean the gun body and tip. From what I understand, paint won't have the same quick flash times as 2k primer.

Re: My 78 K15 High Sierra build - Fish Tremble
 

I understand that Harbor freight sells disposable cups for ( at least some of )their paint guns, in case you could use the info..

Re: My 78 K15 High Sierra build - Fish Tremble
 

Can't wait to see some color....

Chris

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks for the tip swamp rat. I found them, and they are the same brand as the gun I was using so pretty likely to have the adapter that would work. $6.99 for 5 of them looks like a good investment. Sure beats cleaning the cup a dozen times in a day! Good luck on your door repair.

You and me both Chris! Can't wait to see yours completed, and for the big reveal when we get to see the whole truck in one picture!

Re: My 78 K15 High Sierra build - Fish Tremble
 

I've got to finishing reading this one but cool build!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks for checking it out!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Hey Rick! Are you done yet? :)

Re: My 78 K15 High Sierra build - Fish Tremble
 

I wish! Nah, haven't posted much lately because I'm just doing a lot (well... maybe not a lot:lol:) of block sanding. That's a tough part of this for me to get real motivated for. Haven't seen an update from you in a while Mike - you getting out to the garage lately?

Re: My 78 K15 High Sierra build - Fish Tremble
 

No, I've had to take a break. It's just too overwhelming right now :-). In the meantime, I've been out playing with the RZR. Oh, and HAD to upgrade my new truck to a duramax lol. I will get back to old blue shortly.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Hey, congrats on the new ride Mike! But where's the picture? And with a ride that nice how is it going to motivate you to work on Ol' Blue? I'm deliberately driving my wife's hand-me-down 2002 Tahoe (freshly beat to hell by hail) with 200K+ miles on it to motivate me to get my truck done:lol: Plus, she won't let me buy an upgrade just to keep me on track :lol:

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks Rick. Well, that is a good point :) I am planning on getting out in the garage today and at least do a little cleaning around the truck so that I can at least see it again :lol: I'll upload a pic in my build. I guess that will show people why I've been slacking LOL

Re: My 78 K15 High Sierra build - Fish Tremble
 

Very nice. im in:metal:

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks! Looks like you'll be driving yours again shortly. I'll be interested in how the stroker you built works out. I only know that my 350 "ran a couple years ago when I parked it" :lol: but I may end up having to build it after I get to the point I can drive the truck.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Not a lot of progress, some sanding but mostly other things taking up my weekends. But, I did pick these up for $45.00 + shipping. I think that's a pretty good price. One of mine "walked off". Tore my shop up looking for it but never found it.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Good deal!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Nice'n Shiny. Good deal.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Nothing picture worthy, but I did have a good day in the shop yesterday. Member Boynton came by last weekend and spent a few hours helping me do the initial blocking of the 2K primer. Really appreciated, and if you guys haven't already done so, check out his builds. He's finishing his third in the time I've been working on this one!

I'd gotten yard chores and stuff done Saturday, so yesterday was shop day. Got a good start at around the crack of dawn, err maybe 11:00ish:lol: The block sanding had shown about a dozen other spots that needed further bodywork, so sand all the 2K off those spots. Mix some filler and slather it onto a few spots. Grab a cold one and called best friend in Indiana while filler set. Sand those down, mix more filler for a few more spots. Grab another cold one and call my brother in NC. More sanding and fill the last few spots. Grab another cold one, decide its time to start the grill for some ribs. Decide I've had enough cold ones I'm likely to cause myself more work if I do any more sanding, so sit there in the front of the shop with the cold one and a fly-swatter watching, smelling the ribs grill. Stereo that evening was radio from back of shop and cicadas tuning up for the evening outside.

That's what I call a good day in the shop! I bet many of you can relate. Not a lot to show for it, but that's how I like to spend my "day of rest":lol:

Re: My 78 K15 High Sierra build - Fish Tremble
 

Not bad at all!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks, It is running great at this time. Im still trying to finish putting the bed on it.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Hey, I just read this whole thread. Really great work, doing some professional level stuff here.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks for looking it over. I appreciate the comment, although I think "professional level" may be overstating for my first project :lol: I have a tough time settling when I think I could do a better job, which is where I am stuck now. I just haven't been able to get happy with all my filler work so keep on re-doing it, but I am really close to being finished now. Decided I've posted enough on bodywork so updates and pics when I actually get some color on the truck.