My 78 K15 High Sierra build - Fish Tremble

[rgunlock]

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.

[rgunlock]

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.

[rgunlock]

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. Think I might stick with this theme --- NOT!

[rgunlock]

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.

[rgunlock]

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.

[bilfman]

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

[rgunlock]

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.

[MTCK]

Nice truck and good work! What sizer tire are you going to run?
Posted via Mobile Device

[rgunlock]

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.

[rgunlock]

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

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

[rgunlock]

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.

[rgunlock]

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 Not too happy how this job turned out either. I'm thinking I got my practice, and will probably just buy another fender.

[MTCK]

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...
Posted via Mobile Device

[rgunlock]

Originally Posted by bilfman

Keep up the good work, I like following this one!
Posted via Mobile Device

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

Originally Posted by mjensen

That is looking great!

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

Originally Posted by MTCK

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...
Posted via Mobile Device

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.

[mjensen]

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

[rgunlock]

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.

[rgunlock]

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...

[MTCK]

Looks good! You'll be glad you did it when it's all done... That dolly is a good idea. I bet some 35's will look just right with your lift, if you're going to regear down the road anyway. There is always the granny low to get rolling Keep up the good work.

[rgunlock]

Tonight's posts are not all in the order I progressed. These are before and after of the transmission and tcase. My daughter came home for a visit and decided she'd rather help me clean parts than go shopping with mom, so she's helping scrape off the grunge.

[rgunlock]

I don't have the tools or knowledge to rebuild these, so after we cleaned them up, they went to a drivetrain shop. First pic is after we cleaned them up, and then the "afters". At this point, I'm still debating whether to try to convert over to a hydraulic clutch from the manual setup you can see here. I'm sure it won't be any easier to do it after I get the truck further back together.

[rgunlock]

While the transmission and tcase were out for rebuild, I worked on the fuel system. I wasn't able to start the engine, and when I pulled the fuel line off the carb and cranked, I got nasty orange stuff squirting out. I had a new fuel filter, so hopefully that crap didn't get into the rebuilt carb. Probably could have cleaned and relined the tanks, but found the Spectra Premium tanks (PN GM11A) on RockAuto for about $75 each and figured it was pretty cheap insurance to use new tanks. I'd seen a number of good reviews on Spectra Premium tanks on this forum and other places. Gas gauge was all over the map so got new sending units, also Spectra Premium (PN FG05B and FG05J for right and left) which cost almost as much as the tanks. Also got new straps.

[rgunlock]

Also redid the fuel line from the mechanical pump to the carb using my new tubing bender from Eastwood. I had previously tried to use a tubing bender I picked up at the local O'Reilly's parts store, but it got bent up worse than the tubing - total POS. This was a real challenge for me, but eventually got it where I was OK with it. The Eastwood bender worked great, the problem was figuring out all the bends. Also had to do a double flare on one end. We'll see whether or not it leaks somewhere later down the road.

[MTCK]

Looks great Rick. Having spent a couple hours the past few days laying on my back cussing, my vote is to do the clutch linkage swap now if you are going to!
Posted via Mobile Device

[rgunlock]

Thanks! I'm seriously considering it. Only thing is I've already got all new linkage for the manual clutch setup and haven't even tried it out yet. I've still got time to think on this.

[rgunlock]

Here are a couple of "befores" of the exhaust on the truck. I was impressed at how they reduced from the muffler output to the size of the tailpipe, and also the patch job