Started to strip paint off of PS of truck, and this is what I found. This side was up against the shop wall so I haven't paid to much attention to it. I thought it was in pretty good shape since it had a new rocker panel hung on it. Why would you waste your time covering up all that rust? Oh well, deja vu. Here I go again on the PS

http://i89.photobucket.com/albums/k233/jarosaj/msoCBA72.jpg


http://i89.photobucket.com/albums/k233/jarosaj/mso289D1.jpg

http://i89.photobucket.com/albums/k233/jarosaj/mso525BA.jpg

http://i89.photobucket.com/albums/k233/jarosaj/mso28C9D.jpg


http://i89.photobucket.com/albums/k233/jarosaj/mso9A363.jpg

Always an ugly site.Not rare to see,though.

Wow, it's amazing to see the amount of rust that some of you guys start with. Luckily vehicles around Colorado don't tend to rust as bad. Good luck.

Dang, good luck getting that all back together.

I see "show trucks" that look great from the top side but have rusted out cab supports, floors, etc.

It takes effort to make it right, most people won't put that much effort into it.

Don't give up, do it as right as you can (It's hard to know when to stop...), and you'll have a better blazer than most.

Good luck, Rg

Always the biggest battles, rust and P/O's.

Good luck keep us posted on your progress.

Good pics BTW.

Hey James, visors are on the way ;)

FeDeX # 045740433140784

Thanks guys, its just so dang fustrating cause I spent amonth on the drivers side. Maybe this time I am truly done shoveling crap off the workshop floor, hehe I can see the light at the end of the tunnel, and there is no rust around it.
Thanks Kurt, I just got it from my wife for my birthday, still learning how to use it. Alot different than my 35mm I had 30 years ago. While I have your ear, how did you make out with cutting your top in half? Curious? I might be headed down that road!
Thanks Luv, enjoyed seeing pics of the GQ, that is really sweet. What size tires and lift? I like the way it sits!

Time to start ordering pcs. from Goodmark, I should buy stock in 4 1/2" cutoff wheels, can't imagine how many I went thru so far:blah: :blah: :blah:

Thumb through this to see what it takes:

http://pg.photos.yahoo.com/ph/jason_burkhart/my_photos

Thumb through this to see what it takes:

http://pg.photos.yahoo.com/ph/jason_burkhart/my_photos
Thanks for the pics. nice work, someday mine will look that good if I live long enough! Jim

It took us 1 1/2 years and we still don't have the top finish. (it is my son's-orangeuavol-)

wow those boxes are long gone.

wow those boxes are long gone.

You sound like there should be some kinda boxes there, he he. Neither side had much to speak of, mostly just held up a bunch of mud and large flakes of rusty metal. I plan to rebuild with sliders to put back the rigidity i lost with the rocker boxes gone. I can't decide if the slider should have a urethane mount or not, since it is tied between the frame and the body??

I wasn't going to do anything, but a buddy was wheelin' with the same truck like mine and his doors became stuck shut on some of the steeper inclines. Got me thinkin...

I know how you feel, more rust than you were prepared to deal with....kinda gives you t hat sick feeling...but I just finished all the body work on mine Can't think of much I didn't replace...lol...pillar bottoms, door bottoms inside and outside, floor pans, kick panels, rockers, inside rocker panels, front fenders, and several floor patches in the bed.....blocking it off now, waiting on the money to paint.
JUst take your time, measure twice, tack it measure again.....good luck...if you need advice these guys are great....

Boy does that look familiar!

Good luck...you can do it!!

Sick feeling haha. It's a never ending battle, I look at the trucks where they spend lots of money on the purchase, and wonder if maybe I should have gone that route. Nah, I can say I built it when it's done. $700.00 was cheap, just don't let my wife add up the receipts

Hey James, visors are on the way ;)

FeDeX # 045740433140784

Visors arrived today, thanks for the deal. It's addictive I can't stay of the parts board.

Yeah, man! I've been there. Good luck with it

OK, here's my present progress. This side was alot easier as the PO hadn't added many patch plates. Every thing was cut out with a 4 1/2" angle grinder, channel locks and a pry bar. Once you pry up on the spot welds you can see the little detents and grind the metal till it gets blue, then you are almost thru the metal and won't damage the under layer your trying to save. Taking it apart I actually saw some shiny metal, what luck. Plan to spend a good couple of hours around the body mount to cab brace, they are really spot welded in well.http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace002.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace001.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace003.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace004.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace00-1.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace006.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace007.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace008.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace009.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace010.jpg


Alot of my new sheet metal came in so I'll be cutting, fitting and cutting, fitting...

WOWSERS, Hope your keeping this pic's for reassembly later :lol:

I could only post up 10 pics, so maybe I can do it this way and re-reply. Hope the picture cops don't catch on! I've put a white dot where the spot welds are so in case yours are all rusty you can still locate them, I had 5 spot welds fail in the area of the spreader plate and that is where the most rust was!!

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace011.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace013.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace014.jpg

Any questions?? Jim

WOW, I wish I had the nerve to try that, I would have kept several
vehicles in the past if that wasn't so scary to me, nice work, cya ;)

Luv, I see this truck in my sleep after 4 years!!! What's that saying: some assembly required. This is the last piece of rust and crap pile on the work shop floor, I hope.

Rusty Parts has been my mentor thru this hole process, I thought if he could do it, well so can I.heh heh

I've done worse, used to cut english sports cars in half to put floorboards in those. Rusty pcs. of sh!t...

Wow...great pics!
Please keep them coming during the assembly process, they are very helpful. I will be working in the same area soon.
Thanks.

Nice detailed pics, brings back alot of rusty metal memories I thought I had finally put behind me. :o :lol:

J/K, great work, your on the 'fix it' side of things now.

One question I can't see from the pics, is the hard top on?
If not it really should be to keep those lower door pillars where they need to be.

I like this pic with the coffee cup...speakes volumes. :metal:
http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace006.jpg

I have the cowl hangin' from a pipe that goes across my workshop, plus I have taken a diagonal measurement across the door opening. When I mount the door back on that becomes the final check, worked for the drivers side. I think that as long as you don't fool with brace/channel that connects the cowl with bed evrything should stay in place. Only do one side at a time, I think you said this? I usually give the winch 1 or 2 clicks up after I cut to prestress the metal. I guess there a lot of ways to do this.
Your green truck has always bin one of my fav. ones, although mine will never be that nice, I shot for that excellance
Sorry to bring back rusty memories, I think the cure is to buy a Arizona truck. Hope they realize how lucky they are!!

wow thanks for the pics. that looks just like my junk in 2000. be really careful about putting in the rocker panel. I set mine in a little high on the drivers side and had contact with the door. To fix it, I took a 5lb sledge and a piece of oak to "settle" the rocker. I didn't cause any visible damage but I'd rather not have had to do it that way. :banghead:

Sometimes newmetaltherapy is the only way to put that ole rust into remission. But it feels sooooo good to get rid of it.

Nice work.

I have the cowl hangin' from a pipe that goes across my workshop, plus I have taken a diagonal measurement across the door opening. When I mount the door back on that becomes the final check, worked for the drivers side. I think that as long as you don't fool with brace/channel that connects the cowl with bed evrything should stay in place. Only do one side at a time, I think you said this? I usually give the winch 1 or 2 clicks up after I cut to prestress the metal. I guess there a lot of ways to do this.
Your green truck has always bin one of my fav. ones, although mine will never be that nice, I shot for that excellance
Sorry to bring back rusty memories, I think the cure is to buy a Arizona truck. Hope they realize how lucky they are!!

Sounds like you have it covered.
Knowing is half the battle. ;)

AZ. rides definetly have an advantage but their not perfect by any means either.
I flew out to AZ. and drove my green one home because I was thinking along those same lines, cool adventure but not even close to rust free.
Not meaning to highjack and nowhere near your metal replacement but here's what my AZ. blazer was like. (yes, there was more on the other side too)

What color are you going to paint it when the body work is done?

... I think the cure is to buy a Arizona truck. Hope they realize how lucky they are!!

Just make sure it lived it's whole life out there and when you get it home disassemble, clean and rust proof it!!

Sounds like you have it covered.
Knowing is half the battle. ;)

AZ. rides definetly have an advantage but their not perfect by any means either.
I flew out to AZ. and drove my green one home because I was thinking along those same lines, cool adventure but not even close to rust free.
Not meaning to highjack and nowhere near your metal replacement but here's what my AZ. blazer was like. (yes, there was more on the other side too)

What color are you going to paint it when the body work is done?

After looking at the green one, I thought it came that way and you just picked a clean rust free Blazer, had no idea you did all that work. Looks like an original one, nice work, I think we all strive for that level of craftmanship. I don't know what you do for a living, but sure could get into the restoration business.

Didn't know you were hijacking, lot to learn on this here computor.

I would really like to paint it two-tone, white panel w/dark green metallic to match my dash. I was going to use the early trim to cover up my eyebrows as they are still a little tatty. Maybe gun metal panel to be a little different...

Sometimes newmetaltherapy is the only way to put that ole rust into remission. But it feels sooooo good to get rid of it.

Nice work.

Thanks Rusty, you know, right now I have air where the rust used to be and it still looks a hole he!! of alot better.heh heh

After working on these things for 35 years, I should have a BS degree if not a Doct. in rustymetalolgie.

Thanks Rusty, you know, right now I have air where the rust used to be and it still looks a hole he!! of alot better.heh heh

After working on these things for 35 years, I should have a BS degree if not a Doct. in rustymetalolgie.

Amen Brother, Amen.

Rusty, it must be beerthirty in Ol' Kentucky by now!!

OK, here's the last step of disassembly. Take your time on the seams as you don't want to destroy the sheet metal underneath. The method that works best for me is as follows
Pry up what ever you can get and pull back with pliers, it helps if you can wedge a small screwdriver on the other side of the spotweld, now when you use your cutoff wheel it will grind both sides of the spot weld, top and bottom, try pulling some more and you should see movement, if not grind some more. After it breaks lose, you'll end up with a 1" pc., cut that off and start on the next one. It's sorta like opening an old ham can. Channel locks work best as they have a rolled head that is helpful in the cam action that is required. BTW you should be cutting, grinding in the same direction that your seam is running! Once you see blue metal, you are almost thru the first layer of metal. Give yourself plenty of light, so you can see exactly what you are cuttin'
Here's some pics.

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace016.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace017.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace019.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace020.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace021.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace022.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace023.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace024.jpg

BTW, your seams should be cut flat, like a ribbon, as any angle on it will only give it more strenght and you don't want that!!

As you can see in one of the closups, I had planned to just weld up the hole that looks like a sailboat, but after separating the seam the rust was hidden and it doesn't make sense not to fix it at this stage, as it will only bite you in arse a few years down the road.

OK new parts are here from Goodmark, time to cut and fit, cut and fit .....

Sounds like you have it covered.
Knowing is half the battle. ;)

AZ. rides definetly have an advantage but their not perfect by any means either.
I flew out to AZ. and drove my green one home because I was thinking along those same lines, cool adventure but not even close to rust free.
Not meaning to highjack and nowhere near your metal replacement but here's what my AZ. blazer was like. (yes, there was more on the other side too)

What color are you going to paint it when the body work is done?

Dude, that rocker floorboard is freakin' ugly, then I see a post elsewhere with a prestine orange painted floor and a blue cowl. What gives?

Dude, that rocker floorboard is freakin' ugly, then I see a post elsewhere with a prestine orange painted floor and a blue cowl. What gives?

That would be a different project blazer currently under construction. :hm:

That pristine floor is original paint and the blue cowl is from a truck that I grafted a blazer windshield frame onto, it's about five different parts trucks being put together to make a blazer for my daughter. :cool:
http://67-72chevytrucks.com/vboard/showthread.php?t=156022

Floorboard is in loosely, have to trim everything up to get it to fit right, I'll take pics. when I get back from salmon fishing in N.Y., truck still not ready for yet another fishing trip. Oh well, maybe for the spring trip!

Well here is my current progress, the kickpanel is a PITA, so I'll get into that later. BTW, pics. are loaded backwards

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace02-3.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace02-2.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace02-1.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace01-7.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace01-6.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace01-5.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace01-4.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace015.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace01-3.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace01-2.jpg

Any questions?

Damn you guys build some rusty trucks. I guess if you had no options than........

Here are some current pics with the flange being worked on

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace015.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace01-4.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace01-5.jpg

I'll describe the steps later with the flange bent

clecos! whish I had them when I did mine. lol

Looks good including the cinderblock door

Yeah, they are one of my most fav. tools. Shop is a little small, but it has everything I need. 14'x18' Thanks

Here's some pics. of the flange bend. I've kept my tools to a minimum so anyone with basic hand tools can do it. Channel locks are great for making the flange bend

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace01-9.jpg

Looks like you do good work.:D

Thanks Krue!! Better than putting it in body shop prison, if you can find one to do it. Actually it's good therapy for me, I enjoy taking a rusty POS and turning it into something usable. Someday it might even look as good as VT's green one!! Jim

Wait until you see what I do next, the purist"s are going to scream!

:lol: If I ever get my wife a house built, I'm gonna build me a shop and get started on my trucks.

Damn you guys build some rusty trucks. I guess if you had no options than........


COME up here to the salty north and see for your self. you can look on a 1 year old truck and it will have rust that is why alot of us store the nice ones during the winter months. Also that is why i bought my truck down in Texas

:lol: If I ever get my wife a house built, I'm gonna build me a shop and get started on my trucks.

I got a better idear, live in a trailor and build a workshop. I'm sure the Mrs. would love that idear:lol:

Wait until you see what I do next, the purist"s are going to scream!

No chance...No way...couldn't happen... :rolleyes:

J, your bringing another one back from the brink, keep it up. :metal:

No chance...No way...couldn't happen... :rolleyes:

J, your bringing another one back from the brink, keep it up. :metal:

Dude seriously, they are going to scream foul on this mod., I may have even out thought myself-ROTFLMAO

Dude seriously, they are going to scream foul on this mod., I may have even out thought myself-ROTFLMAO

Come on, drop it already...

Watcha got that's SO wrong?

Stop holding back whats the secret mod??

Nice looking work and nice pics! Keep them coming! Jeff.

Stop holding back whats the secret mod??

Not sure if I can bring myself to do it again, although it should match the drivers side. It"s really hideous,but I think I'm forced to do it again. I'm on the fence!

Thanks Jeff

:drama::lol:

where did you get the repair panel for the kickpanel area?

My replacement panels are all Goodmark, find a vender on the west coast and it will save shipping. I think GMC Pauls is in your area.

In one of the pics., you can see that the panel is a 1/4" short, so you will probably have to section it. I didn't do mine yet, but if you hang around I'll take pics. when I get to that area. I'm getting ready to start the cab mount to support channel today. Jim

Not sure if I can bring myself to do it again, although it should match the drivers side. It"s really hideous,but I think I'm forced to do it again. I'm on the fence!

Your holding out on your blazers buds...:floss:




Come on already, what's the plan? :hmm:

He must have painted the other side pink!!!!!!

Come on already, what's the plan? :hmm:


Yeah...what he said!

Looking forward to the next set of pics.

Not pink, but I may get my user name turned to yellow!!!

Back to work...

The ol' man has finally went off the deep end!!! Cutting holes in his new floorboards, what on God's green earth was he thinking. Maybe he built to many car models with the windows closed, who knows.....

Any way, putting in the cab support box is a real challenge, not impossible, but probably the most difficult of the project. Tied to the z brace first with zip screws, makes it easier to manage. I like to drill a 1/8" hole first so the threads don't catch on the outside layer of sheetmetal and walk up, thus separating your joint. After that is attached, you can pull back on the cab support to line it up with the leading edge of the floor board. Don't forget you have a doubler plate that mounts the front fender in. the doubler has to sit against the forward edge of the cab support, not the flange, but the leading edge of the cab support.
Don't be afraid to use a body hammer to tighten up the flanges and corners after it is zip screwed, they bend very nicely with a little bit of effort...

OK here's the pics.

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace00-2.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace00-4.jpg
http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace00-5.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace00-6.jpg

Here's some more...

BTW, check the welds on your cowl to floorboard brace, both of mine were lose. About 7 or 8 spot welds broke loose, so this is a good time to reweld them.

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace00-8.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace00-9.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace00-10.jpg

Looks SOOO good with that new metal! :lol:

What are the 'goals' for this coming weekend?

Looks SOOO good with that new metal! :lol:

What are the 'goals' for this coming weekend?

Thanks for the comps. Planning on working on the 'A' post, also want to work on the back seam, by the seat. I want to flange this area to give it more strenght. that should take care of most of Sat., Sun. I'm headed over to JC's to pick up a TH350 and a NP203.
How did you make out with cutting that full top, did it look right when you were dun?

I'm headed over to JC's to pick up a TH350 and a NP203.
How did you make out with cutting that full top, did it look right when you were dun?

Why a 203? Are you planning something...? ;)

When I did my top, I cut it "fat", so I could do some final trimming but never did get to the trimming part.
It looked okay and I'm still considering it.

'Cause I already have the xtra NP205, I found demensions of the adapter plate.
Post up pics. of what you have so far on the top, I'm considering it, but I thought I would let you do all the thinkin'. J

Any progress lately?... We're waiting for more pics.

Thanks.

Just a little work on the 'A' post patch panel, totally screwed it up, so I'll have to call this thread what not to do. Soon as I download my camera, I'll put it up.

'Honey Do' list had to be worked on last weekend!!!! J.

Here's some pics:

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace00-14.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace01-11.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace00-13.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace00-11.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace01-10.jpg

Not much work done, and I have to work this week end, so it will sit awhile.
Did get my new trans. and transfer case though, and my 3/4 ton master cylinder and booster came in. Thanks to Frank's Pick-M-Ups

OK, here is my current progress over the weekend:

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace00-21.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace00-20.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace00-19.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace00-18.jpg

http://i89.photobucket.com/albums/k233/jarosaj/Passengersidefloorboardreplace00-17.jpg

Still have to clean up reinforcement plate for front fender and install, then the the "A" post patch panel is done.
Unbelievably strong at this point, you can shake the truck by the repair work!! J.

Looking good :metal:

Looking good :metal:

The 'end' is in sight. Thanks for the comps.
You must have your hands full with 2 of these things! J.

Excellent work!

Looking forward to the next set of pics.

:c2:

First off, great pics, great job, love to see the progress. Will help me when I get into mine here soon.

Second, I'm dying to know what those things are sticking up from your new metal. I'm assuming your using them to hold everything together aligned until you weld. Inquiring minds want to know?