41DegreesSouth Build Thread

[1985-GMC]

Now that'll be cool! I've never seen one of those.

[Dieselwrencher]

Great build you have going on here! It's turning out super nice! I really like the sway bars you went with. I might think of adding them to mine at some point. Don't feel bad about your build taking so long to complete. Mine has been a real long time too. I was reading through your build and it was going through my head all the little stuff I have and need to put on my truck. Gee whiz. Good luck getting it painted and together soon!

[Billhilly]

Originally Posted by ryanroo

I totally dig the idea of a welder. i had that idea a few times, but in the end i decided it wasnt a necessary add on for my truck. i am dealing with confined space as it is anyhow and the reality of it is that i will probably just drive my truck and pull trailers once in a while. it wont ever be for serious work... haha i am already planning the 'for everyday use' build on my yellow truck so i dont have to drive the spiffy one everywhere if i dont want.

those relay holders are this

https://www.alliedelec.com/te-connec...1002/70199126/

they work with the normal 4 or 5 pin Bosch/Tyco relays. they do require a certain double crimp terminal to lock into the holder. they are linked in the lower part of that web page. they interlock so they can be mounted in a gang like i did, or they can be mounted individually.

Yeah the welder thing was outa my price range, but a guy down here had bought some Zena stuff in and it didn't sell, so half price to me! Thanks for the link, I found some Hella ones local. They will be here this week. Didn't know how I was going to handle the relays so was timely seeing your deal.

Originally Posted by 1985-GMC

Now that'll be cool! I've never seen one of those.

Don't know how much it will get used, but I needed a new alternator anyway. And it continues to over complicate things!

Originally Posted by Dieselwrencher

Great build you have going on here! It's turning out super nice! I really like the sway bars you went with. I might think of adding them to mine at some point. Don't feel bad about your build taking so long to complete. Mine has been a real long time too. I was reading through your build and it was going through my head all the little stuff I have and need to put on my truck. Gee whiz. Good luck getting it painted and together soon!

Hey Ryan, Thanks! Yeah the time frame is starting to get embarrassing now! In my defense I took a bunch of time off in '07 and rebuilt my (120 year old)($$!!) house so it was more comfortable for my daughters (they've now left!) and was sick for a year starting 2012 so I've certainly managed to drag it out!
Oh, after working through the other Ryan's build thread, I am in the process of getting through your's! Looks very cool. You guys certainly lift the game. Plenty for me to think about!
Got a few nights in this week sorting through everything I had, and everything I need to order.... Lead time down here is a little longer than you guys have to deal with! Got the doors off last night and some basic panel work done. PO musta had something heavy (long?) under the seat and kept slamming the door on it... or was it the seat belt end? Who knows but he put a good little dent in there! Scraped the under seal out from the inside of the doors so I can treat the surface rust, and have just finished paint stripping the outer skin. Good (basically) rust free doors. Will sand blast the rest of the paint off.
Day's passing me by. Better get back at it...

[Dieselwrencher]

Nice work repairing the dents. My doors had weird located large dents in the doors. It really makes ya wonder how much stuff people used to cram in these things and slam the doors til they shut.

[Billhilly]

Must have taken some slamming huh! I've made it through most of your build thread. I see you spent the time and re installed the front fender seals. I've got new seals down here and was wondering if it was worth the agony of putting them back on. What exactly do they do? They stop spray coming through? And they were not on the base models, only on the higher spec trucks? Just another job to do but would appreciate your thoughts.

[Dieselwrencher]

If I remember correctly they were only installed on air trucks. They're supposed to deflect warm air from the engine compartment from getting in to the door jamb. My cab had the holes and I had the brackets so I figured I better put them back on other wise I would have regretted it later. Plus it might slow the dust down from getting in the door jamb too.

[Billhilly]

Really need to bring this up to date.....
With the doors done I moved back to the cab. With all the main rust repair done, I thought I'd get everything sorted in a couple of weeks, not! The cab had had a camper on and there was rust around the rear window, and a row of dome holes around the inside. I thought it was just surface rust but was proved wrong when I wire brushed it off. I managed to fill all the holes with the welder. The sunburnt roof ended up being much more pitted than I though as well. I wire brushed it, then paint stripped it twice. Then some DA action, followed by a couple of hours of hand wire brushing and phosphoric acid.

[Billhilly]

I wanted to carry a two stage hydraulic jack and tools in the cab so spent way to long making up holders for everything. I am also going to install three lap/shoulder belts so added am additional belt point for the middle shoulder belt. We have pretty strict rules for this sort of thing but managed to keep everyone happy. You can see where I mounted it below the rear window with a series of spot welds.

[Billhilly]

Again, to keep progress slow I thought I'd add my po' boy cowl hood deal. Well, instead of a cowl hood, I've got... cowl air. Anything to lower under hood temps, and propane loves the cold too. I will wait and see how everything lines up, as to whether I run some enclosure around the air cleaner or not. It'll be interesting to see how much flow I get. I didn't like how it looked once trimmed down so added the lip, and if I add a boot it gives something to bolt to.

[Billhilly]

The trip to the sand blaster was delayed a few days so the next/last big cab job was RHD wiper linkages. Easy huh!? Just follow the drawings in the assembly manual, how tough could it be? Weeell, The more astute of you may be able to spot a few 'inaccuracies' with the drawings, but I blundered right in and had to learn from my mistakes. Might come as a shock, but not for the first time! Anywho, My long suffering lathe guy had turned up a couple of critical pieces so the rest was just slice and dice. Ha! Ended up being one of those jobs where half millimeters and offset were critical, and clearance to the cowl was almost non existent. I may be out by a couple of degrees of sweep, but please don't judge me to harshly! I've never seen pictures of this, so I give you my interpretation of RHD wipers!

[Billhilly]

So on Wednesday I got all the ducks lined up and headed out for the sandblaster, paint booth for epoxy prime. I haven't seen the bill from the blaster yet but it took a few hours.....Anyway the weather was great, a frosty start in the valley, and it was painted late in the afternoon and spent the night in the booth. Unfortunately in the rush to get it to the painters and cleaned down, I forgot to take any photo's of it in the raw. Stupid.
Final shot's of it in original paint leaving my shop.

[Billhilly]

After 24 hours to let the epoxy harden, I started on the bog work. Something I've really done none of before. Anyway yesterday (Friday) I got started. I certainly won't be be getting a job doing that any time soon!
At this stage the plan is to finish up the bog, then back to the booth for primer. Then back to my friends panel shop for block sanding. Then drip rail, and seam sealer, then home for final paint work. How long can I drag that out for!

And that brings me up to date. Well, I actually spent the entire afternoon cleaning up the shop. The truck has gone from basically fully assembled, to exploded into a thousand bits. Finding space for everything, and sorting out all the bits, and what still needs work filled in the entire afternoon.

Inner guards need bog over pitting, radiator support is pretty good then I can sling a coat of satin black on them. I wanted a chrome grill, but mine isn't good enough, so it will be dip stripped then bogged up and painted a 'shiny' colour. Then I can say I'm done with body work!

[1985-GMC]

Looking really good! That's a ton of work

[swamp rat]

That right hand drive has me pretty jealous, thanks for the update!

[Billhilly]

Originally Posted by 1985-GMC

Looking really good! That's a ton of work

Thanks! I couldn't believe that a cab that was basically 'ready for paint' could soak up so much time. The 'to do' list ended up running onto the second A4 page!

Originally Posted by swamp rat

That right hand drive has me pretty jealous, thanks for the update!

I don't think I will be doing another one anytime soon! My one bit of advice to anyone considering buying one of these trucks is to save yourself some money and spend more on a rust free (and potentially original paint) truck!

[sharpmark]

great photos thanks.
doing one of these up isn't for the faint-hearted especially over here!!!
well worth it in the end - I love driving mine

[Billhilly]

Originally Posted by sharpmark

great photos thanks.
doing one of these up isn't for the faint-hearted especially over here!!!
well worth it in the end - I love driving mine

Thanks Mark. Yeah, not being able to drop down to the wreaking yard and get spare parts is a bit of a drag!
I continue to underestimate the time required on this job! Anyway after three days of professional help the cab and doors are now ready for primer.
Then block sanding, seam and drip rail sealing and final paint!! It will get primed in the booth tomorrow and we'll bring the bits home for the final coat.
One step closer right.

[DeadheadNM]

Nice progress!

[cmabolt]

Looking forward to seeing that one in paint. Can't imagine restoring one of these trucks in New Zealand. Parts, shipping, etc. etc., but if there's a will there's a way I guess.

Chris

[ssuth9]

Very nice... keep it up.

[Billhilly]

Thanks for the encouragement guys. Yeah, freight, and exchange rate are real killers on a project like this. Still, down here, everyone's driving a Hiluxs, Isuzu's, and Rangers so this will certainly be something a bit different. I dropped the cab/doors around to the painters today for primer and will pick them up first thing tomorrow. Block sanding next week!
Oh, and a new Hilux is around $65K!

[Billhilly]

Primer done, will try and get it block sanded on Tuesday.
I didn't like my original exhaust. I did it with the cab and bed off and it was too high, too low, and too short! So I started last night with the slice and dice. Lower through the cab area, longer so I can run second skid plate cross member, and I will lift the mufflers four inch's... Before and during shots.

[Billhilly]

All done inside the chassis rails. 1 1/4" lower through the under cab area, 3" longer to allow for the second mid cross member. Just like it should have been the first time! New cross member fits in good now.

[ryanroo]

Looking good Bill!

My lady travels for work, so we talk on the phone a lot. last night i was chatting with her, whining about how i swear i've built the whole truck twice. i had just gotten done remodeling some pipe work myself. i have a saying. "We do it nice, because we do it twice!" its funny, but its not... haha

[Billhilly]

Originally Posted by ryanroo

Looking good Bill!

My lady travels for work, so we talk on the phone a lot. last night i was chatting with her, whining about how i swear i've built the whole truck twice. i had just gotten done remodeling some pipe work myself. i have a saying. "We do it nice, because we do it twice!" its funny, but its not... haha

Thanks Ryan! I nearly stopped posting pics after seeing your work though! I don't feel so bad doing this after seeing your attention to detail. I always thought I wanted an auto trans, but just recently I've had a complete change of heart. I think that might have to wait for a bit! We do it nice, because we do it twice, HA! I might have to use that.
So block sanding filled in Tuesday, and drip rail and seam sealing filled in quite a chunk of Wednesday. The rain held off and I got the cab home in one piece. Tomorrow (Friday) we start painting the cab...