Left for dead: 72 2wd blazer build

[1956cameo]

JimmyFloyd, Thanks! I will definately keep posting as many pictures as I can.

Oldblue1968chevy, Thanks for the recognition! It has definately been some work.

[1956cameo]

I got a chance to work on the blazer a little today. I spent most of the day tearing out all of the rotten panels in the passenger side door area. I belive there was about 20 pounds of rust and dirt that came out of the truck today; and one rats nest.


I got the drivers side rocker box set into place, but my dad threw his back out so we were unable to weld it in today.



It felt so comforting to complete the metal work on the drivers side door and rocker area. Then it felt very deflating to start it all over again on the passenger side. Here is a shot of the passenger side before starting. It was much better than the drivers side when I started on it.



After taking off the rotten rocker panel I was left with the typical rotted out lower door pillar.



At least on this side I was left with enough metal to take pictures for references.

[1956cameo]

I was able to get the outer section of the old floor out today and cut the reproduction outer floor section down to size. I would have been able to get it tacked in today if it weren't for my dads bad back and a rotten hat channel.



Since I couldn't tack any new metal in I continued cutting out rotten metal. I tore down to the 1/4 panel brace. I was hoping it would be in good shape but it was rotten as well. So I cut it out to use as a template on making a new one.



I was thinking I might be able to keep the original rocker box in place and just patch it but it is pretty pitted so now I am thinking it will be replaced. I know this doesn't sound like alot but that was a days work! Hoping to make more progress soon. Here is a parting shot of the way she looked when I left her today.

[68,69 K20]

Thumbs up for taking on a project most guys would have probably sent to the crusher or stripped for parts...

You do great work, especially the repair work you did on the rusty cowl, nice....

[1956cameo]

68,69 K20, Thanks for the compliment! It's been alot of work so far, but still alot of fun.

[vectorit]

WOW! I just stumbled across your build here, and dang you sure are going the extra mile on reviving that Blaze! Very interesting to read, and see all of your progress photo's.

Keep up the good work, and I can't wait to see it all come together now!

Subscribed

[1956cameo]

Vectorit, Thanks! I am trying to show as many pictures as I can for both information and entertainment value. Whenever I am done with the blazer I plan on starting on my 72' suburban. It should be a cakewalk compared to this old girl!

72' Deluxe, with factory 402 big block. A spectator at the local cruise night called her "The Battle Wagon". I liked the name so thats what I now call her.



Not much in the way of rust. A little over the windshield, but that is it. Those specs you see aeren't small rust holes but little tar balls. They come from Texas asphalt roads that get so hot in the summer they make your tires sling up tar goop.

[1956cameo]

I got back out to the shop this weekend and made more progress! The first thing I did was get rid of all the rot in the rear door panel. As you can see it did not leave a whole lot left. I'll admit at this point I was wondering where to base dimensions on how to place things back into place.



I figured the piece that would be the hardest to screw up would be the vertical flooring, so I started the rebuild process here.



Next I started the long task of rebuilding the 1/4 panel to door jam brace. It is no where near as pretty as the repro's (or the D/S one I made) but I really need to put that money in other parts of the blazer.



After getting the 1/4 panel brace welded in I got the rear door pillar patch welded into place.

[VA72C10]

nice work on the rust repair...and that burb looks like an EXCELLENT start!!!

[1956cameo]

VA72C10, Thanks! I will be glad when I am done doing rust repairs in the door and rocker areas. I feel like I have been working on this part of the blazer for ever. I am not sure how eager I will be to start on the suburban after the blazer is done, I might need a break by then!

[hgs_notes]

Originally Posted by 1956cameo

I am not sure how eager I will be to start on the suburban after the blazer is done, I might need a break by then!

You might be surprised. You may find yourself getting revved up to work on something different.

[Muleman100]

You have a break every other weekend.

[1956cameo]

hgs_notes, I hope that is the case. I do find myself thinking about things I want to do to the suburban even though the blazer is no where near completion.

Muleman100, HA! I think you forgot how "relaxing" it is when you have 2 under 2 at home!

[72MARIO]

your work looks great

I did the same thing to my 67 short box. My only mistake was not aligning the doors on the cab first and then welding the rockers on. If you dont make sure the door fits and has a nice vertical line against the 1/4. Then hanging the rocker horiziontal to the bottom of the door the gaps are really hard to get looking right.

[1956cameo]

72MARIO, Thanks! I am definately concerned with what the door gaps are going to look like. On the drivers side I bolted the blazer door on while welding the rocker panel on. Unfortunately the original door is completely rusted out and I am not using it. For the most part it all fit up okay. There was a little rubbing of the door and rocker at the very front. I just hope that the door that I am going to use (cut down truck door) fits up at least as good if not better than the original door. I should find out the next time I work on the blazer.

[1956cameo]

I got more work done on the blazer this past weekend. I finished tacking in all of the patch panels on the passenger side of the blazer and got the rocker panel to line up beautifully with the door. Unfortunately I did not get a picture of the finished door jamb area by itself, but here is a picture with the original door in place to help me guide the placement of the rocker panel.



After getting the rocker panel lined up I tossed the original rusted out door to the side, and took the doors off of my factory big block parts truck. Here is a picture of the parts truck door before going under the knife.




I got the doors on the blazer without too much of a problem. However the drivers side door does rub on the rocker panel so I will have to do a little shaving there. Also I still have to convert these doors (70') into 72' doors and I have to put all the blazer hardware onto them. Here is a picture of the former truck doors on the blazer.

[1956cameo]

After getting the doors bolted into place I started the task of taking the top off. I have been eagerly anticipating this so I can see how much rust I need to fix in the windshield frame area. I was pretty nervous since every other part of the blazer has had an above average amount of rust.

For once I was happy to see an unexpected lack of rust! I didn't even find one pinhole on the top of the frame. This part of the project should be a breeze to repair.



I was expecting to find quite a bit of rust hiding out under the top on the bedsides. Again I was happy to find only one problem area. It is a good size rust spot but I will repair it with a donor section from a truck bed.



Thats all I got done this week. Below are some pictures of the blazer with the top off. My dad said taking the top off made it look even shorter.

[Big Block]

Wow, It's start to shape up. I wish the po would have had the doors on before he welded the rockers on my Jimmy. They don't even come close. The front of the rocker sticks in at least an inch in front of the doors. Nice work. Looks good.

[1956cameo]

Big Block, Thanks for the comment! These definately aeren't concours quality gaps, but for as much metal as I had to remove and build back I am extremely happy with the way it all turned out (even though I have a little aligning left to do).

[1956cameo]

I got out and worked on the blazer some more last week on Labor Day. As everyone that has followed this thread knows I have practically replaced all of the metal in the floorboards. Once I got the passenger side rocker panel in I figured I could count everything in that section of the truck done as far as metal work is concerned. As I was sitting back, looking at my achievement I noticed a small quarter sided hole in the bottom of the firewall. I am starting to think the rust is growing faster than my cutting wheel!

The small section cut out of the bottom of the firewall.



The donor piece from a parts suburban trimmed and fit into place waiting for the welder.


As simple as that was it was just the warm up for the most critical challenge in this build. The repair of the dreaded blazer windshield frame! Overall mine wasn't in too bad of shape but it still needs plenty of patching. First step. Go back to the donor cab that I cut the floor out of.



It was a little harder to cut out than I thought because without the floor the cab immediately buckled but I got the needed section out!

[1956cameo]

I feel bad destroying a cab that still had/has so many good panels in it but I know its all for the best. Heres the rest of the rest of the cab parts cast out to the boneyard with the rest of the parts vehicles.


The next thing I did was cut out all the areas of the passenger side windshield frame that had rust holes or any weak metal. My plan is to cut out a donor panel from the truck cab and weld it into the blazer as a single piece.


Heres a shot of the back side of the trimmed down windshield frame.


It took the rest of the day but I got the donor piece cut out. It needs slight trimming to fit into the blazer perfectly but it looks like its going to do a great job of repairing the blazer. Unfortunately by the time I got this far along the day was over. I am very eager to get this piece in so expect another update soon.

[VA72C10]

Keep up the good work!

[PHAT TONY]

It's gotta end some time!

[SOON2BLAZE]

Good job saving your windshield . Thats not a job for the faint of heart. keep up the good work.

[1956cameo]

VA72C10, Thanks! I will definately keep on keeping on!

PHAT TONY, Thats what I keep telling myself! I have seen others on here take on worse and end with show winners. That always helps me to stay motivated.

SOON2BLAZE, Thanks! I will admit this is the part of the project that has been on my mind the most. I think if I can repair this the rest of the metal work will be a snap.