Not Another Rebuild Thread....

[McMurphy]

Since this build has spun wildly out of control, like our buddy Bomp, I decided a Table of Contents was in order.
Please excuse any hubris on my part, but frankly, I will find this handy too !!
These are all listed in order of original appearance.

1. 1990 Blazer Fuel Tank: Page2 Post32-45
2. Heater Box Rebuild: Page4 Post78
3. 1985 GMC Sierra Donor Truck: Page4 Post93
4. Drip Rail Shave Mod: Page5 Post123
5. P-Side Cab Shoulder Patch ~ My Artwork: Page7 Post155~147
6. Cab Mud Flap Mod: Page8 Post177
7. Guage Cluster Bezel Mod: Page8 Post186
8. Hood Release Mod: Page8 Post187
9. Let the Rust Repairs BEGIN!: Page10-14 Post230-342
10. 1985 Donor Truck Cannibalization: Page12 Post290
11. Cab Corner Floor Plates: Page14 Post350
12. Dash Mod - Heater Controls: Page15- Post354-
13. Under Dash Extension: Page16-32 Post377-794
14. Front Disc Brake Mod Using donor 1981 GMC 1500: Page16- Post390-
15. HydroBoost Power Brakes Mod: Page16 Post396
16. Dome Light Mod: Page16-27 Post400-661
17. SBC 350 Before & After: Page18 Post428
18. Seat Belt Shoulder Anchor Mod: Page18 Post444
19. 1955 Two Ton Dump Bed and 1966 Tempest and 1972 LeMans and Summer Vacation: Page22 Post527
20. RearEnd Takedown: Page22 Post535
21. 1 Year Anniversary Post of Before and "After" Photos: Page23 Post555
22. Fresh Air Vent Mod: Page24 Post595
23. Transmission Access Door Mod: Page27- Post661-
24. Pioneer Stereo System to be installed: Page27 Post653
25. Cab Floor Herculiner: Page31 Post755
26. Under Dash Speaker Panels: Page33 Post802
27. AutoMeter Guages: Page34 Post826
28. "Coulter Trim": Page34 Post839
29. Custom Made Guage Cluster: Page35 Post871
30. Cab Back Panel Mod/Fab: Page37 Post915
31. Emergency Brake Conversion/Set Up: Page39 Post954
32. Door Mods and Paint: Page39-40 Post973-
33. Speaker Baffle Install: Page41 Post1007
34. Side View Mirror Mods: Page41 Post1018
35. E-brake Cable Mod: Page44 Post1082
36. Bench Seat Reupholstered: Page44 Post1098
37. Battery Cradle Relocation Mod: Page45 Post1120
38. Bomp and McMurphy meet / 1964 Tow Truck Page48 Post1176
39. 2 Year Anniversary Post of Before and After Photos Page49 Post1213
50. Headlight, Face, Grill, Air Dam mod start Page52 Post1277
51. Grill Backlighting Page52 Post1298
52. Apache Custom SS emblems Page54 Post1327
53. Hideaway Headlights Page55 Post1352
54. Air Dam mod Page56 Post1386
55. Turn Signal Well shave, Hood Center Mod, Hood paint and mounted Page58 Post1432
56. Modern Cable Hood Release Mod Page62 Post1533
57. Rear Fender Tail Light Shave Page63 Post1556
58. Cheese Cake!! Page64 Post1582
59. Tailgate Illumination Mod Page64 Post1588
60. First Car Show Fathers Day 2014 Page68 Post1693



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THE VIDEOS

1. Fresh Air Vent Mod: Page25 Post609
2. Black Friday/Shifter Adapter Fab: Page28 Post677
3. Pizza Box Templates/Transmission Inspection Plate Fab: Page28 Post691
4. The Christmas Video: Page30 Post740
5. Bomp vs McMurphy/Challenge Accepted Video: Page35 Post862
6. Applying Herculiner on Vertical Surfaces: Page38 Post931
7. Moose in Yard/Other projects: Page40 Post987
8. Interior of Cab Done: Page43 Post1066
9. It's ALIVE....First Engine Start Up in 18 Months: Page47 Post1157
10. 2013 GoodGuys Car Show Video Page48 Post1189
11. 2 Year Anniversary Montage of Before and After Photos Page49 Post1222
12. Hideaway Headlilghts Page57 Post1401
13. Maiden Voyage Page68 Post1693


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Not Another Rebuild Thread......
Oh Yes, 'fraid so.

Hello all.
I have been lurking on this site trying to read thru some of your threads but there are too many and some of them are monster long! But there are enough to give me hope that a shmoe like me cannot screw up a rig so bad that I could not find the solution here... so here goes.

About me: I just rolled 20 years of active duty in the Army on the 18th of August this year. I was stupid enough to take a 7 year break in service which at the time, getting out of the Army seemed like a good idea. My wife and I are both career soldiers, and I am in until Aug 2014 (or until I get too pisst off and retire) and my wife has until March 2017 to make her 20. We are from Spokane WA, and have already started our dream retirement homestead up there. I got into classics because of Kelly Wilson. So if this project kills me, my bank, or my marriage, I will blame him. His whole family is into hot rods, racing or engines of some sort or another, and he introduced me to the joys of building plasic models so we could get free tickets to the Auto Boat Speed Show. One thing lead to another and I got my first classic in Sept 94, the same year my daughter was born and I bought my first house.

Fast forward 17 years and here I am in central Alaska and I am 48 years old. The idea of spending another 9month long winter up here playing World of Warcraft is just not as appealing as it sounds. So I started looking for a project truck, again I blame Kelly Wilson because a few years back he showed me a stepside chevy luv 4x4 truck that was just too cool and I wish I had gotten it. But as I stewed on it I knew I wanted the truck we had when I was a kid, so I started looking for a mid 60s stepside chevy.

I was driving around Fairbanks to the boneyards to see if there were any resto candidates and as I passed by this one shop on the outskirts I happend to spot the 1937 Fire Truck. As I got closer I spied the 66 stuffed in the thick growth of saplings in the corner, almost too well hidden.
I met the owner, chewed on the idea for a day or two, then on 22 Sept with $500 it was mine. Problem was the kid had no title for it. Not insurmountable, but still a bummer.
First pic is what I saw when I got in the gate of the yard, then side and a shot of the cab. Last photo is it arriving at my apt in North Pole.

[McMurphy]

On 23 Sept I wasted a half a day at the DMV, not only did I wait entirely too long but I had to endure the pissy attitude of the gal behind the counter that had to explain to me the process of getting a bonded title for the truck, but I only walked out of there with more paperwork than I took in with me.

Before I bought the truck I took down the VIN and did a search on it, mostly just to make sure it wasnt stolen since the guy I got it from didnt have a title to it. In the sunvisor was a very old registration certificate that showed the name and address of the person who registered it at that time (June of 98). On a whim the wife and I drove out to the address on that registration and even tho it was a long shot in the dark, the fellow actually still lived there and was jazzed to know someone had gotten his old truck and was going to get it back on the road. He agreed to meet me at a tag and license office and see if he was still the last person to hold the title. We met up today, 01 Oct 11 and luckily he was so now I have a clear title to the truck!

All week I have been buying stuff, compressor, tools, odds and ends, and paint. I also tore into the cab, getting all the 70s era carpet off the walls and floor, and looking for the rust that I knew was going to be there. I will post those pics later when I have a before and after set. Before I could really tear into the truck though I had to get an ATV tent up and get my snow plowing Polaris out of the garage. The tent will also serve as a parts storage. The tent went up this afternoon, and I got to work on the rig...

First pic is the ATV and parts tent. Second and third is my rear passenger side wheel before and after. I took a wire wheel to the rim and painted the brake drum behind it. The last 2 are with the grill off...

[Ornery37]

cool! like the camper shell, not too sure about the carpet door pannels though

[Corts60]

That's great that you finally have yourself a project! I would've thought it would have been impossible to find a short box 2 wheel drive truck in AK.

Welcome aboard and thanks for your service! I spent 9 years in the Coast Guard my self.

[McMurphy]

Thanks for the replies guys!
I was on the fence about the camper shell until I met and talked with TDaley the last registered owner and found out some of the history of the truck.

It started life as an Air Force fleet of trucks that were sublet to a local communications company for their linemen to use in keeping the Air Force Base lines up. It was the dark, Air Force blue and came with the 292 IL6 and as you can see on the passenger side fender, the "slave cable" jumper outlet. It served in this capacity until the AF retired it, and the fellow it had been assigned to bid on the option to buy it. I guess he had it for a number of years until owner #3 (TDaley) got it. He is the one that built the camper and he dated his wife in this truck. He used it to haul his fishing boat down to Anchorage until he threw a rod in the engine coming back to Fairbanks.

He had it hauled away by a local boneyard, never to see it again; or so he thought. It traded hands to 2 other fellows until it came to a 6 year rest in the yard behind the business where I found it. The young guy I got it from said his dad was going to do something with it, but died before he could get anywheres with it, and so there it sat until I came along. In reality I am the 6th owner, but by documentation I am the 4th. Not sure if there is an equivalent to the Pontiac Historical Services for these trucks, but it would be nice to have all that information for car shows.

The truck is incredibly solid, as is the camper, which will only take some wood glue, caulk, a few replacement parts, stain and some laquer to refinish.
My plans for this truck are to use it to haul my 66 Tempest to car shows that are outside of Spokane in order to attend, and still keep my odo milage down. Something deep in the back of my soul is saying that a 66 truck hauling a 66 converible would be something to see at a car show....
Right now I just want to get it back on the road with some look and style, some repair and upgrades, but hold off on a frame off until I get my shop built back home. Then it will be a retirement project for me after I get the house built.

First pic is 25sep11 of the bed of the truck which had 2" of dirt and dust, 3 batteries, my driveline, 4sp transmission, heater box assembly with 2 cores, and a few other misc parts that I may or may not need or use.
Second pic is the bed after a bit of cleaning. I was totally surprised that I only had 1 broken board in my bed and none were rotted out. Though my metal bed rails are rusted to

[Alan's Classic]

Welcome aboard and cool story so far. If you have a question your in the right place.

[McMurphy]

Thanks Alan, but frankly if your thread dont answer a ton of unasked questions, I dont know what would...

[McMurphy]

Yesterday was spent stripping paint from the door panels and the back of the cab inside until almost dinner time. Then it was off to Sears for their friends and family sale... plus Military discount = about 30% off. So I got some serious tools and supplies to include a pair of angle grinders. A small amp one for stripping paint, and a bigger amp one for cutting and grinding metal. Because I am just that much lazy to want to swap out a disc.... sad but true.

The first pic is my "plan" for the basic look of the trucks paint scheme with some of the mods, like an air dam-lowered front bumper, and removal of the wing window. I want to do an in-cab hood release and grill in those two snorkel ports between my parking lights in the hood too. And the big dream is to do hideaway headlights for a straight black face. I looked at 69 Camaro hideaways but they pivot on a vertical spindle whereas I want a flip up or flip down door like a 69 Ford, or a 69 GTO (respectively). We will see, I do tend to be as stubborn as I am lazy... go figure.

Second and third pics is my cab back wall stripped and then painted.
Thanks for tuning in !

[Alan's Classic]

Originally Posted by McMurphy

Thanks Alan, but frankly if your thread dont answer a ton of unasked questions, I dont know what would...

Posted via Mobile Device

[fryer1979]

Cool, I like the drawing. I'm in.

[McMurphy]

Ok so yesterday I tackled both door panels, and my passenger side door. This is my progress...

#1 one is the door panel off and stripped.
#2 is painted with semigloss Rustolem over the self etching primer grey I like so much..
#3 is the masking for the detail off. Since I like the flat gray color, and I cannot find a semi gloss in this shade, I am thinking about shooting some clear coat over the primer and calling it good. Thoughts or potential problems with this idea anyone?
#4 is the door in all its grungy, carpet stripped glory.
#5 is the two reunited with the handles for show...

One thing I have noticed about graduating from plastic car models to classic vehicles, is I skin my knuckles alot more on than I used to.... sorry that was supposed to be funny.

[bubba327]

Nice score!!! Up in the north country I have heard the winter months are also called "garage season" Maybe you will be finished up and cruising in the spring!! Welcome to the site!!!
Check out the regional section here , I have seen some posts from some others in the Alaska section!!

Maybe you could put in a good word in to the big jolly bearded guy who brings me parts and neat tools around the end of December.
He could hook you up with parts at reasonable shipping!!!

[McMurphy]

Nice score!!! Up in the north country I have heard the winter months are also called "garage season" Maybe you will be finished up and cruising in the spring!! Welcome to the site!!!
Check out the regional section here , I have seen some posts from some others in the Alaska section!!

Maybe you could put in a good word in to the big jolly bearded guy who brings me parts and neat tools around the end of December.
He could hook you up with parts at reasonable shipping!!!

I will give it a go for you Bubba! From what I hear Santa rides a Harley up here in the off season, but I have yet to spot him!

Outstanding! Great truck and story, looks like you're really making progress. Welcome to the forum!

Thanks Mark. I have read your thread and really dig your caddy lights! I am from Spokane, grew up out at the end of Long Lake went to school at Springdale. Would like to catch up to you next August when I am in town, photo shoot your truck with my Tempest!

Nice truck. I think a vehicle isn't officially yours until it draws blood.

rcbildr, one of the nails on the camper shell got me on day 1 of my tearing into it. Tore a nice 3" gash on my left arm... I was so proud. I showed my wife my "first blood" to the truck. LOL too funny!

I really hated to see you ditch the carpet door panels.

I could send them to you maybe? Haven't tossed them out the door just yet ... Hahahah

[markeb01]

Outstanding! Great truck and story, looks like you're really making progress. Welcome to the forum!

[LostMy65]

I really hated to see you ditch the carpet door panels.

[k1rodeoboater]

I like that cap you got on the bed there, you gonna keep it or trash it? I'm amazed at how good of shape your truck is in for being up in AK.

How's that clip on work light work for you? I really need to get more light in my storage unit than my little flourescent shop light can provide.

Also can you take a pic of how the hazards are wired up in your truck for me. I pulled one out of a truck in a junkyard as mine is missing them and I'd REALLY like to have them in there just in case my truck decides to crap out on the side of the road again

[McMurphy]

Originally Posted by k1rodeoboater

I like that cap you got on the bed there, you gonna keep it or trash it? I'm amazed at how good of shape your truck is in for being up in AK.

How's that clip on work light work for you? I really need to get more light in my storage unit than my little flourescent shop light can provide.

Also can you take a pic of how the hazards are wired up in your truck for me. I pulled one out of a truck in a junkyard as mine is missing them and I'd REALLY like to have them in there just in case my truck decides to crap out on the side of the road again

I will do what I can for you K1, but my under dash wiring is pretty tore up. A PO had installed aftermarket guages, two of those and the ignition switch look to have been un-professionally removed LOL. I was not planning on tearing my steering column up-open-out either unless I absolutely have to... have done that with my Tempest and I hate doing it each time.
The clip on the light works ~reasonably~ well. There are some physics involved sometimes meaning the bracket has to be supported in some positions because the clip is not very strong. Alot of the time I have it clipped to the edge of a 5gal bucket, and I move it and point it around like that.

I was at a boneyard yesterday looking at parts trucks (dude has 8 or 9 of these mid-60s back there) and found some tail lights I want. The most radical are on a 60s-ish Plymouth, it has the most bizzare dash inside I have ever seen, but the tail lights are like rocket jet packs on the side of the rear quarter. The other set I am looking at are off a 67 Impala. It may depend on which ones, if either, the old guy is willing to part with.

Pics later today.... almost a decent hour to get out into the garage now. (I live in a duplex, and the two Air Force kids downstairs work the night shift)

[k1rodeoboater]

Depending on what is still left on those trucks you might be able to salvage stuff and ship it out to make some money on the side, or add to your truck for some nicer amenities. I know shipping from AK to CONUS is gonna be killer though

[McMurphy]

About the camper... it is really solid. Some wood glue, a few new nails, caulk, and a once over with sander and laquer and it would be ready for another 20 years. So I am thinking about keeping it. The plan is to load it onto my little Sonomoa and have the Army ship it home for me when I retire. Because I plan on driving this 66 home.

Yesterday I checked out this Hobart Handler 180, and picked it up for $700 with all the stuff the gal tossed in with it. A tank of gas, hood, 2 spools of wire, a 25' extension cord she made for it, and all the spare tips that came with it. She said it is 4 years old, but she didnt use it for the 2 years she was away in college, but to look at it in person it looks fresh out of the box...

So did I score, or did I get chumped?

[McMurphy]

I didnt get as much done today as I had planned.
I did reorganize the stuff we are storing in the garage to make some more room, hung some shelves on the wall to help me get or be somewhat orgainzed, and did some serious sweeping up in there, the floor was getting deep in dirt enough to plant a small garden I think...

Then I started my day off with grinding off the pop rivets that were holding the louvered tail gate skin on, and found a ~decent~ shape tail gate under that thing. So off with the TG and getting all the gunk off that was used to glue the skin on lent to stripping then primer of the old boy. Nothing like fresh paint to really bring the flaws to light !!

I may snag another TG on Sunday while I am boneyarding it if I can find one that is better, or that can be used to reskin my top edge. I think if I cut a good ( just less damaged) one, and weld it over my dinged up one, it would help.

Then it was off with the passenger side fender, and the front bumper. I am thinking repro for both sides on these. The pass-side has that hole from the slave jumper, is dented to hell there as well, and has the rustrot in the rear. Just too much for me to salvage I think.

#1 and #2 are the TG both sides after primer tho the #2 is not well done, was getting cold and dark outside when I shot the paint was was a rushed job.

#3 is the fender off
#4 is the front bumper off.

It is insanely dirty all up under there. I should drag the whole hulk the 2 miles to the local car wash and spend a few bucks on some pressure washing...

[k1rodeoboater]

Honestly your tailgate is in REALLY good shape. I'd just use your welder to seal up the holes from the rivets and leave it at that. You did score on that welder BTW, the tank was the big score. You'll want to get some .23 wire for welding your sheetmetal with though, and just bite the bullet and get the big roll. Better to have to much than not enough.


I'm honestly amazed at how good of shape your truck is. The rust damage looks very minimal from the photos, my truck is in far worse shape

[McMurphy]

90% of my day was either getting supplies, looking for supplies (who knew Walmart no longer sells plastic models, or paint?), or in the boneyard pulling a tranny while my lovely wife gathered up other needed parts. Got windshield wiper arms, total heater box with core, a transmission with an Indy Hurst shifter on it, and the clutch pedal yolk and linkage. Also got a couple of light fixtures from some import car I may have a use for.

Part of the supplies was a new connector for my welder extension cord so it will plug into the Dryer 220 outlet.

Am bushed tired, will post pics tomorrow of yesterdays progress and todays parts.

[smilts60]

I knew that walmart didnt and it sucks. Even at my age I actualy enjoy building the advanced models and airbrushing them.. Great work so far on your truck great story and looks to be a fun build.

[McMurphy]

Originally Posted by smilts60

I knew that walmart didnt and it sucks. Even at my age I actualy enjoy building the advanced models and airbrushing them.. Great work so far on your truck great story and looks to be a fun build.

Thanks for stopping by and reading up on my truck Smilts!
I want the model paints for my horn button. I have some cool detail work I want to do with it.

[protrash64]

Cool find and an interesting story. What are you going to do about the engine?? I take it its still dead?