72 C20 Miss Olive

[notsolo]

Post some photo's when you get done, so I can see where I went wrong. Spaghetti junction is what I got. I reused the A/C harness, my fan and controls don't work correctly, not sure how many times you can take these apart and still come out with the same results. I did make a clamp to route some of the mess over the steering column.

[Nomadicflyer]

I fully expect to put in troubleshooting time, after all this is done. Nice clamp! It looks a little shaggy in the pic, but I'm sure it's better with everything installed. I went a bit nuts with the clamping and routing. I'll post pics tonight.

AC: if this harness doesn't work, and I'm pretty sure it won't, I will likely sit down and make a new one. Looks like 2 or three relays, a resistor pack and a switch block. It won't be until I'm done with my move, but when I do it, you can let me know if I should make two...

[Nomadicflyer]

A few updates. I haven't been able to keep up with posting, late nights in the shop...

While everything is off the rig, now was the time to replace the heater core. It wasn't leaking, but I had one on the shelf since 2014, when I decided to assemble a pile of parts to eventually put on during the project.

With fenders and interior out, it was a pretty easy affair. I had read of issues, getting to the forward 6 o'clock fastener that's up against the fender. I could see where that might be a pain.

Air blasting the sand that was in there from sand blasting, last year. That stuff got everywhere! Since the cab didn't come off for this project, there were lots of hiding places for sand to go.

[Nomadicflyer]

Block heater~ And I'm a cable routing GEEK, so between the heat of the exhaust manifold above and Y pipe below, I figured I'd better load for bear. Or beer, something like that. At any rate, I don't think I'll have a problem with this cord getting in the way or getting too hot.

That freeze plug was a PITA!!! I've seen everybody and their brother post on how easy it is to pop out a plug, but I went through a song and dance I don't plan on going through ever again... the plug wanted to disappear into the block, there was no 'tipping it out' with hammer and drift. Finally got it.

Pressure tested the coolant system, after the cabin heater and block heater install.... rock solid.

[Nomadicflyer]

Tried to replace the brake hoses, for calipers and rear axle. Again, a PITA!!!

The right side caliper hose didn't want to work with the attach bracket. Had to do some light grinding to get the clips to work. Then, went to put on the left caliper hose and it was tooooo short. Dang it! Called the manufacturer, they said that the hoses weren't meant for a 72 C20. The reseller should not have included C20 in the listing, they don't even make a hose set for a 72 C20. No word yet, from the reseller... emails have been sent.

Napa had the rear axle hose. The fronts are hard to find, I can get a local shop to fab them, but it's gonna cost 40 bux a hose.

Changed the master cylinder for a wet power booster. Nothing got into the PB, just a damp seeping from between the MC and PB.

[Nomadicflyer]

Follow up on brakes:
Speedway offered kind of a generic AN/banjo set of stainless. Needed to order an adapter for the left side line, as well.
http://www.speedwaymotors.com/DOT-Br...-20,36151.html
Required cutting the mount tabs off and replacing with supplied tabs. The banjo fittings weren't canted, the way the factory ones are at the caliper. The lines needed to mount exiting at the 1 and 11 o'clock positions. The lines were longer, but the odd mounting orientation required a few more inches to get the lines turned around and headed towards the front cross member.

[Nomadicflyer]

Other side, and at the caliper.

The adapter fitting is part# 9103183-3/8

[Nomadicflyer]

Some shots of the wiring I did tonight. I pulled the mechanical coolant temp bulb, and installed a new electric bulb. Not sure if the factory, panel mounted water temp gauge works, but I'm wiring it back up. Guess I'll find out.

Wired the choke into the AAW harness lead for ignition, since my MSD set up runs off another circuit.

Built up a few stand offs to support Adel clamps.

Installed the wire gutter on the firewall, by the cowl. Filled it with wires.

I wish I had time to spend on the engine, wiring and plumbing. These are planned for after another project gets done.

[Nomadicflyer]

A few shots of the cab wiring:

[El Dorado Jim]

nice job on your truck,you are very talented to tackle all you are doing.....

[notsolo]

Nice save Making your own brake hoses, PITA you can't get correct replacements. Wiring Looks great, clean and neat, I need to pull some of mine and wrap it up like yours.

[Nomadicflyer]

Thanks Ed, Jim! Truly learning as I go. The folks on this forum make the difference between recovering from a mistake or not. If you're smarter than I am, you learn from the board early and don't even make the mistakes to begin.

I really hope those brake lines do the trick. I don't understand why the 71/72 C20 hoses are so unobtainable. Is that a word? They look like they'll work. Ed, I couldn't tell on your build pages, are you drum or disc up front? Any issues with getting brake lines?

[notsolo]

My Front cross member is off an 83, with disc's and 2 1/2" drop spindles. I think I also have left over parts that were wrong length... After market parts are a crap shoot... NAPA maybe the best bet. I buy some things from Rock Auto but most of that is now Chinese made. Is the bore ID in the brake hose the same size as OEM ? Some one on here may have coined the phrase Unobtainium. So yea you got that going for you. Your making good progress Kevin that's the main thing.

[Nomadicflyer]

My last post was a month ago. I've been a man on the move. I've also learned a few things:

It takes a village to move my compressor.
Carpeting stairs sucks. Real bad.
Epoxy floors look sexy.
I'm not a gardener.
Watching paint dry is not all it's been talked up to be.

Even so, I started the engine and made the lights go yesterday. The first time since tearing out the wiring.

[Nomadicflyer]

I kept back my tool boxes and a rack full of totes. Pressing on until I can drive the truck to the new house. It's not ideal, but then again none of this has been. Adapt and overcome.

So it didn't go without a hitch, throwing the key that first time. As I connected the negative terminal to the battery, the headlights began to warm my lower half. Found the headlight switch post, at the bottom of a box, and installed it. The instrument panel was just sitting there, not fully installed and I had not thought to install the headlight control post, as I'd be getting behind it to fix something. Turned out trying to think ahead gave me something to fix, right away. Easy enough.

I heard the distinct pop of a fuse blowing the first time I threw the key to run. Ugh. Wiper circuit. Ok, the next item on the hit list. Low hanging fuit; headlights worked. The new LED lights (not headlight$, but the rest) worked in park. Had to swap the LED relay and the emergency flasher to get the turn signals to work. Cool, lights work.

Heater fan works, carrying forward a prior issue. Hi, Med works, Low does not. I guess I'll be changing the resistor pack in the air box after all.

Turn the key~ engine cranks. Cool, but will not run. Dang it. Better hit that first.

• Power to MSD box~ check
• Power to MSD coil~ check
• Distributer turning with engine ~ check
• Trigger circuit to MSD box ~ check
• Timing light to plug wires ~ check
• Verify good grounds on heads ~ check

Still, no run.
With faithful adherence to troubleshooting techniques, established well before me, I went through my list of items and corrected the problem. After all, one of the main reasons for having my truck for so long is it's easy construction and ability to fix, right?

[Nomadicflyer]

Great, it's running. And with the growl of an animal that's been caged up in the shop waaay tooo long. The neighbor came over, after hearing it run. He said hearing my earlier attempts at starting the beast kept him from visiting. He knew the party wouldn't start until he could hear the ol girl grumbling through the trees!

Time to put the last wheel tub in. As I did my last look over before installing the left wheel tub, I remembered a chore that somehow didn't make it to my list:

[Nomadicflyer]

I checked all the dimensions from the service manual, and everything is correct; lower shaft bearing to intermediate coupler (gap of the spring), etc. Just looks like everything had slid south on me.

Ordered a rag coupler from Rock Auto. I think it was the Larsen 201. Hope that fixes it. Has anyone had this issue fixed with the coupler? I've seen plenty of posts where there were missing pieces, slipped intermediates, etc... but my rag coupler looks too floppy, and may be where the extra downward is coming from? Any suggestions would be helpful. It's a non-tilt column. All the shaft clamps are keyed, so there is little adjustment available.
<<< Looking at folks like LocDoc!!!! >>>

For what it's worth, a few more pics:
I may repost in the general forum, if my thread has dropped under the radar.

Thanks to all! Be safe out there!!!

[Nomadicflyer]

The options for the rag coupler were 25 spline or 31 spline. No matter how many times I count, I can only get 30 splines. They must consider the flat key as a spline. Sorry for the autofocus, I don't have a way to focus properly on the shaft. It kept centering on the gearbox.

[Husker]

Nice Work On the Truck, Carpet etc. Nice Color.
Ron

[Nomadicflyer]

Thanks, Ron! A few pics from today:
Riveting the data plate in, putting in new weatherstripping, installing a temporary bed deck so I can finish my move.

Spent several days rebuilding brakes, to have a brand new line fail. Replacement on the way.

First drive in 2 years might happen this week! Gotta finish the bed, the brakes and the passenger door window glass. Everything else is either done, or deferred for later.

[notsolo]

Looking good Kevin, I have considered using oak ply ripped for bed boards, with plain stainess strips. Don,t know how it would hold up even if coated...How did the steering column work out?

[Nomadicflyer]

Oh, man that steering column worked out great! I'm sorry for not posting pics, here's how it turned out. I've been showing the house, fixing the house, working on the Snap on van, mowing.... I'm putting in about 70 hour 'work' weeks, between all of it. I have no time for actual work, at this stage!!!

Replacing the steering rag coupler really pushed the lower bearing assembly back up into place!

Next post will have pics, won't attach to this one.

[Nomadicflyer]

Bearing and housing look like crap, but they are where and how they should be.... gotta move on to the other 1500 items in my way of getting outta here!

[Nomadicflyer]

A few pics of the rubber mat going in. The outfit sent me the wrong damn one... they sent a high tunnel floor mat, even though the box shows low tunnel. We made it work.

[Nomadicflyer]

My buddy said to heck with it, push on! I'll bet we can beat to fit, paint to match, and that's what we did. Sure helps having help. We cut long relief cuts where the mat fit up under the ac box. If it wasn't for the ac box, we never would have been able to do this.

Enough cutting and trimming and tucking and folding, and the end result was acceptable.

Next item on the punch list... only 1250 things left to do!