Jim's 1969 Custom/20

[missinfishin10]

Great driveshaft info!

Thanks

[bollybib]

Originally Posted by missinfishin10

Great driveshaft info!

Thanks

You're welcome.

[oldman3]

Hey Jim, nice detailed write up on the driveshaft redo, thanks again....Jim

[bollybib]

Originally Posted by oldman3

Hey Jim, nice detailed write up on the driveshaft redo, thanks again....Jim

Hey Jim, I'm at an in-between-stuff-to-do stage so I sit here and burn up hours on end writing about what I did . Hope all is well with you.

[MindPhish]

Great build thread! This will be a great help to me and many others, thank you.

[bollybib]

Originally Posted by MindPhish

Great build thread! This will be a great help to me and many others, thank you.

Thanks. I hope you'll find some of it useful. There is a lot of good info available on this site if you take time to search it out.

I've been wading through a few issues on my exhaust but I hope to have everything done soon so I can put the bed back on. I drove it to Oceanside and back the other day with a set of trailer taillights and homemade mudflaps installed. The sheriff saw me go by and did nothing so it must be legal enough for an old truck. The rear end is very light so I have to be careful not to let it lock up and skid when I brake. I recently removed the passenger side pipe because I am replacing the mufflers with quieter ones. I'll write something up on this soon.

Peace.

[plummen]

Originally Posted by bollybib

Thanks. I hope you'll find some of it useful. There is a lot of good info available on this site if you take time to search it out.

I've been wading through a few issues on my exhaust but I hope to have everything done soon so I can put the bed back on. I drove it to Oceanside and back the other day with a set of trailer taillights and homemade mudflaps installed. The sheriff saw me go by and did nothing so it must be legal enough for an old truck. The rear end is very light so I have to be careful not to let it lock up and skid when I brake. I recently removed the passenger side pipe because I am replacing the mufflers with quieter ones. I'll write something up on this soon.

Peace.

Attachment 776468

thanks for the motivation!

[bollybib]

Originally Posted by plummen

thanks for the motivation!

Thanks for posting the pic of your white/saddle truck to add to my collection.

A good swift kick in the ass once in a while is a good motivator , too (just kidding).

[plummen]

I can use all the kicks to the ass i can get!
Hopefully i can finish gutting the cab today so i can pull it back off and get going on my frame mods this week

[treveiger]

Ss. Great project an a lot of good info. I was having trouble with my universal joint that connects to my tranny an thought of the c clamp as well. How did you install the u joint?
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[bollybib]

Originally Posted by treveiger

Ss. Great project an a lot of good info. I was having trouble with my universal joint that connects to my tranny an thought of the c clamp as well. How did you install the u joint?
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I'll try to write up a little procedure for you. I didn't take any pics of that work when I did it.

[bollybib]

EXHAUST (Part 1 of 6)

I did this work on the exhaust system between June 3 and August 18, 2011.

While I was doing all the aforementioned work in the bed area, I evaluated the existing exhaust. I decided to chuck the PO's system for several reasons.

* The headers obstructed access to the spark plugs, were in direct contact with a brake line, pipes had been crushed to clear the frame, and they were basically in the way of everything. Some plug boots were burned where they hit the pipes.

* The header pipes interfered with the tiny hex head attaching bolts such that the bolts could not be torqued properly. It was a looseygoosey, leaky arrangement at best.

* The driver side muffler had broken away from the pipe. The passenger side wasn’t too far behind.

* It was all way too noisy for me. I want smooth and quiet, not rough and noisy.

So out it all came. Another easy job (taking stuff apart is a piece of cake). BTW, please feel free to heap abuse on me for using the Fram filter shown in the first pic below.

I wanted straight dual exhaust using original GM part number exhaust manifolds (aka ramhorns). I figured I could install an exhaust kit myself because I installed a kit on my Vette long ago (still in good condition, too). I found several kits available for 67-72 trucks and eventually decided on the Hooker 16621HKR with Hooker 21005HKR mufflers. I found a few threads where guys had used this kit and had no issues with it. If it all comes from the same manufacturer it should fit like a glove, right ?

The kit instructions ---> http://www.holley.com/data/Products/...l/16522HKR.pdf

I found a passenger side exhaust manifold on eBay (GM 3896956) and I bought the driver side from teeitup in the Parts Board (GM 3932469). The old studs are usually a problem (rusted in and so on) but I figured I could get them "good enough" and if there were problems later, I could either get new Dormans or better used ones. So I drilled and tapped and JB Welded and wire brushed and ground until I felt they were good enough to use.

[bollybib]

EXHAUST (Part 2 of 6)

The passenger side manifold arrived first, so I started my my pipe fit-up on that side. I attached the headpipe to the manifold and snugged up the flange with plain stud nuts so that the flared end of the pipe was flush with the manifold outlet (best not to use locknuts just yet, wait until everything has been fit up). I left it loose enough so I could adjust the direction of the pipe once under the truck. I guided the assembly into the engine compartment and secured the manifold to the head by snugging up three bolts, two outer and a center. I then went to take a look at what was happening underneath the truck and the pic below shows what I saw.

Hmm…now what…I e-mailed a notice to both Holley (they own Hooker) and Summit (the vendor) describing what I encountered. More on this later.

While I was figuring out what to do about the droopy headpipe, I went on to the rest of the kit. I don’t have a welder (which may be blessing or curse depending on the situation). So I was thinking I’d clamp the pipe joints and find some way to use fasteners to attach the hangers to the frame. Six hangers are required, three for each pipe run. I got out my C-clamp collection and began to search for good frame attachment points. I hoped I could find holes in the locations where I needed a hanger. I did find a couple for the rear hangers, but I was unable to find existing holes suitable for the others. I had no desire whatsoever to drill through the frame.

During the initial fit-up, I had a hard time keeping the pipe and mufflers from flopping around, falling and generally behaving in an unruly manner. So I made up a pair of wood saddles for the mufflers and set them on a crossbeam and used a lot of wire and clamps plus the hardware in the kit to secure sections of pipe and that helped a lot.

[bollybib]

EXHAUST (Part 3 of 6)

I should also mention that the pipe ends were distorted by the manufacturer’s end cuts. They looked to have been cut with a cutting wheel type tool. As they came out of the box, none of the sections would slide into a mating pipe section or a muffler. I took a file to the ends and removed material at the last inch or so of pipe near the cut. After that, the pipe sections slipped firmly into their mating section.

By this time I got a response from Summit (but nothing yet from Holley). Their response in part was "We've had 37 sets sold in the last three years with 2 coming back, 1 return was similar to yours". Summit offered to exchange my kit for another, but I felt that I’d get the same stuff in a new kit because the left and right headpipes are the same part number according to Hooker’s installation instructions. So I proceeded knowing I’d have to have the droopy headpipe bent by a shop.

I needed to make sure it got bent correctly. To ensure my measurements were accurate, I moved my truck into the garage so it was on a flat surface. I rigged up some layout string across the frame to get a good reference point to measure from. With my measurements and a little trig, I computed that the pipe needed to be bent an additional 6.7 degrees upward. I also measured (with less accuracy I’d say) the compound angles of the outlets on both manifolds relative to the plane of the inlet ports. I found them to differ between the driver side and passenger side by about 6 degrees. This confirmed that the outlet angles of the manifolds are not the same side-to-side and that my calculated angle was in the ballpark. I made up a template on a piece of cardboard, took the pipe to a shop with bender, gave the guy eight bucks, and he bent it for me. I took it home and finally it fit right so I could move on.

Here is another member that experienced the same problem but with a different kit:
http://67-72chevytrucks.com/vboard/s...&postcount=320.

Eventually, I got a response from Holley. Here it is.

"Jim, I have forwarded your issue to product management and discussed your concerns. Unfortunately at this point with this being a cost effective kit with no other complaints YTD on quantities sold they are advising me the kit is what it is basically and if you are not satisfied with it and do not want to make any mods to make it work to return the kit. At this point we are not going to redesign the kit. I apologize for the inconvenience. Thanks Shane Whitescarver Technical Service Representative"

Hmm, cost effective. For them perhaps since they won’t incur expenses to improve the product. Isn’t anyone complaining about the fit of this kit ? And is Holley admitting that they sell a poorly designed product ? I sent a reply to Holley saying that they should add a cautionary note to the kit instructions, i.e., "this kit may require field bending and cutting to achieve correct fit".

[treveiger]

Looking good!

[oldman3]

Nice job Jim, truck sounds good to me, enjoy.....Jim

[bollybib]

Originally Posted by oldman3

Nice job Jim, truck sounds good to me, enjoy.....Jim

Thanks a lot, Jim. Seems things are in good running order now so I'm going to enjoy driving it for a while. It's a lumbering beast but a lot faster than I expected. Without the bed it was quick. Runs on regular OK. Sucks it up like it was, well, 1969 !

[Stricklinator]

Nice write up Jim! I replaced my exhaust a while back too. I bought a dual kit from LMC, but gave up when I couldn't get the manifold collector bolts to budge. Trucked it down to a muffler shop and had them do it for me. He broke almost all of those bolts on the manifolds and spent quite a bit of time re-bending the supposedly pre-bent pipes. I am not happy overall, he did a poor job lining everything up and put hangers in poor places, but it sounds good and sure beats the rusted out single pipe! Happy trucking; I love your Corvette too by the way!

Paul
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[treveiger]

Originally Posted by Stricklinator

Nice write up Jim! I replaced my exhaust a while back too. I bought a dual kit from LMC, but gave up when I couldn't get the manifold collector bolts to budge. Trucked it down to a muffler shop and had them do it for me. He broke almost all of those bolts on the manifolds and spent quite a bit of time re-bending the supposedly pre-bent pipes. I am not happy overall, he did a poor job lining everything up and put hangers in poor places, but it sounds good and sure beats the rusted out single pipe! Happy trucking; I love your Corvette too by the way!

Paul
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can I ask what's a price range on getting custom pipes if you already have the mufflers?
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[Stricklinator]

Originally Posted by treveiger

can I ask what's a price range on getting custom pipes if you already have the mufflers?
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I paid $300 for the muffler shop to fit my "pre-bent" kit and weld all the joints. I thought it was pricey, but I don't have much experience with muffler shops so I am not sure.
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[treveiger]

Ya I have seen a few also just hoping its not to insane
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[bollybib]

MORE MISCELLANEOUS FIXITS (1 OF 2)

Here are a few more things that needed attention that I’ve completed since my last FIXIT post in May 2011 (Post #21).

* Interior rear view mirror

The PO’s mirror didn’t look like it belonged in a truck.

From what I could gather here in the Board, 1969 was the last year that interior rear view mirrors were an option, so the one I inherited must have been added by a PO. I bought an OG mirror offered by 72shortbed12 in the Parts Board and installed it. It came from Utah so that was kinda cool since my truck came from Utah, too.

I looked for pics of mirrors in the Board to get the positioning as close to stock as possible. Pics were not easy to find, very few people take pics of their rear view mirrors. The cover should be saddle, not white, but I can paint over it or find a saddle cover later if it causes sleepless nights.

Here is a thread discussing these mirrors or lack thereof - - - - > http://67-72chevytrucks.com/vboard/s...d.php?t=473824

* Glove box emblem

My Chevrolet was a Custor so I got a new emblem from Ironhorse in the Parts Board. I glued it on with silicone glue because the studs were broken. Now my Chevrolet is a Custom like it should be.

...

* Glove box light

I got one of these from thelonerife in the Parts Board - - - > http://67-72chevytrucks.com/vboard/s...love+box+light. It was cheap and easy to install. The old liner was shot so I trashed it. I’ll get a new liner later.

[VA72C10]

Nice progress and enjoy the writeups!

[bollybib]

Originally Posted by VA72C10

Nice progress and enjoy the writeups!

Thanks. It's a windy, rainy day here this morning (rather unusual the rain is this time of year) so I figured I'd amuse myself (and hopefully others) with a bit of a ramble on my truck.

[oldblue1968chevy]

You do an amazing job! keep up the GREAT work!