The "In over my head" build thread

[SeventyOne]

9/23/19 - Insert quippy headline here

Made more good progress Sunday. Trying to get the under dash stuff buttoned up so worked on getting the wiper sprayer nozzle hoses through the firewall plug and pressed onto the washer pump. This was way harder than it need to be - ended up popping the grommet out of the firewall while pulling on those hoses and it was a PITA to get back in. As always lube is your friend and some vaseline really helped...slide...the hose into...the hole....

With that out of the way I got the dynaliner foam finalized in the rest of the footwell/under seat area then I got a little ahead of myself and threw the carpet in place




ACC carpet fits well out of the box - probably should have left it warm up in the sun but I'm impatient. It massage into place pretty well and i think will only require minor trimming where it meets the rear corner by the door. Should be covered up by the sill plates anyways.

Then I removed the cowl to install the nozzles and connect the hoses then put on the wiper transmission arms to the wiper motor, and got the firewall wiring gutter in place.




Finished up the courtesy wiring/switches, got the heater harness in place and started on the heater cables but I need to run to the hardware store to complete that.

PUNCH LIST
Under Dash
-Heater control cables (need hardware)
-Radio + Aux/USB in the cig lighter + hidden antenna
-Speedo Cable (on order)
-Throttle Cable (on order)
-Tap into Wiper white wire for carb choke (buy red wire)
-Fix rear body wiring connection
-Connect dash grounds

Interior
-Install door seals
-Cut MLV and install under carpet
-Finalize carpet placement and make holes for shifter, dimmer switch, + seat bolts, seat belts
-Install shifter, boot, + trim ring
-Drill holes for: CST rear panel strips + standoffs, front + rear carpet strips, sill plates, tailgate seal vertical strips, center console mounting holes

and lots more...

[jaros44sr]

mount the seats before you trim carpet, they tend to pull carpet

[SeventyOne]

Originally Posted by jaros44sr

mount the seats before you trim carpet, they tend to pull carpet

Thanks for the pro-tip!

[jaros44sr]

Originally Posted by SeventyOne

Thanks for the pro-tip!

actually, I got it from the TV show garage squad, but your welcome

[SeventyOne]

10/8 Drilling Down

Slowly but surely I'm making progress!

Got the correct length speedo cable installed and installed a stock style throttle cable. I was surprised it fit so well with the engine moved forward 1.75". I originally mocked in a 4x2 throttle cable but it was WAY too long. So it went into the "sh*t to sell" box that keeps growing



I got the heater control cables routed but I need the correct size push nuts (5/16" I think) to hold them onto the plenum actuator shafts. I bought a bunch of the 1/4" push nuts since that's what size is needed on the heater controller but apparently they're larger on the plenum

The cables seem to operate OKAY but they are pretty stiff and getting the correct amount of travel to operate properly is a huge PITA. Anyone else have the same issue with new heater cables?

I then turned my attention to the rear cargo area. My K5 was not a CST truck and did not have the any of the holes drilled from the factory. So I put 24 new holes in my truck (so far haha) so I could mock up the CST panels.



Then I wanted to get the carpet laid in so I could drill holes for the carpet strips...this is where I ran into a snag.

I ordered my carpet from StockInteriors.com (it's ACC carpet) and while the front carpet fit rather well and I'm over all happy with it, the rear carpet seems to be cut way off. With the carpet centered around the wheel wells the carpet is roughly 4" short from the end of the bed when it should be tucked under the carpet strip. This pic shows the issue.



I am EXTREMELY happy to say that StockInteriors is standing behind their product and all it took to have them ship me a new piece was a couple measurements and pictures - even though I ordered this carpet 18 months ago!

So new carpet is on its way and I can resume making new holes in my ride

And this pic is just because she's a stunner


aaaand finally here's an update to my ever evolving to-do list:

PUNCH LIST
Under Dash
-Finish Heater control cable installation (need 5/16" push nuts)
-Radio + Aux/USB in the cig lighter + hidden antenna
-Connect choke wire to wiper plug
-Connect dash grounds
-Check carb gets to WOT with pedal travel
-Install glove box

Interior
-Install door seals (ordered new press on seals)
-Cut MLV and install under front carpet
-Finalize front carpet placement and make holes for shifter, dimmer switch, + seat bolts, seat belts
-Install shifter, boot, + trim ring
-Install new rear carpet
-Drill holes for: front + rear carpet strips, sill plates, tailgate seal vertical strips, center console mounting holes

Underhood
-Install heater hose nipples to engine/water pump
-Install Evap canister and hook up hoses
-Install brake booster hose
-Finish mounting battery tray
-Finish underhood wiring
-Install radiator overflow
-Install wiper fluid resevior

[jaros44sr]

Nice progress, punch list is getting rather small...back when I was working on my heater control panel, I thought the single core cables were quite stiff, then it occurred to me why not use a multi strand cable like the throttle cable from lokar. More flexible

Any way keep up the great work, very good write up, tons of info., and thanks for sharing

[SeventyOne]

Originally Posted by jaros44sr

Nice progress, punch list is getting rather small...back when I was working on my heater control panel, I thought the single core cables were quite stiff, then it occurred to me why not use a multi strand cable like the throttle cable from lokar. More flexible

Any way keep up the great work, very good write up, tons of info., and thanks for sharing

Please tell me more about your heater cables! pics, part numbers etc!

In doing some reading I may need to lube up these cables. Will do that and reply back!