1965 Suburban Resto-Rebuild

[hemifalcon]

...been awhile as I've been working on a few different projects (1972 Kellogg 80gal air compressor, Trinco Sandblast cabinet, and my '62 VW Bug preparations for cross-country trip..).. Finally wrapping them up while acquiring another (ahem.. '48 Ford Sedan..)

I picked up these doors for the burb... and NO the fire truck theme will not remain.. These doors are in very good shape--and my others are for sale in the classifieds..

[hemifalcon]

Got back on the 'burb today.... Finished the rocker on the driver's side and also ground smooth all the welds on the roof lip and roof gutter clips. Came out well.
Next project will be to finish all the welds around the windshield perimeter on the inside then tackle the passenger side.. I feel like I've been re-charged after seeing some of you other guys progress.. I need to make my own so that I can get the bottom side done and mounted back on the frame this year!! geez I'm slow.. :-)

[likaroc13]

Nice work. Good to see progress. Good looking doors too!
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[Nobby]

Great work man...Keep it up...

[Modges'66]

Super-nice score on the doors!
Something great to work with always helps!

[piratexpress1369a]

awesome work ..keep up on it ..

[hemifalcon]

Thanks guys.. Gonna get the passenger side all wrapped up this week..

Started by filling some of the holes in the floor and repairing some stress cracks from the jump seat mounting area.



Gonna replace the inner rocker/step section approximately 2" inward from the inner rocker using the truck floor section scrapped from the '65 Cab. (just like on the driver's side).. Really doing this right after seeing a completely "restored" shortbed yesterday in which the bottom of the A pillars were gone-but new rockers had been slapped on.. I just don't get doing all that work and half-assing things.. I almost pointed it out to the guy who was driving it--but I didn't want to burst the bubble as he bought the truck all prettied up..



apparently the passenger door had been opened too far at one time..

[hemifalcon]

Well--I managed to actually meet another goal. I set out to finish the passenger side rust repair and did so.. I just have to repair the far passenger side seatbelt mount point and clean up all the plug welds for the floor and rocker.. I'm pretty happy to be done with this side--as I had to do the exact same repair as the driver's side.. Here's the pics.. (I attribute my progress to staying off the computer prior to going to work each day...)

From the previous post--to this.. Started with cutting the inner rocker/floor portion out which would be replaced with scavenged sheetmetal from the '65 Truck cab...Like pulling little bits of meat from a chicken bone--almost used up all the cab..



Here I was ALMOST hopeful that the lower kick panel was salvageable--didn't even bother...



Floor cut away..



Floor support/body mount was solid on this side--just full of dirt, cobwebs and bee nest. Cleaned it out and treated the bare metal



Fitting the new lower kick panel







And here is where I mixed up my steps.. I realized the floor/inner rocker didn't want to squeeze behind the kick panel--but I used a little force and snuck it in behind.. phew..



The old one on top-and the replacement piece on the bottom.



All welded in place.



And the lower a-pillar which was also scavenged.. It was in much better shape than the original--but I still had to do some work to make it nice and solid once again. See patchwork in pics. The pitting on the lower curved portion was just too deep to save it.











Door position wasn't perfectly dialed in here.. It fits pretty good all the way around--



You can see at the very front of the rocker I had to slice it to tighten it upwards towards the inner rocker.. Fits perfectly now.



I believe my count was 41 weld points on the rocker.. Maybe 43.. It's all nice and solid again. I'll knock down all the plug welds and I still have to replace the rocker-quarter panel gusset. But, the passenger side is basically done. Just want to toss out a big thank you to all the guys who have documented their repairs on these areas. I am a foreigner with regard to these trucks-well, up until I became a member here. So--thank you to all you guys working on saving these old trucks.
-John

[likaroc13]

nice work yet again! that computer stuff can really slow a fella down can't it?

[hemifalcon]

Originally Posted by likaroc13

nice work yet again! that computer stuff can really slow a fella down can't it?

Yeah man.. Thank you sir.. I am trying to avoid the PC-as it totally gets in the way.. But--every now and again it helps stir the motivational fluids..

[hemifalcon]

...been awhile since I've worked on the 'burban.. So--my motivation level is up and spread amongst my '61 Biscayne, '48 Ford and the old 'Burb.. I spent a bunch of hours today plug welding various holes drilled over the past 48 years on the interior floor and panels.. I then decided that there was no way to make the "cut-outs" on the rear roof gutter area look good. So--I set out to repair them. They ended up looking really good--I'm very happy. I considered this to be a pretty difficult repair due to the need to MIG so close to the body-roof seam without getting any stray boogers stuck in the seam, while satisfactorily making the repair. Here's the before and after. (Passenger and Driver's side were hacked the same..)





And after..









Now--I'll have to put new drain slots/holes in.. What are they supposed to look like and if anyone has a picture to display their approximate location-please post it here.

This is the front A-Pillar drain..


And-the drain hole/slot above the first side window..

[likaroc13]

Nice to see you still plugging away. Good job on that drip rail! Wish I could help with the drain hole appearance/locations, but I'm sure somebody will chime in.

Btw, my brother has a '62 Biscayne "more-door." It was my great-grandfather's car. And is your '48 Ford a car or truck?

[hemifalcon]

Originally Posted by likaroc13

Nice to see you still plugging away. Good job on that drip rail! Wish I could help with the drain hole appearance/locations, but I'm sure somebody will chime in.

Btw, my brother has a '62 Biscayne "more-door." It was my great-grandfather's car. And is your '48 Ford a car or truck?

Thanks brother... Well--If I was a smart man I would only have one "project" car, but instead I have a couple for "down the road" and I seem to have automotive A.D.D.

With regards to the other cars--these are the pics..

1962 VW


1961 Biscayne


and the newest of the old--'48 Ford Super Deluxe Sedan

[likaroc13]

Originally Posted by hemifalcon

Thanks brother... Well--If I was a smart man I would only have one "project" car, but instead I have a couple for "down the road" and I seem to have automotive A.D.D.

With regards to the other cars--these are the pics..

Cool projects! Aside from my '66, I have a couple future projects in mind as well. My dad bought a 4-5-6 Chevy Burb that I'd love to build, & my grandfather will one day pass down his vehicles, one of which is a '50 Ford Coupe. He restored a Nash Metropolitan that my wife has already spoken for.

Oh, & I had a '63 Beetle which I sold right before I got my '66. Don't wanna whore up your thread with pics, so I'll just link you:

http://smg.photobucket.com/user/lika...?sort=6&page=1

http://smg.photobucket.com/user/lika...?sort=6&page=1

http://smg.photobucket.com/user/lika...?sort=6&page=1

[piratexpress1369a]

nice job on the drip rails

[hemifalcon]

Originally Posted by likaroc13

Cool projects! Aside from my '66, I have a couple future projects in mind as well. My dad bought a 4-5-6 Chevy Burb that I'd love to build, & my grandfather will one day pass down his vehicles, one of which is a '50 Ford Coupe. He restored a Nash Metropolitan that my wife has already spoken for.

Oh, & I had a '63 Beetle which I sold right before I got my '66. Don't wanna whore up your thread with pics, so I'll just link you:

http://smg.photobucket.com/user/lika...?sort=6&page=1

http://smg.photobucket.com/user/lika...?sort=6&page=1

http://smg.photobucket.com/user/lika...?sort=6&page=1

Thanks man--you've got some fun stuff you're working on as well.. I've followed along on your threads--really like what you do.. Thanks for the links brother..

Originally Posted by piratexpress1369a

nice job on the drip rails

Thank you--they turned out pretty danged well--I'm happy with them.
I started to strip the roof today--ran the wire wheel all the way around the drip edge. I decided to chemically strip the roof--and I'll continue on the rest of the truck unless it gets too tricky.. The only thing I'm cringing about is stripping around all the steps and detail areas on the firewall and in the door openings. I don't want any extra stripper getting trapped and then causing any bubbling after primer is applied.

On a side note--does anyone know off hand (before I use the "search function" what hydraulic supports will work for the rear barn doors on the suburban and panel to allow full closing and opening of the doors??)

[piratexpress1369a]

i saw that tread and it is from this site but i think it was done on a 67-72 model ..i'll look for it too i need to bookmark it too.
found it here is the link
http://67-72chevytrucks.com/vboard/s...d.php?t=507930

[hemifalcon]

It's been awhile, but the cold weather is here and I'm going to try an get moving as the other cars are in cold storage and not fun to work on when it's under 35 degrees..
I spent my days last week getting my new (old) air compressor on line with piping and filters and a few different drops. I also got my Trinco Cabinet sandblaster going--which is a great asset when doing these old cars and trucks. I got used to using other peoples blast cabinets or paying--or doing the stripping by hand--

So--here's what having a REAL air compressor setup allows me to do with a DA sander.. (yes--it's a mess in my garage..)
But--there is a lot of smooth sheetmetal on top of these burbs!!!

[69 chevy 1]

nice to see you have your compressor running there is def allot of metal on those roofs,nice to see you back at it,as i am still battling mine

[hemifalcon]

You aren't kidding... If I hadn't gotten the compressor with some real air capacity--this wouldn't have happened... Long way to go... Gotta keep steppin though.. One thing I'm considering is trying to find someone parting out a penal or sub as I want to put 3 more of the roof "trusses" in to further reduce the flex and oil-can nature of the roof.. Just gotta find them

[LT1 Burb]

Mine oil cans but only above 80 MPH and only if I have the windows down.

[piratexpress1369a]

Originally Posted by hemifalcon

It's been awhile, but the cold weather is here and I'm going to try an get moving as the other cars are in cold storage and not fun to work on when it's under 35 degrees..
I spent my days last week getting my new (old) air compressor on line with piping and filters and a few different drops. I also got my Trinco Cabinet sandblaster going--which is a great asset when doing these old cars and trucks. I got used to using other peoples blast cabinets or paying--or doing the stripping by hand--

So--here's what having a REAL air compressor setup allows me to do with a DA sander.. (yes--it's a mess in my garage..)
But--there is a lot of smooth sheetmetal on top of these burbs!!!

nice work now get some pimmer down on that roof ..it will not take long to start rusting

[kikkegek]

clear coat it! will look killer!

[hemifalcon]

Not for any reason aside from luck-my garage stays quite dry in the winter and the garage doors remain closed with a small radiant heater--65 degrees is the norm.
I will leave the prime step until I'm happy with the roof. A good friend came over and borrowed some of his home made slapped which allowed me to almost eradicate the dips on the back if the roof..
I opted to use USC All-Metal filler in some spots where lead is not going to be best. Speaking of lead-I leaded the lower seams below the windshield as I don't want to use the soft seam sealer in those spots..
..came out pretty good..

[hemifalcon]

...spent some time in my ever shrinking (so it seems) garage with the burb today.. I've fussed around with some dents at the very rear of the roof where it seems someone may have set something on top--or it was just like that from the factory.. I was able to tap forward on the roof lip flange and the low spots popped up really easily.. Looking like a very very very little bit of filler ill make everything super smooth.
With he idea of getting the top in primer, I decided to get the interior side of the roof cleaned up. Let me tell you--I really hate removing old insulation and asphalt-rubber under coatings. What a frickin pain and mess.
Well- the plan is to get as much of the dirty off of the bottom of the burb, and get it coated. I don't want to be throwing farm dust and dirt debris all around after I spray primer. Some paint/sanding dust I can handle--but the dirt an crap seems to linger in the air for day..
Just curious--you guys use anything which works particularly well chemical-wise for removing the old undercoatings?
Anyway-here are the pics from today as I also finally removed the rear barn doors. (thinking still about removing the floor so that I can put down some new rubber matting on the plywood...Anyone else done this??)



The rest of the pics are in my album..