Project "Financial Burden": 1968 SWB C10

[Old_Truck_Fan]

I had my stock hood hinges rebuilt by Willie Wilson at https://www.hoodhingerepair.com/. They turned out great and operate very smoothly. I was excited to bolt on the hood. It has been awhile since all the body panels were installed at once on this truck. I've got a lot of work to do to dial in the panel gaps, but this was a big accomplishment. Also, if you are curious, I have more than 1 inch of clearance between the hood and the Holley high ram intake.

[68 C10 Driver]

Originally Posted by Old_Truck_Fan

I also found some rust lurking underneath the dash that was quite a challenge to repair...

I have this issue also, but on the driver's side and a bit more extensive. Being a challenge is an understatement, I guess that is why I am leaving that repair for last.

[Old_Truck_Fan]

Originally Posted by 68 C10 Driver

I have this issue also, but on the driver's side and a bit more extensive. Being a challenge is an understatement, I guess that is why I am leaving that repair for last.

Hi 68 C10 Driver, those locations are tough spots with not much room to work. I had trouble squeezing my welding helmet up to where I could see what I was doing. An auto-darkening lens is a must have in my opinion. I also had to do a little work inside the cowl panel that I just barely had access too. At least those areas will be out of site; so just make sure it's solid. Good luck with your repair.

[Old_Truck_Fan]

I thought test fitting the tail light housings would be straight forward, but I had to weld up and re-drill the mounting holes in both bedsides since they were way off. While doing that, I noticed the lower section of sheet metal was not fully formed on one side so I fixed that as well. I had a similar issue on one of the reverse light flanges. Details, details...

[Old_Truck_Fan]

The new grill moldings worked out well, but the clips are a bit of a trick to install. I had planned on just opening up the fuse panel hole for the American Autowire Classic Update kit, but then decided it would be a good idea to layout the wiring. Down the rabbit hole I go.

[Old_Truck_Fan]

I'm still working through wiring, but decided to take a break and tackle a few heat shields for the turbo and down pipes. It was a good project to test out my new 3D printer to create a press tool and hammer form. The PLA parts turned out to be quite strong and worked just fine. Now back to wiring...

[Old_Truck_Fan]

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[layinrocker65]

Awesome stuff happening in this thread

[TA_C10]

Very awesome 👍

[SkidmoreGarage]

Nice job on those pieces. I'd like to hear more about the curved turbo shield process.

How well did it hold the large radius curve? What would you do differently? It looks like the shoulder radius was hammered over the form?

[Woodnears]

Very nice use of the 3d printer. I have one as well and have made a few parts for myself so far. Interesting to see what others are doing with these machines! Nice project!

[72 tigger]

Excellent fab work

[YellowK5]

That is some nice metal work...I am guessing it is part of your daily work?..a bit better than a back yard mech.

[MONTE]

You have some crazy skills!! Keep it going.

[Old_Truck_Fan]

Thanks for the motivating comments. I appreciate it.

Originally Posted by SkidmoreGarage

Nice job on those pieces. I'd like to hear more about the curved turbo shield process.

How well did it hold the large radius curve? What would you do differently? It looks like the shoulder radius was hammered over the form?

It would have been easier to just weld the two pieces together at a 90 degree edge but I wanted the look of a stamped piece which the large radius curve helps pull off. I really like the hammer forming process. You basically sandwich a primary shape between two forms while you hammer the material over an edge to form a secondary shape. I split the two pieces along the centerline of the radius so that the shaping was even between the two halves. You could have put the full radius on just one piece but it requires a lot more shrinking to turn the corner. With enough hammering the part will conform to the form very well, so there were no issues with the part conforming to the large radius. The only thing I would have done differently is perhaps rolled the edge of the heat shield on both sides instead of just where I welded it to the mounting flange. I thought I could only assemble the shield from the rear of the turbo but it actually can be assembled from the side too. So I could have curled over the front edge instead of leaving it straight. I'll attach a few more pictures that might be helpful.

Originally Posted by Woodnears

Very nice use of the 3d printer. I have one as well and have made a few parts for myself so far. Interesting to see what others are doing with these machines! Nice project!

I've really enjoyed using my 3D printer as well. I bought it as a kit earlier this year so it was a fun process just putting it together and understanding how it works. Its been easy to use and I was able to get successful prints right out of the box. I'd recommend the PRUSA mini as a good machine for someone just getting started with one.

Originally Posted by YellowK5

That is some nice metal work...I am guessing it is part of your daily work?..a bit better than a back yard mech.

I'm a mechanical engineer but I don't get much hands on exposure at work.
All of my metal working skills have just been picked up through reading, videos, a few metal working workshops, and a lot of trail and error. I'm just a weekend warrior but I really enjoy it and try to make every part better than the last.

[Old_Truck_Fan]

I needed another distraction from wiring, so I decided to recover my bucket seats. These are from a 1971 Blazer that I found on eBay many years ago. As expected the driver side was broken down on the entrance side, but nothing an electric fillet knife, 3M super 77 spray adhesive and some new foam couldn't fix. Watching a few YouTube videos also helped. The passenger side was mint. I think they turned out pretty good for the first time giving it a go. I'd also recommend OEM Automotive Tools Hog Ring Plier set PN 25931.

[geunther]

As you already know, nice work on all of it.

[68 C10 Driver]

Originally Posted by 68 C10 Driver

I have this issue also, but on the driver's side and a bit more extensive. Being a challenge is an understatement, I guess that is why I am leaving that repair for last.

Update, finished that under dash repair...

[Old_Truck_Fan]

Originally Posted by geunther

As you already know, nice work on all of it.

Thanks geunther.

Originally Posted by 68 C10 Driver

Update, finished that under dash repair...

Nice repair work 68 C10 Driver. You've got the hard part done, good luck on your dash reinstall.

[BigBird05]

What did you spray on the interior of the fire wall?

[dnd1978]

Great fab work. The only problem was on the first page where the fleet side came in. Haha. following

[Old_Truck_Fan]

Originally Posted by dnd1978

Great fab work. The only problem was on the first page where the fleet side came in. Haha. following

Ha, thanks dnd1978. You'll be happy to know I sold the step side bed to a gentleman who was changing over from a fleet side. So I haven't changed the population of step sides in the world.

I recently finished rebuilding my vent windows, refreshing all the internal door components and installing new glass. The only thing I struggled with was getting the right glass setting tape. I ordered from a few different venders, but was finally happy with the 5/64 thick tape from Bob Drake which you can get through Summit Racing. I blacked out all the vent window trim and handles. Here are a couple videos that helped me with the glass setting procedure.

https://www.youtube.com/watch?v=zUY1XXIBiiA

https://www.youtube.com/watch?v=w9JC_8LmNJk

[Old_Truck_Fan]

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[Old_Truck_Fan]

I picked this up from RPM Transmissions over the holidays. It's a close ratio T56 magnum with a 2.66 first gear ratio and 0.63 sixth gear.

[Jiggers72-GMC]

Very nice Transmission, it will be fun to run through the gears .....