1972 K5 4x4 modified build

[67Steven]

Next I needed to build a battery box for the firewall, as the air cleaner was taking the normal battery position on the core support. I still had some aluminum scrap, so I decided to build it from that.

Sides cut:

For the bottom I cut and bent a flat sheet a little wider than the battery:

The two sides with holes drilled. Good for 5-10 horsepower I’m told:


Next I bent up a top hold down plate. The dimpled holes hold it nice and snug:



Welded and mounted on the firewall:


Installed the fenders and grille surround. I painted the inner grille grey instead of the silver color it was, that way I can do touch-up if needed. I had to repair the grille surround with the TIG in a couple of spots then sanded it down to get a nickel finish look. I might have it nickel finished in the future:

[boonedogs72]

Wow nice build!

[67swb72klb]

mad fab skills!!

[mx289]

Very nice.You got some skills.!

[mud.man.rj]

Man that is a beauty, did you do all that when I slept last night, I wonder if you work 24 hours a day.

[67Steven]

Thank you, thank you! This is my first project, so I learn as I go. And no, I am not working 24/7 on this. This is more of a recap of my past work. I just never made time to sit down and post. But I have a cold, we have 7" of snow and ice on the ground, so I have time now. I am nearly done, just have a few more small items to address.

On to the pictures:

I got some help, manually lifted and put the body and cage in. It started raining right when we got done:



Tailgate and roll pan going on. I had planned on using the original rubber items, but new was pretty inexpensive:


I put the dash pad on, bolted the glove box door on (yes, it clears the cage) and started the wiring. I had a large chunk of aluminum left over from another project, so I turned a couple of billet cup holders for the console. I had rough cut them for mock up, but finished them now:



I had a buddy give me a load of ¼” stainless button head bolts so I am trying to use them up:

[67Steven]

I installed the new sport mirrors and the window regulators on the doors and then hung them. I then taped off the tops to install the glass:



I got the Danhard heater tucked into position:


Then it was onto wiring. I love wiring; this is probably my favorite job. It can be tedious sometimes, though:


I looked for a decent dash panel to run the Autometer gauges I bought, but I decided to build my own. So I took some .125” aluminum and cut it out in the shape of the original, then welded a flat strap on the outside to get the original face angle and standoff.

The back wired up:


The front. I like the Sport Comp II; if you squint, it looks like the Chevy bowtie symbol:


Here is where my project went askew. If you look under the console, you can see the placement of the ECM. I had purchased a new wiring harness from PSI which allowed me to put the ECM inside the tub:

[boonedogs72]

Love the fab work.

[Posted]

Sick sick sick, oh SICK!!!! Nuff said! You are one talented dude!

[Splash4195]

WOW unreal build!

[SONOSADSACK]

WOW!

From a wanna be fabricator, how about some advice on shop equipment? What bender are you using? What are you using for making dimples? Etc. I need to start building a better shop and any advice would be much appreciated. I have zero for fabrication tools and my next project is going to be very similar to what you have created. Knowing what equipment is required up front would be great.

[notsolo]

Nicest Mad Max build Yet ! ( if Mad Max had an HVLP gun and some color paint ) Paint turned out Excellent. Fab skills set a new bench mark, Total package. 10 out of 10. You now have to change your SPID tag to say Extra Heavy Everything.

[67Steven]

Originally Posted by SONOSADSACK

WOW!

From a wanna be fabricator, how about some advice on shop equipment? What bender are you using? What are you using for making dimples? Etc. I need to start building a better shop and any advice would be much appreciated. I have zero for fabrication tools and my next project is going to be very similar to what you have created. Knowing what equipment is required up front would be great.

Sure, here you go. If you need more info just holler:

For the standard stuff I use a Miller 210 MIG welder and I try to use a DX200 water cooled TIG. I have a ESAB plasma cutter and a Delta Drill press, along with a 13x40 lathe and 20 ton press. A few angle grinders and drills, etc.

For a bender I use the JD2 Model 3 bender with 270* dies from 3/4"-2" in size: https://www.jd2.com/p-32-model-3-bender.aspx
I added a air/hydraulic ram to bend the big tube, but you can bend up to 1" easily by hand. I built my own, but you can get this unit: http://www.ebay.com/itm/SWAG-Tubing-...item3f2afa9fb8.

I use these style of dimple dies. They allow you to use them anywhere in addition to a press: http://www.ebay.com/itm/SWAG-Off-Roa...item3f2dd228d1 I also have a 3" unit which is kinda spendy.

SWAG (dimple die guy above) also has a bandsaw stand and plate that I copied and I use it daily. It uses a Milwaukie Port-a-band and makes it a table top bandsaw. http://www.ebay.com/itm/SWAG-V4-0-Po...item3f2bac5c3b

These jewels are indispensable in my opinion: Greenlee DTAPKITM M3-M10 6-Piece Combination...And add the 5/16" and 3/8" drill taps. I use these to make new and clean out old threads. Buy extras of the ones you use most, and pre-drill with the right size bit before using.

That's about it, really. If you want to know something specific, let me know.

[67Steven]

I am overwhelmed by the compliments, thanks so much. I got a lot out of this site, so I posted not only to have a record of my build, but to help out others or give an idea or two.

I hope someone does copy, it's the sincerest form of flattery, after all.

[mud.man.rj]

So what do you do for a career, build trucks, seems like it with yours, should I drop mine off for a bit of cool fab work. OK to far away. You do have a lot of good ideas to twist to something else, thats what i look for on this site, inspiration, things to sleep on..then build. So thanks.
Mudman.

[fun in dirt]

Dang! There's is so much very slick stuff on this build!!!

[Tom Vogel]

How well does that little port a band saw work for you? Id like an upright metal cutting band saw, but price and space have stopped me so far.

[jaros44sr]

You, Sir have a very creative mind, enjoyed watching your build, and it has been a beautiful build.....but, we need more pics of the semi-finished progress so far, looks great out in the snow, congrats

Is the ECU ok mounted in the engine bay? Wasnt sure if i could mount mine in there

[67Steven]

Originally Posted by jaros44sr

You, Sir have a very creative mind, enjoyed watching your build, and it has been a beautiful build.....but, we need more pics of the semi-finished progress so far, looks great out in the snow, congrats

Is the ECU ok mounted in the engine bay? Wasnt sure if i could mount mine in there

Thanks! I've been busy, but I will get more pics this weekend while I work on it.

The ECU for the Hummers is actually mounted vertically down by the steering pump in the engine bay, so no worries. Of course it's cleaner in the cabin, but I did the best I could. If there seems to be an issue with the way mine is mounted, I will build a cover of some sort.

[jaros44sr]

Originally Posted by 67Steven

Thanks! I've been busy, but I will get more pics this weekend while I work on it.

The ECU for the Hummers is actually mounted vertically down by the steering pump in the engine bay, so no worries. Of course it's cleaner in the cabin, but I did the best I could. If there seems to be an issue with the way mine is mounted, I will build a cover of some sort.

Yeah, thats where i mounted it, didnt think it could get wet.....thanks for the info.
So, how does it run?

One more question, could you post up more info. on your bump stops when you get time

[67Steven]

Originally Posted by jaros44sr

Yeah, thats where i mounted it, didnt think it could get wet.....thanks for the info.
So, how does it run?

One more question, could you post up more info. on your bump stops when you get time

It runs great. I have only done a 3 mile shot to set the speedo, but I can tell it wants to scoot.

I built the bump stop mounts out of scrap 11ga sheet metal and tubing. The cans themselves are Daystar Stinger bump stops: http://daystarweb.com/productdetail.php?productID=1089

I have read mixed reviews, but the mounts will hold the standard air stops if I choose to upgrade. This truck probably won't see high speed desert runs, so I think what I have will be sufficient.

Hope that helps, if you need pictures or more info on them let me know.

[67Steven]

Originally Posted by Tom Vogel

How well does that little port a band saw work for you? Id like an upright metal cutting band saw, but price and space have stopped me so far.

It is awesome, and I use it daily when I work in the shop. I mostly use it to cut smaller tubing, flat stock and sheet metal designs. The only drawback is the small space to the left of the blade (where the motor is) but you can work around it.

I have entertained the thought of buying and modifying an old wood band saw, but this has done well for me so far I haven't pursued it.

[wannabefastcrf]

this is defiantly my new favorite k5 on here!

How did the wiring on the NP241 VVS go. I believe you use two of the three wires right?

[67Steven]

Originally Posted by wannabefastcrf

this is defiantly my new favorite k5 on here!

How did the wiring on the NP241 VVS go. I believe you use two of the three wires right?

Thanks!

You only need two wires, ground and signal. My 241 only has provisions for two wires. I think the drivers drop ('88-??) have a three wire bundle, so you might need to verify connection if that's what you have. Signal runs into the back of the speedo, and you calibrate it by driving the two miles. I grounded it on the frame rail near the cross member mount. Very simple.

[mtully79]

Sick build, love the orange/gray combo. Very nice work and an awesome truck!