My 78 K15 High Sierra build - Fish Tremble
 

I've debated whether to do a thread on my build, because its mostly stock and not too exciting compared to many on this forum. Decided to anyway.

I'm not new to working on my cars and trucks, but I am not in the trade (I'm an engineer in the computer industry), and this is my first real build. My kids are now out of college or will be this semester, so I'm starting to have more time if not extra money to do one of these.

I actually started out building a 4wd 1959 chevy swb stepside and made some progress and collected a lot of parts from a few donors, but thats for another thread when I get back on that one. My dad found this 78 GMC and thought it might be a good donor, but I like this body style and owned a couple like it years ago, so decided a straight restoration might be a better first project than the 59 custom project I originally started.

Enough history. This build is a 1978 GMC K15 High Sierra SWB fleetside that is original as far as I can tell. I has a 350, SM465, NP205, 3:07 gears, came with dual saddle tanks and dual exhaust. This may be a good point to claim that "DirtyLarry" made me do it! I love his '78, but not quite ready for the upgrades he's done. Mine's going back together pretty much stock.

First, I really liked this bumper sticker that came on the truck, and plan to keep it and titled the thread for it.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Here are some pics of how it looked when I got it. Not too bad, but rust and dents in a lot of spots. At least it was a complete truck which I've discovered is a big benefit to start with, even if you end up replacing a lot of the parts you've got.

Re: My 78 K15 High Sierra build - Fish Tremble
 

And a few shots of the "designer" interior. Note the matching camo floor and sun visors, the fuzzy dash, and last but not least the custom headliner.:smoke: Think I might stick with this theme --- NOT!

Re: My 78 K15 High Sierra build - Fish Tremble
 

My original plan for this was to just get it safe to drive and to pass an inspection. I already had a project after all so just wanted to drive it while working on my '59 project. Started with things like replacing all the bulbs, wipers, wiper/washer motor, and rebuilt brakes front and back. Discs and drums were too far gone to turn. Front hubs cleaned and regreased, with new seals and bearings.

Re: My 78 K15 High Sierra build - Fish Tremble
 

I've already spent a little over a year on this project and it's going to take me a while to get this thread up to date. Mostly because I didn't organize my pictures too well. For now, I'll say that I never got the truck inspected. Kept getting in deeper and deeper and going a step further. Over the next few days, I'll get this all posted, but today, I've got the chassis pretty close to done and started on the body. Here's how it looks now. Too much invested now to give up, so this is one of the reasons I decided to go ahead and start a thread.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Looks like a great start, I'll be watchimg this one!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Truck ran, but not very well and it was hard to keep running. Somewhere along there, with inspiration from WhiteElephant's thread, I decided I needed to make the truck somewhat reliable, as well as safe. The truck needed new tires to pass inspection and I wanted a bit of a lift so I could go a little bigger. Long story short, I pulled everything off in front of the cab.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Found even more rust than I expected in the front sheet metal. Some shots of both fenders, inner fender and core support.

Re: My 78 K15 High Sierra build - Fish Tremble
 

I'm not thinking "frame off" at this point, but since I had it stripped down, I at least wire brushed the easy to reach parts of the front frame, cross members, etc. and spray bombed them with Rustoleum Hammered Black. I'd also got a 4" Tuff Country EZ-Ride spring lift and installed the front springs.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Cleaned up the Dana44 and hit it with hammered black also. Wish I'd read WhiteElephant's thread a little earlier so I would have thought to replace ball joints and oil seals at the diff housing, but I didn't. Once I knew better, I didn't feel like pulling apart the brakes, hubs, etc. I'd already replaced. Hopefully, that won't come back to bite me. Anyway, here is a before and some afters. I did replace the steering arm with the drop arm that came with the Tuff Country kit. Also, new drag link, cross link? tie rods, steering stabalizer, shocks and engine mounts. Steering gear box is cleaned up and painted, but not rebuilt. Far as I know, it doesn't need rebuilt - we'll see. At this point, I'm really starting to realize how much time on this kind of build is spent on just cleaning parts!:waah: Not really planning to redo the hard lines for the fuel and brakes, so they are still on the truck at this point.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Also cleaned up and painted the sway bar and installed with new Prothane bushings.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Not too crazy about this rake:lol:

Re: My 78 K15 High Sierra build - Fish Tremble
 

Looking good!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks for checking in guys. Clutch hadn't been working right, so I planned to replace it which is one of the reasons I pulled the engine. Turns out, looks like the PO had already replaced the clutch. Went ahead and replaced the clutch disc anyway, along with new clutch fork, boot, ball stud and throwout bearing.

Re: My 78 K15 High Sierra build - Fish Tremble
 

While the engine was out, it got cleaned up and new gaskets for all the external parts like oil pan and valve covers. I originally painted the block chevy orange, but that just wasn't working for me this time. Went with pewter gray and black accessories. I think I am still going to replace the valve covers with something nicer. Also installed new extended brake hoses up front from Rough Country.

Re: My 78 K15 High Sierra build - Fish Tremble
 

I also did all the typical tune up stuff like new plugs, distributor cap and rotor, thermostat, etc. The truck came with a new starter and I replaced the fuel pump. Freind gave me a rebuilt Quadrajet from a 97 vette when I boogered mine up trying to rebuild it. I later redid the fuel line to eliminate the hose.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Next, I decided to attempt to repair the rusted out corner of the core support. I'm a novice welder, and this is my first attempt at thin sheet metal, but it won't show after its back on the truck, so I went for it. The outer part was a piece of cake to get all those bends in using my high-end brake... NOT! The "brake" is shown in the 3rd pic.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Didn't turn out too bad. The last pic is getting a little ahead of myself, but I had a hard time finding a good pic of it back on the truck. The lower frame of the radiator had rusted out as well, so I got a new aluminum radiator and hoses.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Actually, I did find a couple of pictures from that point in the build. The truck didn't come with a fan shroud, but I had one from a 76 Blazer donor for my other project. Cleaned and painted with paint for plastics. Also, the sheet metal for the core support patches came from the roof of the blazer.

By this time, I'm getting really tired of all the "ugly" on the firewall, but had decided I had to draw a line in front of the firewall or knowing myself, I'd have this truck in a million pieces.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Replaced both inner front fenders with repos from LMC. Arrived undamaged, but if anyone knows where to recycle foam peanuts let me know. I have about 30+ cubic feet of them in the boxes the inner fenders shipped in!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Then I decided to take on the fenders, starting with the passenger side. I could (and may still) buy some new ones, but I still wanted to work on my sheet metal welding. Here is one of the worst spots on the inside. 3rd pic is upside down, but to bend all the contours I ended up making 7 patch pieces. Came out ok considering it will rarely be seen.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Then the outside of the passenger fender. Couple patches there. Nothing exciting, but if anyone can tell me why I keep getting these burnout holes behind my welds, I'd appreciate the advice.

Re: My 78 K15 High Sierra build - Fish Tremble
 

looking good!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Nice truck and good work! What sizer tire are you going to run?
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Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks! I'll probably go with a 33" tire (not sure of width yet). I wouldn't mind a 35" and the 4" lift should handle that, but I've got 3.07 gears and hadn't planned to change them now, so not sure I'll be happy with the truck's performance with larger tires. What's on there now are about 30-31". For that matter, I might end up wishing I'd gone with a 2" lift, but we'll see.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Taking me longer to get this thread up to date than I expected - just like progress on the truck itself! Turns out it is a lot easier to read other people's build threads than to organize my pictures for my own. I'll be glad to get it caught up because posting updates while the pics are still on the camera has got to be easier:lol:

Anyway, moved on to the driver side fender. Most of the damage on this one was outer skin. Front lower patch went ok.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Over the wheel was a bit more of a challenge. Making that patch was definitely a stretch of my fabricating skills! I'm starting to remember at this point that I'm a lousy welder. The gobs on the lower lip/flange? are my attempts to fill the holes I was burning. Should have made a new lip rather than trying to weld onto the old one. Doesn't look too bad in the finished picture, but there is a pretty deep crease along the top of the patch that I'm not happy with. I don't think I was patient enough and let the heat build up too much.

Re: My 78 K15 High Sierra build - Fish Tremble
 

The rear lower was a total botch. Might have been the liquid refreshments during breaks that was catching up to me, but I was having a hell of a time burning holes. You'll notice that I'm making patches to fix the large burnouts I was creating, and then having to patch over my patches in the original patch:lol: Not too happy how this job turned out either. I'm thinking I got my practice, and will probably just buy another fender.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Finally called that a done deal and mounted it back on the truck. Remounted the hood also. Initially, the driver corner of the hood was coming down on top of the fender. Managed to adjust it over enough to clear, but gaps were horrible. I think I jacked the cab out of square with the frame while I replaced the front cab mount bushings.

Re: My 78 K15 High Sierra build - Fish Tremble
 

The cab wouldn't move much with the front sheet metal on, even with all the bolts loose. I still needed to replace the rear cab mount bushings also and was just ready to move on to the rear of the truck, decided to just put off dealing with that. So off with the bed, then the rear axle and suspension.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Frame got wire brushed and a coat of the Rustoleum hammered black. New springs and bushings went on. Rear axle got cleaned and painted, new gasket and oil (gears still looked fine). Hard brake lines are just wire brushed clean and reused. I did use a new extended brake hose. Brakes were already done in the initial stage, before this was going to be a "build":lol:

Re: My 78 K15 High Sierra build - Fish Tremble
 

New stance looks much better:metal:

Re: My 78 K15 High Sierra build - Fish Tremble
 

Keep up the good work, I like following this one!
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Re: My 78 K15 High Sierra build - Fish Tremble
 

That is looking great!

Re: My 78 K15 High Sierra build - Fish Tremble
 

Looks good! I like the stance. I had 3.08's in my old blazer with 36's. it was a PIG. So was my current 77 with 3.08's and 32's for that matter...
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Re: My 78 K15 High Sierra build - Fish Tremble
 

Thanks bilfman. You have a great looking truck - looks like it belongs down here in Texas!

Thanks mjensen. Looking at your thread, it looks like we've covered a lot of the same ground... and both computer geeks to boot!

Thanks MTCK. I like a lot of the upgrades you've done to your truck. Don't need all the cold weather improvements for mine, but will have to revisit your thread when I get to round two on my truck - upgrades from stock. I'm also concerned that mine is going to be a dog with these gears, but figure I'll get it driveable first and then figure where to go from there.

Re: My 78 K15 High Sierra build - Fish Tremble
 

Well from one geek to another...keep up the good work :lol:

Re: My 78 K15 High Sierra build - Fish Tremble
 

These are the shocks I put all around. Bought them with the Tuff Country springs. I'd decided I didn't want to use the headers that came on the truck, so I cleaned up some exhaust manifolds from another donor, painted them in exhaust paint, and replaced the studs where the exhaust pipes connect. Later decided to put the headers back on so I could connect the existing exhaust till I could get to a muffler shop.

Re: My 78 K15 High Sierra build - Fish Tremble
 

So by now, things were looking pretty good in front of the cab, and behind it. As I've mentioned, the cab wasn't square on the frame, so I had to remove the front sheet metal again to adjust that. BUT... I just couldn't leave it alone. The parts I'd finished looked too good, and I'd spent a lot of time by now (about 15 months into it by now) staring at the nasty firewall and the 1/2 inch of crud coating the transmission and t-case. I'd pulled the camo floor covering and found a good bit of rust in the floor board and lower edge of the kick panels. Spent about another week arguing with myself about that line I'd drawn on how far I was going to go with this build. You probably can guess what the next post is...

Re: My 78 K15 High Sierra build - Fish Tremble
 

Yes, I broke down and decided to pull the cab so I could finish the chassis. Built a dolly for the cab based on others I've seen on this forum, and some upgrades from previous ones I built for the apache cabs you may have noticed in some of my pictures. This one is stout, and a few screws remove the step-up for a flat top when I need it that way.