Project: Kechi AD S10 4.3 auto
 

in keeping with the kansas town names, I picked Kechi, which is just north of me in doo dah.

I really liked the formula I stuck to with wamego, the mantra of "use every part of the buffalo" gave me a really complete and sorted truck that almost every part including the HVAC was available over the counter by asking for a 2003 S10.

I tried to find another 03 donor, it was the last year and they sorted them out by then with MPFI and the LU3 engine. but all I found was a 2002 with the L35. it was as rusted as I have ever seen, but man did it run. this is all there was, no longbeds or shortbeds, literally the only truck with a sub 2k asking price that was above 1998. on another subject, everyone is taking apart s10s, craigslist is glutted with sheetmetal. I needed a good truck at a fair price and this is what $1000 buys.

http://67-72chevytrucks.com/vboard/a...1&d=1550461042

in the pros column this one has solid front end work and a new rad. no matter how I try I have never been able to reuse a used rad, and only one truck has had suspension I thought was good enough to drive on. so these are two big pluses in my opinion, even if I order drop spindles, not needing to replace the whole front end will be nice.

in the con column, it had a little vibration at highway speed and was 100% the double cardan joint that they used on 2000+ ext cab driveshafts. since I have to replace the driveshaft anyway this isnt a big deal except the ext cab got a flange mount pinion instead of a u joint cap. There are conversion flanges, but some cost as much as a different rear. this is a 3.42 open diff, so I will watch for a nice 4x4 blazer axle right up until I need a rearend. its also an ext cab so it will need shortened, one thing I dont really see as a con per se, because I can give it a 117 wheelbase and not a 118.

and thats it for the con column, it drove WONDERFULLY and quiet, I actually drove it around last week to make sure it was thoroughly shook. shaken? the exhaust was SUPER quiet, like the belt noise was louder, and I had my suspicions, more on that later.

so lets take it apart. first thing was to put on my roller set of wheels, the original wheels were nice and had brand new tires, they lasted a whole 20 minutes on craigslist. if you have done it before, you can unbolt the front fenders and cut the frame horns right behind the core support and have the whole front end off in about 45 minutes. the rad and condenser stay with the engine too!

http://67-72chevytrucks.com/vboard/a...1&d=1551566840

then the bed

http://67-72chevytrucks.com/vboard/a...1&d=1551566842

then roll it in because its 22 degrees outside haha.

http://67-72chevytrucks.com/vboard/a...1&d=1551566842

this is the first truck that the T47 torx on the seat didnt break on removal

http://67-72chevytrucks.com/vboard/a...1&d=1551566842


then its removal of the interior. my goal here is to get the firewall clean and the HVAC off in one piece.


http://67-72chevytrucks.com/vboard/a...1&d=1551566842


picture limit! see next post for more.

Re: Project: Kechi AD S10 4.3 auto
 

you can remove the s10 HVAC without disconnecting the charge. just take the blower box/condenser off the firewall and unbolt the compressor. there is a single wire to the alternator to disconnect and then with a helper the whole thing comes off and is set aside fully charged.

http://67-72chevytrucks.com/vboard/a...1&d=1551567295
http://67-72chevytrucks.com/vboard/a...1&d=1551567295


then take the cab off, my friend stopped by at the perfect moment to run the forklift. dont forget the shifter cable that goes through the floor! thats what I was doing while he was lifting, guiding it through.
http://67-72chevytrucks.com/vboard/a...1&d=1551567295
http://67-72chevytrucks.com/vboard/a...1&d=1551567295

I didnt need the WHOLE bed, just the floor. choppy choppy.

http://67-72chevytrucks.com/vboard/a...1&d=1551567295

picture limit! next post!

Re: Project: Kechi AD S10 4.3 auto
 

like I said, craigslist is full of sheetmetal, so I picked the parts I could sell and threw away the stuff everyone was trying to sell. I didnt keep much.

http://67-72chevytrucks.com/vboard/a...1&d=1551567638

a little pressure wash then start pulling the motor. this thing was used in a field and it showed, I took about 100 lbs of mud off in my driveway.

http://67-72chevytrucks.com/vboard/a...1&d=1551567638

remember to pull the dizzy and the oil pressure sender! the chain will fall right on them and break both.

http://67-72chevytrucks.com/vboard/a...1&d=1551567638

found the reason for the quiet exhaust. that is one plugged cat.

http://67-72chevytrucks.com/vboard/a...1&d=1551567638

its not possible but its even colder the next day, so in 11 degrees I pulled the motor.

http://67-72chevytrucks.com/vboard/a...1&d=1551567638

picture limit, more to come!

Re: Project: Kechi AD S10 4.3 auto
 

my garage is pretty full of parts but the good news is that I sold about $300 worth, plus $60 from scrap, plus the $250 for the wheels and tires, means I have about $390 in the donor so far. considering I dont need a $500 front end rebuild, or a $200 rad, I would say I am ahead so far!

ready for shortening.

http://67-72chevytrucks.com/vboard/a...1&d=1551568164


I followed bartmans tutorial and it went perfectly, separates easily and chopped 6" out.

http://67-72chevytrucks.com/vboard/a...1&d=1551568164
http://67-72chevytrucks.com/vboard/a...1&d=1551568164

I would have it welded together but the 2002 frame has a couple threaded holes that kept the frame from sliding back together.

http://67-72chevytrucks.com/vboard/a...1&d=1551568164

we are expecting snow tonight, I was planning to go see wayne this weekend with his old trailer in tow, but it may need to wait.

more to come!

Re: Project: Kechi AD S10 4.3 auto
 

oh boy ...another build already underway......looking at your pile of scrap truck parts makes me wonder...I didn't know the s-trucks came with a optional washer/dryer....haha

Re: Project: Kechi AD S10 4.3 auto
 

Damn, you're knocking these out like clockwork now.

Re: Project: Kechi AD S10 4.3 auto
 

Argh, disassembling two trucks to build one looks like a lot of work!

Re: Project: Kechi AD S10 4.3 auto
 

Russ, your not wasting any time on the next start. I'm along for the ride...Jim

Re: Project: Kechi AD S10 4.3 auto
 

Re: Project: Kechi AD S10 4.3 auto
 

And on with the next one..... I can't wait to see what you do with this one!

Re: Project: Kechi AD S10 4.3 auto
 

joedoh-

You need to change your name to "Joedoe"- making all of that $$$doe$$ selling these AD restomods. LOL

You are makingthe rest of us look bad completing so many AD trucks per year!

I guess this is a good source of extra $ income since you have streamlined the process now?

I like how resourceful you have become.

Re: Project: Kechi AD S10 4.3 auto
 

thanks fellas!

jesse, it only took a day and a half to get here. its not as big a hassle with a plan.


65black thats kind of my thing, I always want things to get better and faster. I remember in high school working fast food, closing the grill was a 2 hour job and I whittled it down to 22 minutes and it was better than the 2 hour jobs.


the old project pays for the new one. so really I am just pushing the same stack of dollars around. but rather than sitting around waiting for the perfect time that never comes and the perfect part I can never afford, I am constantly moving and building and having fun. thanks for checking out the trucks!

I have been down with a headache for a couple days, not sure whats going on. wayne isnt answering his phone either. I may take a drive to see whats up.


edit: feeling better today, got the frame trimmed so it would slide back together. it was almost too easy, I kept measuring to see if I had it straight and square but it lined up just right. I welded the top side, I have lots more welding to do on the cab and engine mounts so I will wait till I have that ready to finish the insides and bottom, just in case I run into a gotcha

Re: Project: Kechi AD S10 4.3 auto
 

Off to a running start again, looking good!

Re: Project: Kechi AD S10 4.3 auto
 

Another build! Do you specifically look for 98 and newer s10s?

Re: Project: Kechi AD S10 4.3 auto
 

You make it look too easy.

Re: Project: Kechi AD S10 4.3 auto
 

Joe

Wow wow wow, no grass growing beneath your feet. The important fact is that you enjoy what you are doing and it's FUN !!!!!!! Tell daddy take the T-bird.......

Strong work dude.

Sorry to see "rattle can red" go off into the sunset, thought you might-a hung on to this one a little longer. Oh well as long as the $ meter is working for ya your in good shape.

Keep on keepin on

Nutts

Re: Project: Kechi AD S10 4.3 auto
 

Off to a running start again I see. I've got my '49 on the back burner for now. Going to "finish" the Z28 and then "finish" the '49.

Re: Project: Kechi AD S10 4.3 auto
 

I'm going to follow along I like the way your heading. I always wanted to do a s10 ad truck but I have to finish my c10 first. I have been a s10 guy forever 3 in the drive and just scrapped 2 blazers.The last time I checked you had to have a longbox frame but I see you used the xtended. I'm glad to know that my parts truck is an xtended. My zr2 is xtended but it has a one piece aluminum driveshaft in it.

Re: Project: Kechi AD S10 4.3 auto
 

My goal is to finish my truck before you finish this one.

Re: Project: Kechi AD S10 4.3 auto
 

gabe and nut, thanks!

matt, yes I love the distributed electrical architecture of the 98+ s10, older trucks were point to point wiring. so when I can use a 98+, I will. which is nice too because almost no one else wants them as donors, I know guys that waited a whole year to find a 1987-1990 s10 with the 4.3/700R4 just for the trans.

Marc I get so bored, so quickly. have to keep moving. Good to hear your plan!

Ol skool you can find how to's on shortening the ext cab and stretching the reg cab! the zr2 had a one piece because it was factory lifted, a one piece on a 2wd would rub the cab when loaded.

28tudor, go man go!


did the motor mounts today. kept the offset to the passenger side and used my jigs from the last truck to set the mounts up 16.5" apart at the same height as stock (with the same down angle) and 8.75 inches back.

http://67-72chevytrucks.com/vboard/a...1&d=1552439320
http://67-72chevytrucks.com/vboard/a...1&d=1552439320
http://67-72chevytrucks.com/vboard/a...1&d=1552439320
http://67-72chevytrucks.com/vboard/a...1&d=1552439320
http://67-72chevytrucks.com/vboard/a...1&d=1552439320


picture limit, more in a minute!

Re: Project: Kechi AD S10 4.3 auto
 

finally tracked down wayne, he is all right and just had a knee replaced. I bought FOUR more trucks from him, well, cabs and a couple front ends. :lol:

we pulled kechi from his resting place and loaded him for the trip home.

http://67-72chevytrucks.com/vboard/a...1&d=1552439655
http://67-72chevytrucks.com/vboard/a...1&d=1552439655
http://67-72chevytrucks.com/vboard/a...1&d=1552439655

he was 1/2 full of kansas farmland, and it was tough to get in the nooks and crannies so I just turned him on his nose in the grass.

http://67-72chevytrucks.com/vboard/a...1&d=1552439655


it was raining today, good day to run the pressure washer.

http://67-72chevytrucks.com/vboard/a...1&d=1552439655


funny story. when I was down at waynes with wamego, his barn cat followed us all over the farm looking for attention. when we were in the shop it came up and bit/scratched the ever living crap out of my hand, and when wayne said "whats the matter with you?" it bit/scratched him!

so when I didnt hear from wayne for a while and had that intense headache, I thought for sure the cat was rabid and had killed us both. its funny to laugh at now, but I was in a panic one night and got zero sleep.

best thing, when I picked up kechi, the cat was there crying for attention again and this time I ignored it. well that little b-tard snuck up behind me and attacked my leg! then when I was leaving and opening closing the gate, he was on the flatbed staring at me menacingly. I am a cat person but I almost kicked a field goal. :lol::lol:

Re: Project: Kechi AD S10 4.3 auto
 

last update. I got a cab and front end, I have doors, I had a bed and running boards, but I needed rear fenders and aprons. the swap meet was saturday and I came up with aprons and a front bumper, he ALSO had a GMC core support and a 41-46 lower apron so I picked those up for future use.

http://67-72chevytrucks.com/vboard/a...1&d=1552440371
http://67-72chevytrucks.com/vboard/a...1&d=1552440371
http://67-72chevytrucks.com/vboard/a...1&d=1552440371


then I heard from a local friend who had some rear fenders, he is building a couple 41-46 so I partially traded the apron for the fenders.

http://67-72chevytrucks.com/vboard/a...1&d=1552440676


tomorrow rain permitting I will pop the motor back in after cleaning the front clip.

Re: Project: Kechi AD S10 4.3 auto
 

I decided to do the trans crossmember with the engine out again. still working out the fastest way, I think this works best so far.

first I marked the current location square on the frame then measured 8.75" back. the frame gets narrower so I needed to section out a couple inches from both sides.


second, lets take a look at the passenger side offset that I have talked about before. pretty easy to see with the long straightedge.

http://67-72chevytrucks.com/vboard/a...1&d=1552536921

GM did this to give room for the steering shaft. you can see I respected it when I built the mounts, they are ~1/2" offset and if you blur your eyes you can see the hole in the trans crossmember and the carrier bearing mount all line up with the engine mounts.

Next, I caught a picture of a 2.2 98+ frame on craigslist and noticed the trans crossmember went waaaay back on the passenger side

https://images.craigslist.org/00o0o_...y_1200x900.jpg

I did some measuring and sure enough, it was just right for the 8.75 inch move. I sectioned it and built a plate for welding the narrower crossmember to. on the drivers side I cut a piece of 11ga 1.75" wide and bent the ends in a vise, much easier than the three piece setup I normally use.

http://67-72chevytrucks.com/vboard/a...1&d=1552536923
http://67-72chevytrucks.com/vboard/a...1&d=1552536923

while my welds were cooling I popped out the side plates of the cab mounts.

http://67-72chevytrucks.com/vboard/a...1&d=1552536923


when everything cooled down I power washed it again, wire brushed some of the harder to reach areas of the frame and suspension, and put on some satin black (rustoleum rust reformer)

http://67-72chevytrucks.com/vboard/a...1&d=1552536923


guess what? kechi is BLUE. I think I have remmuluns (how an old boss said remnants) of a blue front clip and definitely have a blue bed, so maybe maybe maybe my first non green truck (wamego was red at the end but green from the plant)

Re: Project: Kechi AD S10 4.3 auto
 

Re: Project: Kechi AD S10 4.3 auto
 

Very nice fab. Fits like The engineers planned it.

Re: Project: Kechi AD S10 4.3 auto
 

Russ, lots of tips for others doing this, looks good...Jim

Re: Project: Kechi AD S10 4.3 auto
 

I believe it "was" the same shade of blue as my GMC.

Ferrara Blue, Dupont code 93-3380

Re: Project: Kechi AD S10 4.3 auto
 

thanks all!

jim I will keep trying different methods. I have made a crossmember, sectioned another few, even store bought a tube one, just to try different things. this one worked really well though!

marc I think yours ls darker, gmc got a special blue for the ADs, and a special green, both were darker. I think this is mariner blue.

no work today, temp dropped to the 30s and I didnt even brave it to put the new motor mounts on. well and beeps is out of school for spring break so we chased each other around the house and made a special dinner for mom.

Re: Project: Kechi AD S10 4.3 auto
 

after a week of muffin making, kid chasing, cold then agreeable, days, I plopped the motor right down on the mounts. worked out grrrreat! (the second picture is the motor mount with a bolt through it, can be hard to make out)

http://67-72chevytrucks.com/vboard/a...1&d=1552789797
http://67-72chevytrucks.com/vboard/a...1&d=1552789797


worked on the cab, got the windshield out and started the firewall mods.

http://67-72chevytrucks.com/vboard/a...1&d=1552789942
http://67-72chevytrucks.com/vboard/a...1&d=1552789797
http://67-72chevytrucks.com/vboard/a...1&d=1552789797


should have the cab mounts on the frame tomorrow, I picked up the cab corners last week so I might do those first.

Re: Project: Kechi AD S10 4.3 auto
 

You're making great time. What is your timeline to finish?

Re: Project: Kechi AD S10 4.3 auto
 

well I hope its driving around by easter. finished some time after that.


got the firewall side welded, still have to do the inside where the bottom welds are.

http://67-72chevytrucks.com/vboard/a...1&d=1552952248

got the body mounts tacked together and on the frame

http://67-72chevytrucks.com/vboard/a...1&d=1552952248

I used the forklift to turn it on its nose again, had to trim the reinforcement on the rear body and remove the shackles, then I plopped it on.

http://67-72chevytrucks.com/vboard/a...1&d=1552952248

rolled it in, but had to roll it right back out because after unbolting the old heater a 20 lb squirrel nest fell out. a brown recluse nest was under the gas tank too, they all had there front legs up and their fangs showing. a little carb cleaner fixed that.

trans trim needs just a tiny more trim.

http://67-72chevytrucks.com/vboard/a...1&d=1552952248

started laying out the pattern for the HVAC

http://67-72chevytrucks.com/vboard/a...1&d=1552952248


valve cover is a 1/2 inch off the firewall, bolts dropped through the mounts (except the one shackle hole with a broken bolt. pretty happy I got it on before the rain tomorrow.

Re: Project: Kechi AD S10 4.3 auto
 

You make it looks so easy! I know, practice makes perfect, but darn you move so fast.

Re: Project: Kechi AD S10 4.3 auto
 

Daaaannngggg looking good! Driving by Easter???? WOW I wish mine would be ready by then.

Re: Project: Kechi AD S10 4.3 auto
 

Ok...Easter wow....maybe I won't beat you.

Re: Project: Kechi AD S10 4.3 auto
 

Russ, I always get doubles of your pics, any reason why...Jim P.S. moving right along and looks good...Jim

Re: Project: Kechi AD S10 4.3 auto
 

8man a lot of it is knowing what needs done before and what can wait. I dont spend a lot of time on extraneous stuff until its time to do extraneous stuff. It really helps to focus the work on what needs doing, not on stuff that wouldnt even matter if it was done three years later.

Brad, driving means moving, not say, glass or interior haha.

28tudor get after it!


its because I am attaching them to my posts, I gave up on outside hosting, they always want to charge for "free" image hosting. so I attach them, but then I also copy the link and embed them in my text. that way they are in the flow of the post and not just lumped at the end, but since attaching them also posts them at the end, you get doubles. sorry!

Re: Project: Kechi AD S10 4.3 auto
 

Russ, nothing to be sorry about, it does make sense about the text and pic together...Jim

Re: Project: Kechi AD S10 4.3 auto
 

well, one step back, three steps forward. you say I got that wrong? not a chance, read on


I needed a solution to the cowl on this cab, the door was obviously windblown and REALLY dented the cowl as seen

http://67-72chevytrucks.com/vboard/a...1&d=1553042079

the hinge plate is bent a little too, so I figured to make a template from the passenger side (for the correct angle) and flip it to get the jamb in the right spot. I planned to cut along the jamb, across the lead line, and at a point lower to peel the metal up enough to bang it flat. failing getting it flat, I knew bowtie bits sold that repair panel, but without the vent. so I ran by to look.

first, he has the 35 style taillights in stock again, I have wanted to use them on the last 3 trucks and they were completely out of stock everywhere. even online sellers showed them as available until you added them to cart. so I picked up a set for Kechi. I need to do an LED conversion, but I love the look.

http://67-72chevytrucks.com/vboard/a...1&d=1553042079

I also picked up a core support while I was there, I was going to cut that GMC one I got at the swap meet but heck, might as well start with a chevy. and here was jeffs solution to by bent cowl

http://67-72chevytrucks.com/vboard/a...1&d=1553042079

so while it LOOKS like I have to swap the s10 firewall chunk over that is welded in my current cab, its much easier done than said, AND this cab has a glovebox door AND this cab doesnt have rust in the windshield frame AND this cab has 3 hinges AND this cab has good hood hinges... so all I really need is some OEM 5 window glass because I have heard horror stories on making new glass fit

oh wait, remember that guy I cleaned out in salina a year ago? two sets of original corner glass. :lol:

http://67-72chevytrucks.com/vboard/a...1&d=1553042079


so I am wondering what I will do with those days I was going to do rust repair. it needs some flat work on the floor but no problem there, and it has the same holes in the bottoms of the hinge pockets (firewall side) so no extra work there. maybe I will just go to the s10 salvage tomorrow and cut a new firewall chunk? maybe I will just design one from sheet, since I will be doing a few more.

anyway, pedal mounts tomorrow!

Re: Project: Kechi AD S10 4.3 auto
 

What a deal!

Re: Project: Kechi AD S10 4.3 auto
 

You could fall in a pile of manure and come out smelling like roses!