Re: 68 C50 Looongbed pickup build
 

I have an extra set of manifolds that I have been planning on modifying as you suggested. I just wanted to get it back together ASAP as I have a big project looming and I need this off my plate.

So far as the grade 8 bolts, my motto is "if it's worth doing, it's worth overdoing!" That and every build I've seen where a crossmember was drilled out, the rivets were replaced with grade 8. This is a mix of cross members and reinforcing plates, so... Refer back to motto :haha:

Updates from weekend coming soon.

-Richard

Re: 68 C50 Looongbed pickup build
 

Cant wait to see this done!!!!

Re: 68 C50 Looongbed pickup build
 

Hi Everyone,

Here is my weekly update. As usual I did not accomplish anywhere near as much as I had hoped, however good progress was made!

Last week I started trying to find the last piece of the power steering/hydroboost system that needs either re-sealing or replacing. It is the auxiliary electric pump on the hydroboost unit. I had called my main source for this type of item and the news was bleak, over 300 dollars to have it rebuilt and since they have no cores I would have to send mine in with no guarantee that they could rebuild it. Mind you it does work, I'm just replacing it for fear that it is contaminated with brake fluid and I don't want to take a chance that it will start spitting particles of disintegrated seals into my expensive "new" (rebuilt) hydroboost unit. So Saturday morning I removed the aux unit to take to my local auto parts store to see if by chance they could get it. Now this in no O'Reilly or AutoZone, this is an old school guy that knows how to read words written on paper! I know, crazy, right?

Anyway he did couldn't get it but did give me a couple of leads that I haven't had a chance to follow up on yet. I also went by TSC and picked up enough grade 8 bolts, washers and nuts to finish reinstalling the reinforcing plates (along with more Rust-Oleum). I also tried out a burger joint in Meridian Texas (right next to the Sheriff's office/jail) that may be the best burger I ever ate. If you get the chance - Morgan Street Burgers. https://www.facebook.com/Morgan-Stre...6227204225108/

Here are pictures of the aux pump laying beside the old hydroboost unit, along with the tag that has the GM part number. When I googled the number I came up with several hits, just no-one that has it. I did find a nifty diagram that shows it!

-Richard

Re: 68 C50 Looongbed pickup build
 

Next up, I drilled the remaining holes in the frame, installed the bolts and torqued them all to 80 ft/lbs, why? Two reasons: 1) because "if it is worth doing it's worth overdoing" and 2) because that is the spec I found when I looked up torque specs for 1/2" coarse thread grade 8 bolts! I know, most of you think I'm :crazy:

After that I rolled it outside, cleaned off all of the WD-40 that I used drilling holes, washed it with Dawn dish-washing liquid and a scotchbrite pad and then waited for it to dry. After that I hit it with 2 coats of Rust-Oleum satin black paint. I must admit that up close it isn't pretty. You can see every scratch that the 80 grit flap-wheels left and every run I got in the paint, but in the end I painted it for the same reason that GM did 27 years ago - to protect it from rust.

-Richard

Re: 68 C50 Looongbed pickup build
 

Next up, exhaust manifolds: as notchbackgta suggested, the ultimate goal is to cut out the AIR fittings and weld in patches, but that will be a later date with a spare set of manifolds. For now I need this thing running and out of the shop. I settled on carriage bolt heads to fit down inside the manifold, welded them up level and then ground them flat. I'm not going to lie, my welds ain't pretty, but the flap-wheel makes them acceptable. All this went down on Saturday, I had big plans for Sunday but life got in the way: feed the cows, recreational mowing, a little of this and that and next thing you know it's time to head back to the city lights to resume my day job as a computer nerd.

-Richard

Re: 68 C50 Looongbed pickup build
 

Thanks Deer_hunter, it's great to know people are interested. By the way, part of my recreational mowing over the weekend was the field between my deer stand and the feeder in preparation for deer season :bann:

-Richard

Re: 68 C50 Looongbed pickup build
 

Ours starts the first, cant wait for it! and cant wait for your truck to be finished.

Re: 68 C50 Looongbed pickup build
 

Well on the frame the grade 8 are worth it, I could even see using grade 9 because that is a place that matters. But welding the grade 8 into the manifolds is just waste because you will kill the heat treat of the bolts once you weld them anyway. But I totally get it, I overdo and most of my projects snowball into much larger projects because it's worth doing while I am in there anyway, lol

Glad to see you went with something more reasonable :lol:

Re: 68 C50 Looongbed pickup build
 

:dohh: When I set the hex head bolt on the manifold I was just judging the size, I did not realize that I had even picked up a grade 8 bolt. Since so much of the work over the weekend had been bolting the frame back together I had assumed that was the grade 8 bolts that you were referencing. For sure grade 8 there would have been beyond overkill for plugging the holes in the manifolds. The carriage bolts that I ended up using were selected because it was the cheapest sacrificial hardware I could find.

-Richard

Re: 68 C50 Looongbed pickup build
 

AHHH yes the ole c50 pickup, the time when its overkill or nothing :lol::lol::lol::lol::lol::lol::lol::lol::lol::lol:

Re: 68 C50 Looongbed pickup build
 

Ah yes my friend, I see you understand! :bann:

Re: 68 C50 Looongbed pickup build
 

Update for last weekend: I was really hopeful that I would get started breaking the 68 down but that just wasn't in the cards. I had thought out what I needed to finish before tearing into the 68 and came up with 45 minutes work, multiply that times two because I'm always wrong and you still get a lot done. Yeah, right.

On the docket for Saturday:
1) cut, flare and install the brake line that has been laying around for months since I removed it to cut the frame.
2) Reinstall the oil cooler line
3) flush the power steering system (because it was an old used P/S box)
4) reconnect the pittman arm (10 seconds, right??)
5) reinstall the exhaust manifold that I welded up the previous weekend
(yep, didn't even consider the other side!)

Then I'd be ready to start swapping the body over.

So here is what did happen:

I started by digging around until I located the nifty new flaring tool that I picked up a couple of months back from Eastwood. Located. Next I looked up a video on youtube on how to use it: https://www.youtube.com/watch?v=UxeA1lhSCsk Then I went out, measured 18 inches that needed to be cut off the line, went to cut it, figured out the cutter wouldn't go that small, borrowed a smaller cutter from my brother and cut on the line. I started by testing the procedure on the part that I cut off... I cleaned up the inside of the cut by spinning a drill bit in it by hand, then filed the rough edges with the file on my Gerber multitool. I used some anti-seize to lubricate as the instructions indicated and made the flair. Wow, perfection on the first try, for real!

-Richard

Re: 68 C50 Looongbed pickup build
 

Next up, put one bend in the brake line and install it (5 minutes at most).

- spend a half hour looking for the bending pliers I bought 5 years ago
- spend a couple of minutes figuring out which way to bend the line (yes really, I think it is a form of dyslexia)
- bend the line, compare to the old line looks perfect
- attempt to install, bent it backward AND it's an inch to long :banghead:
- attempt to string "bad words" together in some new arrangement
- cut the extra inch off the line
- attempt to "unbend" the line
- figure out that I can no longer slide the the fitting far enough back on the line to re-flare it
- more bad words (I'm actually pretty good at this part :lol: )
- carefully straighten the line using a bench vice and actually succeed
- re-flare and install
- drill new holes for clamps, etc

OK, that five minute job just took well over an hour "mild" frustration sets in...

-Richard

Re: 68 C50 Looongbed pickup build
 

Next I went to reinstall the hard (steel) part of the oil cooler line that has somehow NEVER gotten it's picture taken! (right now I'm wondering if I ever even mentioned this ongoing aggravation. I'll go back and check and if not will write that up). Anyway, when I pulled it off many weeks back I ever-so-carefully dropped 2 of the 4 clamps that tie the two cooler lines together directly on the floor under the motor so that I could find them again. The other two stayed on the line that that I didn't remove. My plan would have worked had I not cleaned up the floor when I last rolled the frame out for paint. I clearly remember picking up the clamps and thinking "I'll never see these again" before I put them away where I could "find them later." Searched for at least 45 minutes taking time out, every now and again, to try once again to rearrange those "bad words" in some manner that I hadn't used before. Never found the clamps. So... very... frustrated :banghead:
I scrounged up 2 other clamps and used them. Wasted at least two hours on this!

By the time I got that done I was so aggravated that I didn't want to even look at it any more. I still needed to flush the power steering box and reinstall the manifold but I didn't have the stomach for it.

I decided to grab the chainsaws and go cut some cedar posts. I have a project looming that is going to take a LOT of posts. My brother is currently clearing some land and there are lots of good posts to be had. If I don't harvest them, they'll just end up in a burn pile. I already had three sizable posts in the bed of the 68 from the previous weekend that would have to be unloaded before I could remove the bed so I figured cut some more and then unload them all, hopefully regaining a sense of calm. It worked. Just one picture of the 68 with a load on it for the last time with the old frame and drivetrain.

-Richard

Re: 68 C50 Looongbed pickup build
 

I didn't finish unloading the posts until after dark on Saturday. Sunday afternoon, after changing the oil in my DD I enlisted some help from my brother and we flushed the power steering pump. I pulled the belt off the P/S pump and rigged up a socket on an electric drill to spin the pump with. I had a gallon of P/S fluid that I picked up at AutoZone to flush it with. I worked the steering back and forth while my brother ran the pump. We went through the whole gallon but were getting nice clean fluid by the end. After that I reinstalled the exhaust manifold, that is about when I realized that I still need to pull and weld up the manifold for the other side. By the way, Felpro exhaust manifold gaskets have a shiny, dimpled side and a side that just looks like a dark grey gasket, any idea which side is supposed to be against the head and which one to the manifold?

That's all for now folks, I hope to make some real progress next weekend!

-Richard

Re: 68 C50 Looongbed pickup build
 

A lot happened this weekend. First I had long ago scheduled off Friday to go to the Good Guys car show in Fort Worth. My boss and another manager from work were going to go as well. Unfortunately both had stuff (important stuff) come up at the last minute that kept them from going. I didn't think it would be much fun by myself so I decided to head down to the country to work on the truck. As usual I had a lot of stuff that had to happen first. A quick trip into Meridian to get my DD inspected, then to Brake & Clutch Supply in Waco to get the auxiliary pump for the "hydro boost" rebuilt. I put that in quotes because they actually called this a High-Power system, that is the AC-Delco version; that same year there was also another more popular version (senior moment, can't remember the manufacturer). Anyway, on the way back stopped in Clifton and tried to buy some good grill trim off a beat up dump truck that I've had my eye on for two years but the guy wasn't having any of it. Exactly what I expected and the reason I had waited two years to even try... I'll probably call him this week and see how much for the complete truck but there isn't much good on it.

Back to Meridian, got the tags for my DD, then over to Morgan Street Burgers for what might just be the best burger in Texas. Then back to it...

I got going on the truck Friday late afternoon. It's finally time to take the body off of the 68! First up remove the bed. As it turns out I only had six bolts holding the bed on. I recall now that was "temporary" :crazy:. In the last picture you can see the spacer that I made to raise the bed up to the correct level. It was some 3x5 box tubing that I had laying around that turned out almost perfect. Anyway, that gets us through Friday afternoon, more to come but that will be after some sleep.

-Richard

Re: 68 C50 Looongbed pickup build
 

Getting in some good progress! I like the Bobcat...very handy.

Re: 68 C50 Looongbed pickup build
 

I think that the Bobcat is the most versatile tool ever invented!

Check out what comes next :D

-Richard

Re: 68 C50 Looongbed pickup build
 

Saturday was tear-down time!

Pull the bumper, then the hood. That was kind of diecy by myself but I made it work. It's really weird, the hood will stand on its butt without leaning it up against anything (forgot to get a picture). Next, remove the fender wells; I was surprised that I only had to cut 3 bolts - minimal carnage. Man that engine bay looks wide open with the fender wells gone! (I admit to a bit of vertigo standing way up there on the fenders). Next came, wiring harness, oil pressure line, clutch, throttle, etc. Nothing exciting there to take pictures of. I will have some work to do on the wiring harness. One of the previous owners had converted to an internal voltage regulator using jumpers in the original harness. I will unwrap it and redo it so that it looks like it came from the factory with an internal regulator. I will also need to replace the resistor wire that ran to the coil with a full size wire.

-Richard

Re: 68 C50 Looongbed pickup build
 

Saturday - continued

Pull the wiper arms; I had a bit of a scare there and thought that I might have to cut one off but it finally gave in and let go. Once the wiper arms were off next was the cowl cover. Then fender bolts. I bagged and tagged everything including the shims so that I can put it back together the way it came apart.

Drain the water and pull the fan shroud then the radiator. Speedometer cable, backup light connector off the trans. Pull the rear wiring from the clips and shove it into the open cowl area. Pulled the master cylinder from the GIANT vacuum booster.

Push it outside and grab the Bobcat again (I LOVE the Bobcat!)

No more front clip! :ennyd:

The third photo is the core support/grill viewed from the back - there are two pieces that you remove to use the wide radiator, pretty cool.

Also I just had to take a couple of pictures of my air cleaner mod. One of the POs had replaced the original oil bath air cleaner with a tiny 4 inch paper element POS. When we pulled the motor from the school bus (the one that donated the steering box) a few years back, it had a full size paper element air cleaner but it was for a 4 barrel. After poking around for a few minutes I made a pattern on a thin piece of wafer board and cut a ring that I silicone'd into the old base. The full size air clear sat down in it quite snug and gave me some peace of mind as well as making it look way better, at least in my opinion.

Enough for Saturday, shoved it back in to the shop and had myself an adult beverage.

-Richard

Re: 68 C50 Looongbed pickup build
 

Love seeing progress on this beast!!!

Re: 68 C50 Looongbed pickup build
 

Last bit on Saturday was to "remove" the cab bolts. The back ones came out easily. Removed the nuts from the front ones and the bolts never turned, WTF?? Turns out someone welded the bolts to the cab floor. That may make this fun.

So that brings us to Sunday.

I remembered that I had not welded up the AIR holes in the passenger side exhaust manifold so I did that and reinstalled it. I didn't take any pictures because it was the exact same procedure as the driver side covered in post #125.

Back to tearing down the 68... I removed the power brake booster from the firewall, then I pushed the truck outside and disconnected the fuel line under the cab. Then I pulled the bolts from the rag joint on the steering box. At this point two of my brothers jumped in and helped, one ran the "skytrac" (it's actually a Lull but few people have heard of that) brother #2 helped watch and direct. The cab came right off without hanging on anything. :D

Next up, I pushed that frame out of the way and took the power washer to the cab while I could easily get to the firewall. I didn't spend too much time but it wasn't greasy, just years of dust and dirt. After that we rolled the 89 frame out and went to set the cab on. There were several runs to the tool box as I had to remove some of the temp braces holding up the master cylinder and just little stuff like that. On the first stab we were off to the driver side and not enough slack to push it over so we had to lift again. It barely caught the shifter knob on the floorboard as it came up and put a small bend that I'll need to hammer and dolly out but that is no big deal. On the second try we were close enough that I was able to get both sets of bushings in place in the front and one on the back. One fork had slid over just far enough to keep the remaining body bushing in place so I set it over a few inches just to support the weight. At this point the cab is still sitting a little crooked so squaring it up and bolting it down will be the first priority next weekend. Nothing was removed from the cab for this procedure so it is very heavy but I have a plan ;)

OK, so I'm pretty happy with the progress this weekend. I've found a couple of new challenges and will need to address some that I knew about all along like the steering column having a different connection and not reaching the box by about four inches as seen in the last picture. I'm hopeful that the column from the 89 will fit, if not I will use that to justify adding a tilt!

Thanks for checking in folks!

-Richard

Re: 68 C50 Looongbed pickup build
 

This is a great thread. Like reading a good book, you can't put it down. Well done!

Re: 68 C50 Looongbed pickup build
 

You Texas guys have all the big cool tools, Bobcat, Lull, tractor and mower...:)

Enjoying the updates Richard...oh, and that description on the hose clamps missing was a hoot....been there myself so many times!

Re: 68 C50 Looongbed pickup build
 

Richard, firs off let me say that I admire you and your work. Top notch for sure. I have a question though, Are you useing the 68 cab mounting "ears" or the ones origonal to the frame? I ask because I am looking at doing the same with a 69 GMC 5500 and a 93 Topkick

Re: 68 C50 Looongbed pickup build
 

LOL, I thought the clamps would pop back in to view as soon as I managed to find something else but so far they're a no-show.

Thanks for checking in Doug!


Thanks or the compliment saxart. I checked out Ol Roy, I really like what you've done so far. That recovered seat looks awesome, it's making me rethink my bucket seats. I'll definitely be following along to see where you go with it.


Hey Deer hunter, glad you are hanging with me. I'm getting pretty excited with the prospect of firing it up again soon.



I need to get in an order for some parts with both LMC and Classicparts soon. I've really let myself get spoiled by Amazon prime and their two day shipping. Having to wait for stuff will be a blast from the past.

-Richard

Re: 68 C50 Looongbed pickup build
 

All of the mount points on the frame are original to the 89 and the cab mounts should line up perfectly. I may need to put a spacer under the core support mount. If so it will be less than an inch, at least that is what I think.

I know that he body changed again by 93, I have no idea what they may have done with body mounting points. Do you already have the Topkick? If so get to measuring! If the frame itself is the same width then adapting the body shouldn't be too difficult. What would concern me is the width of the front axle. I got really lucky that I was able to adapt the newer knuckles to my older axle, I don't know if that luck would extend to the 93 knuckles or not. From the pictures that body style looks to have a really wide axle...

Have you started a build thread for your GMC yet? I'd like to see what you are working with!

Oh, and thanks for the compliment, much appreciated.

-Richard

Re: 68 C50 Looongbed pickup build
 

No thread yet as I still have yet to get the 69 GMC home yet. Worked out the deal but cant find a trailer big enough to put it on, tempted to remove the front bumper and bolt on a tow bar and flat tow it home so I can start working on it. I do have some pictures of it in this thread http://67-72chevytrucks.com/vboard/s...d.php?t=697424. As soon as I get it home and start the work It will get its own build thread.

Re: 68 C50 Looongbed pickup build
 

That looks like great project truck, I recall seeing your previous post now. If you decide to go with the tow bar be really careful, these trucks are big and heavy and could easily overpower what ever is pulling it if you get in to an emergency situation. Just out of curiosity, how far do you have to move it?

-Richard

Re: 68 C50 Looongbed pickup build
 

Great read on your work! I like the C50 and C60 in those years, just as much as the C10's!

Re: 68 C50 Looongbed pickup build
 

Only about 30 miles. Cruise along at about 35 mph shouldn't be too bad. My DD is a 07 Toyota Tundra that is supposed to be able to tow 10,300 pounds so flat towing it should go fairly well. Might have a friend ride the parking brake in the GMC. Also good to know about the body change, Ill have to look into that. Sorry for hyjacking your thread.

Re: 68 C50 Looongbed pickup build
 

Thanks for checking it out. It's funny how my tastes have changed over the years, there was a time when I wouldn't have given the medium duty trucks a second look, now I'm obsessed with them. (I still love my 10's, 20's and 30's too!)

Fortunately that is very close, just keep in mind that since the towed vehicle has 4 wheels and more weight it may have a mind of it's own. However, I'd be lying if i said I haven't done stuff just as sketchy if not worse. OK, I've done a lot worse and walked away, but I'm really lucky.

No hijack perceived, I'm glad to have a good dialog going. Can't wait to see your build thread once you get things going.

-Richard

Re: 68 C50 Looongbed pickup build
 

I had high hopes for this weekend, however things did not go as planned. Job #1 was to get the cab squared up to the frame, when we set it on last weekend only the driver side front mount was in the correct place, the whole cab was rotated clockwise around that mount point. Also when we set it down one of the forks on the forklift had slipped over to where the passenger side rear mount could not even be placed over the hole in the frame. I'd had a whole week to consider how to rotate the cab, so here is what I came up with and what I did:

1) Use my cheap Porta-puller to lift the back of the cab off the mounts and remove them
2) set the back of the cab down on a piece of pipe that it can roll on
3) lift the front passenger side with a floor jack
4) rotate the cab while supported as described
5) set it back on the mounts

This is the only thing that worked right all weekend!

-Richard

Re: 68 C50 Looongbed pickup build
 

More pictures from rotating the cab:

-Richard

Re: 68 C50 Looongbed pickup build
 

After getting things squared up I was ready to drop the cab back on to the mounts however they looked really grungy, there was a lot of rust stuck on them. I checked the 89 mounts and they looked much better and are the same size as the 68 mounts so I used them instead. The bolts for the rear mounts had suffered some rust over the years so I cleaned them up and hit them with a coat of rust reformer paint before reinstalling them. With everything lined up and the bolts ready I lowered the front corner back down on the mount, lifted the back off of the pipe and inserted the mounts and bolted it down.

This was a lot of pictures and dialog describing this process, however the whole thing probably was done in less than 45 minutes. For once something went as quickly as it should. I was convinced that I was on a roll. I was wrong...

More tomorrow.

-Richard

Re: 68 C50 Looongbed pickup build
 

Like I said, I was on a roll, or so I thought. Next up was to connect the clutch linkage. I expected this to be as simple as to pop the linkage in and stick in a cotter pin and move to the next item on the list. When I went to connect it, the rod was a full two inches too far forward and three inches too short. I fooled around with it for several minutes but it just wasn't going to happen. I spent a lot of time trying to measure locations on one frame and then walk a couple of hundred steps to the other one to compare and finally decided that the part of the linkage bolted onto the frame must be different so I went about removing it. Pulling the z bar and mount from the 68 frame wasn't fun but I got it all out in under a half hour. With the big block, full exhaust and a cab in the way it did not go nearly so well on the project truck. One of many frustrations was that the bolts holding it on were 18mm instead of 3/4 inch. That meant a trip across the road and down the way to my brother's shop to borrow an 18mm combination wrench (I had a 17 and a 19 in my box, but no 18!) It's an absolute crap shoot on the 89 what will be standard and what will be metric. Anyway after fighting it for what seemed like forever I finally dropped the exhaust on the driver side and got it loose pretty quickly after that. I then compared the two and although different the difference was negligible. Time wasted, a lot of time wasted. :cuss:
Because of other commitments my available time Saturday was done. What a bummer of a day. Sunday morning before church I had some cows to feed and a missing bull to hunt for. Cows fed, bull not found; I can only hope he shows up soon. Anyway by now I had determined that I needed the clutch rod from the 89. Simple, one cotter pin holding it at the top, five minutes, right? WRONG! An hour and a half later and I finally had it out. Impossible to convey how frustrated I was. I went ahead and pulled the steering column while I was there. It was literally two bolts, 3 screws and unplug the harness and it was loose. I was running so late that I didn't even have time for a shower before church, I just washed my face threw on clean clothes and showed up as they finished the first hymn.

After church and back in dirty clothes I made another pass at finding the missing bull, still no sign of him.

Back to the truck I was able to get the clutch rod out of the 68 cab pretty quickly as it had the proper spring clip instead of a bent up cotter-pin. When I laid the two rods out side by side it looked promising, however when I tried to hook it up it was off side to side and too long. A trip to the vice to put a bend in and the side to side was good (the thin part in the second photo was originally straight), next onto the length. I made marks as to how much needed to be cut out as well as a reference line so I could get it clocked properly (3rd photo). A chop saw made quick work of the cuts, then I ground a 45 degree bevel in both pieces and welded them together. This was at my brother's shop and I didn't have the camera, so no photos. Once back I ground the weld down smooth. Pics 4 and 5 show the finished product comparison and the altered rod (sans the paint)

-Richard

Re: 68 C50 Looongbed pickup build
 

A test fit of the clutch rod and it popped right in and seems to work when I push the pedal. I need to replace the rubber boot that the rod runs through and it needed paint on the ground off bit so the final install has to wait for next weekend. I hit it with primer and then some top coat and set it aside to dry. Then I removed the steering column from the 68 cab and it was installed pretty much like the 89. I was pleasantly surprised to find that someone had already replaced the blinker switch with a newer one so it already has the wiring adapter installed. I stood the two columns side by side and all I need to do is swap the bracket and column to floor gasket and it will bolt right in. I haven't decided yet if I am going to paint it or not. On one hand it is black and matches the interior, however the original column was a contrasting color and I am very tempted to paint it the hammered bronze that I used on the heater assembly (as seen in the 3rd photo). What do you think?

Finally, I just have to brag a bit on my 2004 DD, she hit 300K miles on the way to work this morning!

That's all the updates for this week, more next time.

-Richard

Re: 68 C50 Looongbed pickup build
 

I've been there and back.....its frustrating but when you slide in behind the wheel for the first time and get it out on the road, all of that goes away in a big hurry!

Re: 68 C50 Looongbed pickup build
 

If things go really well with reassemble then that first test drive may not be too far away. I can hardly wait!

-Richard

Re: 68 C50 Looongbed pickup build
 

Weekend update:
First on the agenda was to finish hooking up the clutch. When I pulled the clutch rod out the previous week I noticed that the rubber boot in the firewall was disintegrating. While I didn't have any expectation that the light duty and medium duty would use the same part I ordered one from LMC. As soon as it came in I knew it wasn't a match, you can see from the second photo it wasn't even close. That meant that I needed a plan B. With nothing to lose I set out to remove the old boot from the cab without finishing it off. I ended up using a blow dryer to heat it up to get it soft enough to remove it from the cab without destroying what was left. Once out I cut both apart and then grabbed some tire patch material and bonded the two together. It is a crappy looking temporary fix at best but for now it will keep air from blowing in. If anyone happens to have an old GM parts book I'd love to get a part # so that I can search for an NOS piece. Once It was back together I heated it with the blow dryer again and reinstalled it. Then I popped the clutch rod in and pinned it top and bottom. Clutch functional, check!

-Richard