71 CST Frame Off "Project Duff"

[Rust Buster]

History: I bought this blazer in 2003 for $1500 on ebay. It's a 71 CST with a manual tranny and original 350. It was from Florida and I had it shipped up to MA where I was stationed at the time (Air Force). I did some mechanical work to get it back on the road and had a blast with it for a year or two. I was than transferred to VA and didn't have the space or garage to really do her justice, so she sat at my brother's in MA for a few years. Here's what she looked like the day I got her.

[Rust Buster]

Since then I've moved again and have the shop to do a complete frame off so here's the start of this build. Surprisingly, the truck is extremely solid...lots of surface rust but not as much rot as I was expecting. Some of you may remember me from another built thread (see signature below) where I was working on a 72 K20. I changed course with that build and sold the frame and body but kept all the goodies (383 GM crate engine, mass-flo efi, NV4500, and a ton of other stuff) to use on the blazer.
That's just a teaser though. I learned my lesson on the truck build and will focus on all the rust repair/body work first.

[Rust Buster]

So two weeks ago I started the tear down...
Sorry about the upside down pic.

[Rust Buster]

Got the body separated from the frame, reinforced the door openings and then mounted it to the rotisserie I just built. Mounting it the way I did allows for 100% unobstructed access to the underbody. I was concerned about flex but I've taken measurements the whole way and it has been rock solid.

[Rust Buster]

First thing I am tackling is the torsion boxes, rocker panels (inner and outer) as well as all the brackets and reinforcement panels that attach to these. The torsion boxes had 2"+ inches of caked mud/sand in them, but were relatively solid

[tjsblazer]

In for the ride. Looks like an interesting build.

[Chad22873]

Me too

[hemi43]

It's amazing at how most of these Blazers rust the same. Good thing that with the availability of quality replacement parts they are somewhat easy to repair.Looks like Rust Buster will be getting a complete rear floor for his Blazer along with the typical replacement panels. I should have put one in mine instead of repairing what I had. Live and learn.

[Rust Buster]

Originally Posted by hemi43

It's amazing at how most of these Blazers rust the same. Good thing that with the availability of quality replacement parts they are somewhat easy to repair.Looks like Rust Buster will be getting a complete rear floor for his Blazer along with the typical replacement panels. I should have put one in mine instead of repairing what I had. Live and learn.

Actually, the rear floor (except for the last 4") is rock solid with just minimal surface rust. I got pretty lucky!

[Rust Buster]

Here's some more rotisserie pics as well as the old vs new torsion boxes.
I got the new inner rocker welded in and was pleasantly surprised at the fitment and quality of the panel.

[twp1]

looking GOOD!! you are working out what most would have passed on!!

[Rust Buster]

Originally Posted by twp1

looking GOOD!! you are working out what most would have passed on!!

Thanks! I am building this one to last a lifetime...at least in theory.

[DeadheadNM]

Good luck - off to great start. I'm on board.

[Rust Buster]

Well after a taking a few weekends to complete some long overdue projects, I finally got to work on the Blazer. I mounted the driver's door so I could have that on while doing the rocker to ensure proper alignment and it was pretty far off. I had to put a come-along on to pull the cowl back towards the rest of the tub. It was enough to tell me to go take the time and put the top on, mount the tub back on the frame with new body mounts, and weld in a bunch of 1" square tube to keep everything in place when on the rotisserie.

So when that was all done, I attacked the passenger side from the outside in, learning my lesson from the driver's side. On the passenger side, I'll replace the inner rocker, outer, and torsion box brackets with the torsion box still in place. This should keep everything in alignment as much as possible. It may be an exercise in futility though since at least the inner and outer rockers have been replaced before. Anyway, here are the pics...

[Rust Buster]

More

[lks dcvn]

Looks great. Replacing the mounts and putting the top back on will definitely help in keeping things aligned. I did a lot of research and read as many build project threads to get insight.

Keep making progress and posting pics for the group - it will help you and others who are rebuilding these trucks.

[nobolt]

i'm in too.
you wouldn't happen to have a link to a POWER WAGON build, would you? i love those trucks!

[Rust Buster]

Originally Posted by nobolt

i'm in too.
you wouldn't happen to have a link to a POWER WAGON build, would you? i love those trucks!

HAHA, the Power Wagons are waiting patiently for their time...and it will be worth the wait!

[caseyfromMO]

This ever go anywhere?

[Rust Buster]

Yes and no! Just getting back to the forum after a long hiatus. We moved again, but we'll be here now for 15 years+ so the blazer will get some love. We are just finishing up a monster shop build so things will get rolling again soon!

[SeventyOne]

Awesome - keep at it! My frame off resto took me nearly 11 years to complete!

[Ol Blue K20]

I'm in to watch. Let's get back to it.....