67/72 K20 Rusty build

[67mater]

So I haven't been keeping very good track, but I am in the midst of a frame of build of what was a 67 4x4. This was orginally an Illinois Dept of Transportation plow truck, and it had the rust to prove it. I still have the plow and mounting system but will be going to a modern style of plow mount and hydraulics. i have attached all the before pictures of the 67 i have and will have up to date shots up tonight.

I nearly have my late model HD spring swap done at this point (on powder coated frame, 56" springs using custom fabbed mounts front and rear; some I designed, some from DIY4X) and will begin working on the cab next. I have searched a lot on this site up to this point and for everyone's benefit I am going to document the resurrection of this cab/truck. For those faint of heart or paranoid of rust; turn away now; this won't be pretty. I have no prior experience and minimal training (grandpa and uncle on welding a bit and just the hard way so far) so everyone pay attention and see what can be with courage and a McGyver attitude. Also, I'm a tight as so this is being done on a tight budget, improving when possible and splurging when worthwhile, but this is a work truck not a show truck, so you'll see function over form here.

So far I have taken a rusty 72 GMC cab that had rockers and galvanized corners riveted and bondoed over rusted garabage and put it on a rack (it's actually better than the 67 was). I cut the small window out of the 67 before I scrapped it and have it fabbed into the 72. It needs final welding, but its in place. I did all of that with a 110v fluxcore welder. my uncle is letting me borrow a MIG if I pay to haev the bottle filled, so the rest should be done with that welder. I ordered all the patch panels I'd need (Tri-plus panels from a board vender; Muszclerodz) and will take shots as I go. Hopefully they fit, hopefully I can keep it all square. i have the 67 doors bolted in place to check fit. They lay like garbage, but they prove the opening are square, so I will measure, mark and brace before I start cutting (betetr safe than sorry). Please make suggestions as I go because I'm really diving off the deep end.

oh, and the 72 cab came with the truck so I feel I got nothing to lose but my pride and it wouldn't be the first time! So come along and let's see how a true novice goes!!!!

[67mater]

Sorry, no picks yet. Wife got a job so we celebrated. Will have welding bottled filled tonight and hope to get started on the cab. Will first be measuring and bracing, then working on the cab supports. Also having some guys come over and help me swap beds on my 68 and then going to use 68 bed to fix 67, then buy a better bed for my 4x4.

[thirdstreettito]

Looks like a good start! Paint it DOT Yellow when your done!

[67mater]

funny think about yellow, the 72 cab is yellow and with the red 67 doors my wife calls it "smoothie". I'm not a painter, but I plan to aresol the inside and the jambs and such so I can put it together and then pay to have the outside painted. It's also a work truck, so all I really want is a uniform color and no rust.

[67mater]

oh, silver or gunmetal metallic by teh way; not sure yet.

[67mater]

camera issues are making pictures difficult, but I have started the passenger side floor repair. the door is braced and I have cut the front of the floor out to reveal the front cab mount hole. God Bless air chisels, as that made short work of the rest of the support, the spread plate, and the inner sleave. I am now down to just the outrigger and after some cleaning, metal prep, and weld through primer I can begin reassmbly. I had hoped to keep the floor there, but in addition to the ease of access with the floor out, I also found rust between the floor and spread plate, so it's a good thing. Also thinking about how to redo the cab mount surface, as I have not order panels for that part of the floor. I may go to a carriage style bolt; then I can just do the floor flat with a square hole, rather than having to sink the area around the hole to keep the bolt head low.

[67mater]

some of the beginning

[67mater]

here;s the 72 cab iwth the 67 doors for a test fit

[67mater]

the pieces as they came out

[67mater]

here's the front mount cleared down to the outrigger.

[67mater]

Gotta love new rocker put over rust!!

[67mater]

oh, and here's the small window grafted into the big opening; just tacked in. I have the big window frame if anybody wants it!

[67mater]

Here's a shot of the front of the frame and the new mounts I made to accomidate the 56" leaves. you can see the old rear shackle eye in place, but I am moving them to inside the front cab mount.

[67mater]

I have the front and rear pillars and the kick panel repalced. Have the outer rocker mocked in to test fit the inner. Has been tricking figuring out how it all need to go, but should have the inner rocker tied to the floor and the pillars so I'm just filling in from there. Seems like the cab supports don't fit greta, but I'll make them work. Also not sure how I'm going to finish the floor in the back orner, but we'll cross that bridge.

[72BlckButy]

Great looking project, I love the grafted small window. Good luck with the rest of the build!

[67mater]

i like the small windows, which the 67 had and the 72 cab I'm using needed glass so I figured I had nothing to lose. You can see I screwed up on the edges of the inside as I had to patch back in a section I trimmed off (the radiouses are different and I didn't compensate enough and would have had a 1/4" gap. I need to finish welding it, but once it was tacked I wanted to amke sure I was keeping the cab. I have the passenger inner rocker in now so I'd say it's a keeper!

[67mater]

Here's where I'm at. inner in and everything weld thru primered. also cut out bad in dog house and get it ready.

[67mater]

the round part of the floor had to be cut up the middle and reshaped to match the new floor piece. I also had to modify the rear of the rocker so it matched the rear pillar. I actually started with teh fender cup and got sidetracked with the cab; we'll get there. firewall rot is next; will have to fabricate for sure.

[67mater]

also though I'd show off the 70 impala I bought

[msgross]

nice project, where did you get that rad support mount? The hole in it looks too large, might have to research a little before you buy a new body mount kit with bushings.

[67mater]

mount is from the 72, and I recall the poly bushings I bougth fit ok but I guarantee I didn't look too closely. thanks!

[msgross]

I think 72 2Wd is larger than 67/68 2WD or any 4WD.... won't matter as long as they fit.

I bought an entire 4WD kit from LMC and it was 67-72 with a small hole... only reason I asked.

[arkracing]

Nice. That back window conversion looks like it is quite a bit of work - just take it slow welding it up.


What type of "modern" plow set-up are you planning on using?

[67mater]

the old plow had 7 foot tie bars that had to bolted to the frame behind the transfer case and to the bottom of the axles (nice b/c there' no weigth on the springs) which was a pain in the butt. I want some kind of quick release. It's a big Western plow so I'm gonna take some picks and see what the local dealer says.

[67mater]

christmas in september