The "In over my head" build thread

[SeventyOne]

3/17/19: Almost Home

Another semi update

Alright so got the Blazer painted last Spring but the body shop I have it at also outsources some mechanical work. So i ask if they could help with some things liiiike:

-Custom Trans cooler lines for my 700r4 swap
-Cut down and reflare my stainless rear diff brake hardline to accept the disc hoses
-Set rear diff pinion angle and weld on the spring perches for my 14 bolt swap
-Start my engine (my buddy Mike had trouble with his West Coast Engines 350 and since i got my 383 from the same place I just wanted the shop to start it) up and ensure it at least would run
-Reinstall my NP205 i pulled to fix a leak, I bought a tcase ebrake so he needed to machine it down .25" to fit under the floor pan, and then measure for driveshafts
-Change my front axle gear ratio to 4.56 to match the rear
-theres probably more but this is the big stuff

At the same time the body shop freshened up my top and hatch, welded up a hickey roll bar kit i bought on ebay a while back, replaced my windshield...

Anyways. I told them i want it back mid April. and they're making it happen. Top got mounted. They're going to drill holes for the mirrors and install the strikers and do final panel adjustments.

Here's pics:










Also does anyone know why my pics post sideways?

[BIG BLOCK JIMMY]

Beautiful!

[rsavage]

Looking great!

[SeventyOne]

8/13/19: Are we there yet?

Well April came and went but the plan is to have her come home Saturday and I can begin final assembly!



Also I was going through some old hardware in bags and came up with these gems. 10 years ago my (then 17 year old) brother helped me disassemble the K5 and this are what he wrote on some of the bags

[SeventyOne]

Also about 11-12 years ago I owned my first K5 and I took this dumb hi-beam "foot"swtich off it before selling it. It's been sitting in a bag for at least a decade waiting for this moment:

[SeventyOne]

8/17-18 "An overwhelming Weekend"

The Blazer is home. it's very surreal to me to see it in my driveway. I'm not an anxious or nervous person in general but I felt very...off...on saturday. Like I didn't know what to do, where to start, how to approach anything - I was scatterbrained and just had weird energy. It didn't help matters that after moving the K5 from the street into the driveway (albeit with a super loud, open header'd, lumpy cam'd, 383) I got a visit from my neighbor...

Now let me preface that I've been living here for a whole year and I've never even seen her before. The engine probably ran for 30 seconds before it was in the driveway and shut off and i hear over my shoulder "Puhhhleasssse tell me that thing is not going to be that loud?" I explained to her it's unfinished, it has no exhaust but it will in the future etc etc. She went on to cite some city noice ordinances, saying when she get's home "she just wants some damn peace and quiet" and then complains about my other truck ('65 F100 with cherry bomb glasspacks). At this point I've said all I can, she just wants to be upset/complain...like alright lady, sorry you heard a loud noise at 5pm for 30 seconds on a Saturday.

After her rant I calmly said, "And...who are you?" then "Nice to meet you" about as sarcastically as possible as she walked away.

For what it's worth I am a courteous neighbor. I'm not burning out, racing or revving the engines, etc. When I drive the F100 I just let it warm up for a minute then leave.

But that bullsh*t aside here's some pics!

[SeventyOne]

Sunday I wanted to install some simple parts, calm my nerves, and get some small wins under my belt.

Got some good progress on the fuel system/vapor lines. Still need some hose clamps and the vent hose line I have is for a different year as it's way too short so I need to get a new longer one to install and finish up the install.

If anyone knows where to get nice hose clamps let me know - looking for something better than generic worm-gear clamps.







Then I wanted to get the bumper brackets installed and I ran into an issue with the rear bumper brackets. Since I installed a shackle flip the bracket on the outside of the frame rail blocks the rear-most bolt hole that should hold the bracket in place.

So I notice on my bracket theres an undrilled hole that would allow a second locating bolt to go through the bracket and frame. I got them drilled out and once I mount the rear bumper and make sure the angle is correct, I'll mark the frame and drill it as well.

You can see the 2nd hole is drilled on the top bracket in the pic below:

[underliner6]

My god, the hugger orange on your blazer looks amazing. The decade of work surely paid off!

[SeventyOne]

9/4/19 - 2 steps forward 1 step back

Been keeping busy when I can find time to work on the truck – an hour after work here, couple hours on the weekend there...but i keep running into issues where a simple install that should take 15 minutes, takes 90.

I went to install the MotorCityK5 hydraulic hatch strut kit and as noted in other reviews the lower bracket hits the top to bedside bracket. It was only an issue for me on the driver side, however, as the passenger side fit fine. The real problem I had was a broken screw in the trapped nut where the top strut bracket would go. That took a lot of careful drilling, cussing, and praying that I would get it out. Luckily I did and I gotta say the strut kit is well worth it.



Also been working on the sound deadening with some dynamat. Symmetry is fun!


Plan is to cover 25-50% of panels for sound deadening with the Butyl strips, then I'll use some MLV I bought for a sound barrier basically everywhere I can, as well as some dynaliner on the firewall and foot wells for heat.

Before I get too crazy with the sound deadening I want to get the units that mount to the firewall in place and work around them. So inner heater air plenum box went in, then I took a look the wiper motor mount and found this bent, broke off screw.



I ran out of time yesterday but I'm hoping I can install two nuts to the end of the screw, then use a wrench on the inside nut to twist it out. Wish me luck.

Once I figure that one out I'll finish getting the a couple more dash pieces installed (heater controls, gas pedal) and finish getting the sound deadening stuck on.

Then hopefully onto some wiring, drilling holes for the CST panels and carpet strips.

And maybe jump around to other stuff as I get frustrated.

[72K5CSTDarkOlive]

[QUOTE=SeventyOne;8578745]8/17-18 "An overwhelming Weekend"

The Blazer is home. it's very surreal to me to see it in my driveway. I'm not an anxious or nervous person in general but I felt very...off...on saturday. Like I didn't know what to do, where to start, how to approach anything - I was scatterbrained and just had weird energy. It didn't help matters that after moving the K5 from the street into the driveway (albeit with a super loud, open header'd, lumpy cam'd, 383) I got a visit from my neighbor...

Now let me preface that I've been living here for a whole year and I've never even seen her before. The engine probably ran for 30 seconds before it was in the driveway and shut off and i hear over my shoulder "Puhhhleasssse tell me that thing is not going to be that loud?" I explained to her it's unfinished, it has no exhaust but it will in the future etc etc. She went on to cite some city noice ordinances, saying when she get's home "she just wants some damn peace and quiet" and then complains about my other truck ('65 F100 with cherry bomb glasspacks). At this point I've said all I can, she just wants to be upset/complain...like alright lady, sorry you heard a loud noise at 5pm for 30 seconds on a Saturday.

After her rant I calmly said, "And...who are you?" then "Nice to meet you" about as sarcastically as possible as she walked away.

For what it's worth I am a courteous neighbor. I'm not burning out, racing or revving the engines, etc. When I drive the F100 I just let it warm up for a minute then leave.

But that bullsh*t aside here's some pics!

You should've fired it right back up

[Ptjsk]

Damn!!! That's a beautiful build!

As far as your neighbor goes.....

I guess your neighbor probably wouldn't approve of some AC/DC blasting out of my speakers in my garage. Of course that's probably why I live on 5 acres.

Also, I think the next start up should take place while you're wearing a speedo, a too small white tank top, and the ballcap that holds a can of beer on each side of your head. LOL!

She may think twice about paying you a visit again.

Honestly though, what an awesome rig Bud!

Pat

[SeventyOne]

Originally Posted by Ptjsk

Damn!!! That's a beautiful build!

As far as your neighbor goes.....

I guess your neighbor probably wouldn't approve of some AC/DC blasting out of my speakers in my garage. Of course that's probably why I live on 5 acres.

Also, I think the next start up should take place while you're wearing a speedo, a too small white tank top, and the ballcap that holds a can of beer on each side of your head. LOL!

She may think twice about paying you a visit again.

Honestly though, what an awesome rig Bud!

Pat

Lol yeah I might have to get a little weird on her for next time. Thanks for the compliments, too!

Hope to get some time tomorrow to keep the progress moving - more updates coming

[SeventyOne]

Originally Posted by 72K5CSTDarkOlive

You should've fired it right back up

She would have for sure called the cops. Yeah she's like THAT.

[SeventyOne]

9/9/19 - Getting Wired

Had a productive day Sunday afternoon and called in sick today so i could work on the truck alllll dayyyy. Worth it - just hope they aren't reading this

Sunday i worked on more dynamat on the floors and up the firewall. Still going for that 25-50% coverage. I did put a higher concentration on the firewall and footwells though.

Then today I focused on the American Auto Wire kit and getting all the stuff that needs to be behind the dash installed. I had a lot of worry about doing the wiring but once i got into it it's not that bad! Pretty plug and play, and other times you need to crimp some connectors to move forward.

A few question marks along the way - I have one connector that comes from the steering column bundle...I think it's supposed to attach to a post on the back of the cluster - can anyone confirm?



Then i have these dash grounds - and I can't remember exactly where they go - anyone got pics of where these go?





Then I have the rear body wiring plug - where does it exits the firewall to go down the frame rail?

And lastly - all the dash/steering column brackets I have don't look quite right. Is this gap supposed to be here below the column?

[72K5CSTDarkOlive]

Here's a pic of the rear wiring harness.

[72K5CSTDarkOlive]

My steering column didn't have that plug. I'm curious now what that might be for

[SeventyOne]

Originally Posted by 72K5CSTDarkOlive

Here's a pic of the rear wiring harness.

Super helpful pic Mike! I had homework for myself to figure out what all the firewall holes go to

That circular plate below the brake booster - i'm missing mine...what's it called? so i can buy one?

Originally Posted by 72K5CSTDarkOlive

My steering column didn't have that plug. I'm curious now what that might be for

I happened to walk by my original steering column i pulled out of the K5 and it has a plug like that and it's separate from the "ribbon" of wires (just like on my new rebuilt tilt column) and has a prong and a bulb attached it. I recall seeing a lone prong/tab on the back of my new cluster too...anyone know?

[72K5CSTDarkOlive]

[QUOTE=SeventyOne;8590944]Super helpful pic Mike! I had homework for myself to figure out what all the firewall holes go to

That circular plate below the brake booster - i'm missing mine...what's it called? so i can buy one?


I believe that is the cover for the clutch if you had a manual. You can have mine since I won't be needing it anymore

[SeventyOne]

Originally Posted by 72K5CSTDarkOlive

I believe that is the cover for the clutch if you had a manual. You can have mine since I won't be needing it anymore

Right yeah you wont need it - yeah I'll take it!

[SeventyOne]

9/16/19 – Plugging Along

Spend a good chunk of Saturday working on the Blazer. My goal was to get the firewall as close to done as I could. I ran into a couple snags but I'm close. For instance my speedometer cable was way too short. It's about 68" long, probably for a 2wd, so I found an 83" online that should work perfect.

Got the wiper, rear wiring, and oil line plugs in place.



Then I got the e-brake cable in place, and then tackled the heater core install. But, first I wanted to affix dynaliner (1/2" foam) to the firewall and footwells to keep engine bay heat at bay. It's basically a 32"x54" foam sheet that you can cut and shape, then peel the backing and stick where you need it. Passenger side around the heater and the middle "hump" were pretty easy to cover. Driver side was a but harder and I ended up using lots of smaller pieces for coverage around all the stuff that mounts to the firewall. Ended up looking good and will of course be covered with MLV and carpet too.









Also ordered some LEDs for the interior lights: dash, courtesy lights, and heater lamp. Once I get all the electrical working I'll get some pics up. Yesterday I also installed the heater controller but I forgot to snap a pic. I love seeing the dash come together.

Going to bring back my punch list for the next set of tasks I want to accomplish...

PUNCH LIST
-Heater control cables
-Radio + hidden antenna
-Heater wiring harness (on order)
-Speedo Cable (on order)
-Throttle Cable (on order)
-Door jamb switches (on order)
-Finish dynaliner on footwells (on order) and MLV
-Install wiper transmission arms + wiper studs
-Install wiper nozzles
-Install wiper nozzle grommets
-Install hoses to wiper pump and nozzles

[SeventyOne]

9/23/19 - Insert quippy headline here

Made more good progress Sunday. Trying to get the under dash stuff buttoned up so worked on getting the wiper sprayer nozzle hoses through the firewall plug and pressed onto the washer pump. This was way harder than it need to be - ended up popping the grommet out of the firewall while pulling on those hoses and it was a PITA to get back in. As always lube is your friend and some vaseline really helped...slide...the hose into...the hole....

With that out of the way I got the dynaliner foam finalized in the rest of the footwell/under seat area then I got a little ahead of myself and threw the carpet in place




ACC carpet fits well out of the box - probably should have left it warm up in the sun but I'm impatient. It massage into place pretty well and i think will only require minor trimming where it meets the rear corner by the door. Should be covered up by the sill plates anyways.

Then I removed the cowl to install the nozzles and connect the hoses then put on the wiper transmission arms to the wiper motor, and got the firewall wiring gutter in place.




Finished up the courtesy wiring/switches, got the heater harness in place and started on the heater cables but I need to run to the hardware store to complete that.

PUNCH LIST
Under Dash
-Heater control cables (need hardware)
-Radio + Aux/USB in the cig lighter + hidden antenna
-Speedo Cable (on order)
-Throttle Cable (on order)
-Tap into Wiper white wire for carb choke (buy red wire)
-Fix rear body wiring connection
-Connect dash grounds

Interior
-Install door seals
-Cut MLV and install under carpet
-Finalize carpet placement and make holes for shifter, dimmer switch, + seat bolts, seat belts
-Install shifter, boot, + trim ring
-Drill holes for: CST rear panel strips + standoffs, front + rear carpet strips, sill plates, tailgate seal vertical strips, center console mounting holes

and lots more...

[jaros44sr]

mount the seats before you trim carpet, they tend to pull carpet

[SeventyOne]

Originally Posted by jaros44sr

mount the seats before you trim carpet, they tend to pull carpet

Thanks for the pro-tip!

[jaros44sr]

Originally Posted by SeventyOne

Thanks for the pro-tip!

actually, I got it from the TV show garage squad, but your welcome

[SeventyOne]

10/8 Drilling Down

Slowly but surely I'm making progress!

Got the correct length speedo cable installed and installed a stock style throttle cable. I was surprised it fit so well with the engine moved forward 1.75". I originally mocked in a 4x2 throttle cable but it was WAY too long. So it went into the "sh*t to sell" box that keeps growing



I got the heater control cables routed but I need the correct size push nuts (5/16" I think) to hold them onto the plenum actuator shafts. I bought a bunch of the 1/4" push nuts since that's what size is needed on the heater controller but apparently they're larger on the plenum

The cables seem to operate OKAY but they are pretty stiff and getting the correct amount of travel to operate properly is a huge PITA. Anyone else have the same issue with new heater cables?

I then turned my attention to the rear cargo area. My K5 was not a CST truck and did not have the any of the holes drilled from the factory. So I put 24 new holes in my truck (so far haha) so I could mock up the CST panels.



Then I wanted to get the carpet laid in so I could drill holes for the carpet strips...this is where I ran into a snag.

I ordered my carpet from StockInteriors.com (it's ACC carpet) and while the front carpet fit rather well and I'm over all happy with it, the rear carpet seems to be cut way off. With the carpet centered around the wheel wells the carpet is roughly 4" short from the end of the bed when it should be tucked under the carpet strip. This pic shows the issue.



I am EXTREMELY happy to say that StockInteriors is standing behind their product and all it took to have them ship me a new piece was a couple measurements and pictures - even though I ordered this carpet 18 months ago!

So new carpet is on its way and I can resume making new holes in my ride

And this pic is just because she's a stunner


aaaand finally here's an update to my ever evolving to-do list:

PUNCH LIST
Under Dash
-Finish Heater control cable installation (need 5/16" push nuts)
-Radio + Aux/USB in the cig lighter + hidden antenna
-Connect choke wire to wiper plug
-Connect dash grounds
-Check carb gets to WOT with pedal travel
-Install glove box

Interior
-Install door seals (ordered new press on seals)
-Cut MLV and install under front carpet
-Finalize front carpet placement and make holes for shifter, dimmer switch, + seat bolts, seat belts
-Install shifter, boot, + trim ring
-Install new rear carpet
-Drill holes for: front + rear carpet strips, sill plates, tailgate seal vertical strips, center console mounting holes

Underhood
-Install heater hose nipples to engine/water pump
-Install Evap canister and hook up hoses
-Install brake booster hose
-Finish mounting battery tray
-Finish underhood wiring
-Install radiator overflow
-Install wiper fluid resevior