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rust repair on the '77...here goes nothin
Wow, what a commitment! Cutting into the body on this truck is intimidating to say the least. I've done some messing around with my mig, but never anything this challenging. What a schooling!
When I've been researching this I've not found very much info about what lies under the roof skin, like where braces are and how things are spot welded together. I went to the junkyard and cut the roof out of an 84 blazer to use part of it for patch panels and to cut it up to see how it's put together. So far my to do list includes the windshield frame above the glass, floors, bedsides, and tailpan. I sold the top and tailgate cause I don't have room to store that stuff and cause I want to use a soft top and truck tailgate instead. Hope I don't regret that later. In Baja this past winter whenever I'd get on a rough road little bits of rust would rattle out of the headliner and fall in my lap. I was expecting it to suck pretty bad when I took things apart, but it wasn't as bad as I thought. Here's some pics from first stage. Rust above windshield frame. https://c1.staticflickr.com/5/4240/3...b547bbc2c8.jpg https://farm5.staticflickr.com/4240/...b547bbc2c8.jpg2017-06-14_08-11-52 by Mick, on Flickr https://c1.staticflickr.com/5/4238/3...033b469e58.jpg Decided I needed a dome and map light so while the roof was apart I placed the wiring and made a bracket for a light out of a '98 Tahoe. Backseat light actually cause it's a bit smaller. https://c1.staticflickr.com/5/4199/3...b8b3a0640a.jpg https://c1.staticflickr.com/5/4274/3...f079bd074c.jpg While the top skin was cut out I used some of this stuff. http://www.eastwood.com/eastwood-int...z-aerosol.html to spray around inside between the layers and down the A pillars. Also used to hit the inside of the pinch weld after things were put back together. Not sure it'll make a big difference, but makes me feel better. A bit later I'll post some pics of the cut up junkyard roof so you can get a better idea of what's going on under the top skin. |
Re: rust repair on the '77...here goes nothin
Nice work.
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Re: rust repair on the '77...here goes nothin
sort of done with the roof for now, just need to do the filler and primer
https://c1.staticflickr.com/5/4221/3...b10085e433.jpg junkyard donor roof https://c1.staticflickr.com/5/4236/3...2eaf3f2d01.jpg A pillar cut away looking down from the roof https://c1.staticflickr.com/5/4270/3...6f215cb820.jpg looking up the A pillar from below https://c1.staticflickr.com/5/4276/3...50fdc900cd.jpg B pillar cut away https://c1.staticflickr.com/5/4219/3...3c9d4b57cc.jpg If you want more pics of how the roof is put together let me know, still have it in the driveway for now. |
Re: rust repair on the '77...here goes nothin
Next up are the bed rails.
https://c1.staticflickr.com/5/4290/3...ee9022fd9e.jpg https://c1.staticflickr.com/5/4241/3...ae51eb8c46.jpg https://c1.staticflickr.com/5/4266/3...8c4c7ce257.jpg the junkyard donor bed rail with spot welds drilled out and separated. https://c1.staticflickr.com/5/4275/3...e77ed1d3ff.jpg the patch https://c1.staticflickr.com/5/4237/3...b27e7ba8d2.jpg the partial fix, just need some epoxy primer and filler and finish https://c1.staticflickr.com/5/4219/3...785f071548.jpg https://c1.staticflickr.com/5/4281/3...3e827a8ef5.jpg |
Re: rust repair on the '77...here goes nothin
what kinda clecos are those
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Re: rust repair on the '77...here goes nothin
They're just a set of stitch weld magnets from Eastwood. On sale for like $5 or something. I've been using them alot, not using the butt weld clamps much though.
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Re: rust repair on the '77...here goes nothin
Wish you weren't two days drive away, I could use the back half of the donor cab. My 79 has rot where the top butts against the half cab. KUTGW...
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Re: rust repair on the '77...here goes nothin
Good job! I just got done doing a couple of patches for my "74's door strikers but nothing like what you're doing. Very satisfying to cure cancer though!!
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Re: rust repair on the '77...here goes nothin
Man I wish I had tour patience. Looking good!
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Re: rust repair on the '77...here goes nothin
Looks like you've taken your time and done a very good job with your repairs. Nice work.
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Re: rust repair on the '77...here goes nothin
Thought I'd throw out an update, as I've had a bit of a eventful summer. Kind of back on track now.
My white truck has had a rod bearing making noise for a while now. Just as I was getting ready to head out on a road trip in July it started to really make a racket. So I had to swipe the motor out of the blazer. https://farm5.staticflickr.com/4489/...66257d25_z.jpg ...and jabb it in the white guy https://farm5.staticflickr.com/4452/...29afd8ab_z.jpg Then rolled out on a 2500 mile road trip into Idaho, Montana, and Washington for some fishing with my kid. North Fork Clearwater, Idaho https://farm5.staticflickr.com/4492/...a64c66a8_z.jpg Coming down into Superior, Montana https://farm5.staticflickr.com/4527/...7d160ea8_z.jpg Montana/Idaho stateline we got woke up by a bear huffing around at 3am. https://farm5.staticflickr.com/4580/...41747928_z.jpg While on the road in Spokane I stopped into a junkyard that had a seat sale going on so I picked up these '99 Tahoe seats for $22 for the pair. https://farm5.staticflickr.com/4523/...44267cb9_z.jpg Then took a big hit getting them re-skinned in buckskin leather. Seats have always been high on my priority list so these should work out. https://farm5.staticflickr.com/4549/...bbd2db01_z.jpg Since the motor was out of the blazer it was time to bite more bullet. 400hp Roller cam vortec 355 from West Coast Engines online. Not sure what I'm going to do with this other than break something. Maybe turn the white guy into a muscle truck later, but that'll require a 502BBC. https://farm5.staticflickr.com/4586/...812ef4fe_z.jpg https://farm5.staticflickr.com/4536/...32940cc4_z.jpg I was thinking since the motor was out and the floor was all cut up that now would be a good time for a NV4500. https://farm5.staticflickr.com/4483/...dd74dbd5_z.jpg Bummer I can't drive it for a while yet. Hope to have it ready for another Baja trip by this time next year. I think I'm done with mechanical for now. Back to body work next. |
Re: rust repair on the '77...here goes nothin
Seats turned out great! Anyone who's paid to redo seats realizes that the TMI stuff is actually a good deal! Nice work as always.
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Re: rust repair on the '77...here goes nothin
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Sorry, what is TMI? |
Re: rust repair on the '77...here goes nothin
Picking up where I left off with bed rails in post 4.
https://farm5.staticflickr.com/4219/...5f071548_z.jpg https://farm5.staticflickr.com/4528/...c70c83d2_z.jpg https://farm5.staticflickr.com/4570/...5dc6bea0_z.jpg https://farm5.staticflickr.com/4572/...8a5f83f9_z.jpg https://farm5.staticflickr.com/4568/...2cd28ee3_z.jpg https://farm5.staticflickr.com/4570/...f9ec62a8_z.jpg https://farm5.staticflickr.com/4569/...1ce8d63f_z.jpg https://farm5.staticflickr.com/4290/...9022fd9e_z.jpg https://farm5.staticflickr.com/4571/...aa1bd5b5_z.jpg |
Re: rust repair on the '77...here goes nothin
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Re: rust repair on the '77...here goes nothin
I guess one good thing about this taking forever is I've got some time to decide on interior. Thanks for the link.
Next on the list is to build a roll bar, which I hope will give the cab some added structure before I cut up the floor. JD Squared model 3 bender https://farm5.staticflickr.com/4524/...4669a6bd_z.jpg |
Re: rust repair on the '77...here goes nothin
Nice work, Rg
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Re: rust repair on the '77...here goes nothin
Man that must be one beefy table! I've got my JD2 bolted to the concrete and it takes some muscle to get it done! Maybe yours is air/hydraulic?
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Re: rust repair on the '77...here goes nothin
Roll bar done. I figure this is a good backup to the work I did in the B-pillars.
https://farm5.staticflickr.com/4526/...549d8fda_z.jpg Also wanted to give a thumbs up to this guy on YouTube for the good tutorial on tube notching without a tube notcher. |
Re: rust repair on the '77...here goes nothin
Sweet sweet sweet.
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Re: rust repair on the '77...here goes nothin
[QUOTE=mickeykreg;
I was thinking since the motor was out and the floor was all cut up that now would be a good time for a NV4500. [url=https://flic.kr/p/GhtU62]https://farm5.staticflickr.com/4483/...dd74dbd5_z.jpg[/url] What is that horizontal bracket for on the left side of the trans over to the clutch housing above the release lever? That's an AA clutch housing, right? |
Re: rust repair on the '77...here goes nothin
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https://farm5.staticflickr.com/4552/...ed121fe2_z.jpg |
Re: rust repair on the '77...here goes nothin
Time for the floor:
This is the single thing that drove me to begin this project in the first place. https://farm5.staticflickr.com/4571/...d64fbe4c_z.jpg https://farm5.staticflickr.com/4548/...65b2f636_z.jpg https://farm5.staticflickr.com/4533/...75ace25b_z.jpg Amazingly this bolt turned out albeit with a breaker bar. https://farm5.staticflickr.com/4520/...cb5fd2ae_z.jpg https://farm5.staticflickr.com/4526/...3c191415_z.jpg https://farm5.staticflickr.com/4554/...184515fe_z.jpg https://farm5.staticflickr.com/4581/...88e18b6b_z.jpg Outer rocker seemed ok so I cleaned it up and left it. https://farm5.staticflickr.com/4546/...f55cc8b3_z.jpg Now to put things back together. Mock up bottom of kick panel https://farm5.staticflickr.com/4585/...0be5e14e_z.jpg bottom of kick panel and inner rocker combo https://farm5.staticflickr.com/4536/...b9b6cac5_z.jpg Inner rocker I got from Tabco had part of the outer floor molded in as one piece which was nice. https://farm5.staticflickr.com/4524/...76d068b1_z.jpg Inner rocker needed some larger drain holes to hopefully not trap as much debris and moisture https://farm5.staticflickr.com/4557/...0c139196_z.jpg https://farm5.staticflickr.com/4559/...ac2b6ff2_z.jpg Got my $3 worth out of this disc. :sexy: https://farm5.staticflickr.com/4547/...eaa02179_z.jpg New floor support https://farm5.staticflickr.com/4569/...94d332d6_z.jpg There was no saving this piece https://farm5.staticflickr.com/4529/...731a16c7_z.jpg so I cut a new one out of the left over kick panel https://farm5.staticflickr.com/4575/...43d8e2fc_z.jpg https://farm5.staticflickr.com/4552/...57c51700_z.jpg Floor reproduction from Tabco sucked because it was made for a truck, but I was able to make it work because the seat mount area was still ok. It's good heavy gauge material though. 16ga I think. https://farm5.staticflickr.com/4569/...2bc6dff9_z.jpg https://farm5.staticflickr.com/4573/...3c3de0a8_z.jpg https://farm5.staticflickr.com/4540/...d6b88c91_z.jpg This area has no reproduction piece that I know of so I had to make it. Almost an entire day in this photo. https://farm5.staticflickr.com/4543/...795c6e84_z.jpg The edge of the left over truck floor had close to the right form so I used it. https://farm5.staticflickr.com/4580/...a1099efb_z.jpg https://farm5.staticflickr.com/4569/...246bff17_z.jpg https://farm5.staticflickr.com/4526/...23edab50_z.jpg |
Re: rust repair on the '77...here goes nothin
Rear fender:
the old: https://farm5.staticflickr.com/4556/...717d2ee9_z.jpg https://farm5.staticflickr.com/4536/...5e1389f3_z.jpg the new: https://farm5.staticflickr.com/4524/...9f8dd271_z.jpg https://farm5.staticflickr.com/4572/...00abd139_z.jpg https://farm5.staticflickr.com/4554/...726d2288_z.jpg |
Re: rust repair on the '77...here goes nothin
Got it started and moved outside long enough to clean up my dungeon. Drove around the block cause I couldn't not. 355 running good for the first time. Need to go break it in, but lots of work to do first.
https://farm5.staticflickr.com/4737/...6dbcbfd6_z.jpg https://farm5.staticflickr.com/4737/...9bfd8621_z.jpg Got sick of bodywork so I built this out of a left over piece of rocker. Just messing around, don't know if I like it, but am looking for somewhere to put gauges, audio jacks, trailer controller, USB charging, without having stuff spread all over the place. https://farm5.staticflickr.com/4682/...74165def_z.jpg https://farm5.staticflickr.com/4537/...88b22ff6_z.jpg |
Re: rust repair on the '77...here goes nothin
With that 4500 shifter in place do you think there is room for an underdash ac unit? Sure don't look like it.
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Re: rust repair on the '77...here goes nothin
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4500 shifter is actually further back than the old one. Couple pics here: http://67-72chevytrucks.com/vboard/s...d.php?t=749980 |
Re: rust repair on the '77...here goes nothin
Passenger side requirement was almost identical to driver side.
https://farm5.staticflickr.com/4688/...785a8a12_z.jpg https://farm5.staticflickr.com/4737/...9a6645eb_z.jpg https://farm5.staticflickr.com/4639/...648c9d19_z.jpg https://farm5.staticflickr.com/4734/...8d118dce_z.jpg https://farm5.staticflickr.com/4687/...c0c5f4bb_z.jpg Stick stuff back together now. Outer rocker was still fine so I cleaned it up and got it ready. Like on the driver side the outer was replaced on a repair in the past. Inner rocker wasn't replaced so no debris could build up between the inner and outer. Kick panel first. https://farm5.staticflickr.com/4601/...6a48a126_z.jpg Inner Rocker https://farm5.staticflickr.com/4596/...4cb06cf5_z.jpg inner and kick with debris clean out holes that I added. https://farm5.staticflickr.com/4634/...f708573b_z.jpg floor support https://farm5.staticflickr.com/4687/...5439c777_z.jpg https://farm5.staticflickr.com/4725/...399acd63_z.jpg https://farm5.staticflickr.com/4589/...011f727b_z.jpg https://farm5.staticflickr.com/4644/...8fba0322_z.jpg I got the replacement floor pan from Tabco who said it's for a blazer, but it's actually for a truck. Flat Blazer floor is much different than a truck so I had to cut the stamped part of the new floor out and use a piece of 18 gauge that I got at the steel supply. Such is life with these Taiwanese replacement panels, actually most of the panels I've used so far have been pretty good. |
Re: rust repair on the '77...here goes nothin
Finally got the floor rebuilt to the point of getting serious about how these seats are going to fit. I got the pair for $22 on sale day at the junkyard, but then dropped about $1300 to get them re-skinned in leather, which I didn't think was too bad of a deal. The low back seats had me freaking out about whiplash protection from getting hit in the ass by a texting driver. Anyway, here's what I did. Hope it's helpful to somebody.
Junkyard seats $22 https://farm5.staticflickr.com/4523/...44267cb9_z.jpg https://farm5.staticflickr.com/4734/...f4f0ef84_z.jpg Old seats/New seats https://farm5.staticflickr.com/4549/...bbd2db01_z.jpg Now just to make them fit. Started with a piece of 2'x2' 3/16" steel plate. Man I wish I had a plasma cutter. https://farm5.staticflickr.com/4646/...14920cd3_z.jpg Driver side https://farm5.staticflickr.com/4689/...2da25905_z.jpg Passenger side https://farm5.staticflickr.com/4739/...760237ee_z.jpg POR15'd https://farm5.staticflickr.com/4680/...f4d0b304_z.jpg Brackets original to the 99 seats get bolted to the adapter. https://farm5.staticflickr.com/4679/...79e0a77e_z.jpg Seat belt gets bolted to this. Original floor is sandwiched between this and the 3/16" plate. https://farm5.staticflickr.com/4725/...3fafe2ed_z.jpg I decided not to make the new passenger seat tilt forward. After quite a few test fits it looks like when the new seat back is folded forward and the seat is slid all the way forward it provides almost as much room as the original gave when it was tilted forward. |
Re: rust repair on the '77...here goes nothin
This bedside patch was an entire day! Whoever did this repair in the past didn't even bother to do any welding. Sheetmetal is screwed in place and covered with nearly a 1/2" of bondo in places. Glad to be getting this fixed!
https://farm5.staticflickr.com/4726/...f3729bf8_z.jpg https://farm5.staticflickr.com/4737/...564499c9_z.jpg https://farm5.staticflickr.com/4644/...971aae04_z.jpg Next up to bat is the bed, stay tuned. https://farm5.staticflickr.com/4733/...3cfd23ce_z.jpg |
Re: rust repair on the '77...here goes nothin
your 77 blazer looks like the 78 blazer I bought out of north Carolina that came out of ohio I brought it to ga. on a rollback got out one day and took off the top . when I took it off both sides of the blazer just fell to the ground it was repaired a one time and it was done poorly just bonded back together with rust and bondo was gona try to drive it but I was scared the rest of the body would fall off the first time I turned a corner :waah:
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Re: rust repair on the '77...here goes nothin
now that you have the rockers all together I recommend spraying oil up in there everywhere. Seen many where the top of the rocker rots first. Nice work
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Re: rust repair on the '77...here goes nothin
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On this one, I've been using this stuff from Eastwood to get behind weld seams and such. No big deal. It's a driver and if it rusts I'll fix it again. http://www.eastwood.com/eastwood-int...z-aerosol.html |
Re: rust repair on the '77...here goes nothin
nice work on the roof repair. My 73 burb has rot in the roof and I've been having a hell of a time finding any info on repairing the roof. Been thinking of replacing the whole roof skin but not sure if it will save much in time comparing to replacing pieces like you did. Do you know if anyone makes a replacement roof?
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Re: rust repair on the '77...here goes nothin
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I don't know of anybody that sells a replacement roof skin. The more I dig into this thing the more surprised I am at how many parts are not available. If I were to do it again I'd find another donor roof, but I'd keep the outer skin intact and replace it as a whole, (like the kid in this video has done). Get the old outer skin off first so you can see what you have to deal with and go from there. With a donor roof you'll have what you need. That's what I would do, but a suburban roof will obviously ad a bit of complexity. |
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