72 k20 project
 

small history
my grandfather bought this truck new. i got it from him when i was 13. when i was younger i thought i should make it into a mud racer, but thankfully that didnt progress far enough to really make a mess of things. so, after high school it pretty much sat with little being done to it. it had been in my dads driveway up untill last weekend. i finally got it home to colorado.

the current build plan is a body resto and a powertrain including a 12v cummins, 6 speed manual and the current 4" lift. so we got a little time today to start the tear down. of course there will be pictures.

http://i94.photobucket.com/albums/l8...k/100_1700.jpg

http://i94.photobucket.com/albums/l8...k/100_1701.jpg

http://i94.photobucket.com/albums/l8...k/100_1702.jpg

i am sure there will be alot of questions to field about bodywork. i am still not sure how i am going to do the body. i may have someone else do it, but i also want to possibly teach myself as well. time will tell.

i was impressed. this truck has been it Iowa its entire life and i was able to unfasten the front body mount bolts with a ratchet. so far the rust problem doesnt seem to be that bad

ryan

Re: 72 k20 project
 

so, progress is slow. while the weather is still nice we are working(slowly) at finishing our patio project. the process of laying pavers is hard on my back and knees and also on my truck progress. anyhow, there has been a little more dissasembly.

i think i decided to have the cab blasted and while it is at the professional blaster i will try to do the frame at work. that is unless the pro gives me a nice price for both.

some pics

http://i94.photobucket.com/albums/l8...k/100_1723.jpg

http://i94.photobucket.com/albums/l8...k/100_1720.jpg

the rust i have to deal with on the cab

http://i94.photobucket.com/albums/l8...k/100_1721.jpg

http://i94.photobucket.com/albums/l8...k/100_1722.jpg


i have these. are they worth anything or hard to find? i know the jack and associated stuff is hard to find for my jeep, but i dont know if this is a good score or not

http://i94.photobucket.com/albums/l8...k/100_1718.jpg

Ryan

Re: 72 k20 project
 

That has always been one of my dreams, to drop a 12v cummins into a 71-71!! Best of luck to you!!

Re: 72 k20 project
 

Finally decided to update. other than a lot of dis-assembly there wasn't much to show. i finally got the frame to the blaster and back into the garage. tomorrow i plan to start boxing the frame in. will return with more pics as progress occurs

http://i94.photobucket.com/albums/l8...0truck/004.jpg

http://i94.photobucket.com/albums/l8...0truck/005.jpg

i sure am excited to work on a clean frame instead of grinding and wire wheeling and suffering

Ryan

Re: 72 k20 project
 

a few progress pics. i thought i took more today but apparently i was slacking. more tomorrow

primered the inside of the frame where the first round of box plate was to be affixed. i also shot the inside of the plates themselves.

http://i94.photobucket.com/albums/l8...0truck/001.jpg

my buddy Derek has been helping me(a lot) and learning about cars and fabrication. for being a first timer his welds are not so bad

http://i94.photobucket.com/albums/l8...truck/0022.jpg

i will get a few more tomorrow with a little more progress. i have to make some decent patterns for the more complicated areas tomorrow hopefully as well

Ryan

Re: 72 k20 project
 

Nice looking project, I really like the way these trucks look in the teal.

Re: 72 k20 project
 

Your truck's condition prior to restore looks very similar to my K20 project. The rust on the cab looks about the same. You made the right choice having the frame blasted. Looking forward to seeing your progress.

Below are some before and after pics of the rust on the floor of my K20 floor. I remember being a little disappointed when I pulled up my rubber mat and discovered the rotted out floors. The driver's side was much worse. If you take your time welding in patch panels, grinding smooth, you should end up being very pleased. These trucks in good condition seem to be rare.
Good luck Ryanroo.

Re: 72 k20 project
 

little more progress

mostly welded

http://i94.photobucket.com/albums/l8...k/100_1733.jpg

all welded

http://i94.photobucket.com/albums/l8...k/100_1735.jpg

finishing the welds

http://i94.photobucket.com/albums/l8...k/100_1736.jpg

http://i94.photobucket.com/albums/l8...k/100_1738.jpg

also filling the holes. alot left to go

http://i94.photobucket.com/albums/l8...k/100_1737.jpg

Re: 72 k20 project
 

That is looking good.

Re: 72 k20 project
 

thanks

Re: 72 k20 project
 

got a little more done to the frame today

where my grandfather had welded in the gooseneck ball hitch plate there was a lot of rust between the frame and the plate and alot of pitting on the top of the frame. in places the original 3/16 material was only 1/16 thick. i didnt like it and decided to repair it before i boxed it in.

before

http://i94.photobucket.com/albums/l8...0truck/017.jpg

http://i94.photobucket.com/albums/l8...0truck/016.jpg

i marked out the areas that i wanted to cut and drilled a hole in the corner so as to leave no sharp corner.

http://i94.photobucket.com/albums/l8...0truck/022.jpg

i guess i forgot pictures of the cuts before i repaired

so here are the after shots

http://i94.photobucket.com/albums/l8...0truck/024.jpg

http://i94.photobucket.com/albums/l8...0truck/025.jpg

http://i94.photobucket.com/albums/l8...0truck/027.jpg

http://i94.photobucket.com/albums/l8...0truck/026.jpg

i also got most of the weld finishing done on the drivers rail where i boxed it. there was a lot of grinding dust on the floor today.

Re: 72 k20 project
 

I had another side project that was eating my weekend time, but it has left, so i got a little more done to the truck

yanked the front suspension and axle

http://i94.photobucket.com/albums/l8...truck/susp.jpg

removed the stock front crossmember. the engine crossmember was taken out long ago. added some bracing to keep the frame square and at the correct width

http://i94.photobucket.com/albums/l8...ruck/frame.jpg

this is the stock cast bushing tube/bracket. it is well known that the stock 1.125" bushings are not known for their durability. they also were in the way of my frame boxing plans

http://i94.photobucket.com/albums/l8...0truck/old.jpg

since i mentioned frame boxing, i will show these. still have to get them in there, but at least i have them...

http://i94.photobucket.com/albums/l8...100_1751-1.jpg

so, to replace the crap stock stuff, i whipped out a pair of these today. bushing tubes are 2" .250" wall DOM. the frame has a 1.875" hole punched for clearance around the stock cast piece. i turned the tube down to slip fit tightly into the stock hole in the frame and will locate and holesaw the other side in the boxing plate after it is firmly in place. the bolt sleeves are just .750" .120" wall DOM faced on the lathe for the cool guy effect. and mostly just because i was there. i will use a normal spring eye bushing for the new upper shackle bushing, hopefully greatly increasing the durability with the added weight of the cummins.

http://i94.photobucket.com/albums/l8...k/machine2.jpg

this is a picture of the idea. i may fishplate around the tube, but i think it would be a bit overkill, and i don't have a lot of room to weld the tube in if i do. that will be decided later i suppose.

http://i94.photobucket.com/albums/l8...0truck/new.jpg

i think i am running to denver for some sheetmetal parts saturday, but hopefully i can get some of this stuff at least tacked in on sunday

ryan

Re: 72 k20 project
 

Great project! Nice fab work on boxing the frame. What are your plans on an engine cross member? I'm guessing fabbing one your self? Keep up the great work!

Re: 72 k20 project
 

i have a mental plan for the crossmember, but nothing more concrete than that. the engine will be supported on the frame and there will be a cradle/crossmember that will be removable. so the oil pan can be removed while the engine is in the truck and supported on its mounts. similar to the way you have started doing in your crew cab. i am pretty sure i will be using a double set of leaf spring t-bushings on each side but i may use the stock dodge mounts. that is doubtful though as i have some hidden childhood fear of stock parts. in my head it is all very pretty and functional. hopefully i will be able to get to work on that in the next few months.

Re: 72 k20 project
 

Nice looking project and frame is coming along great!!!

Re: 72 k20 project
 

Cool deal man. I look forward to the progress! I'll be adding to my Longhorn's mounts when it gets back from the body shop.

Re: 72 k20 project
 

Nice looking project! I am looking forward to seeing how you mount the engine, trans & transfer case. I am planning a swap for my '72 GMC K2500.

Burnett

Re: 72 k20 project
 

Hey Ryan, your project looks great!! Should be a real stump puller!! :metal:

Re: 72 k20 project
 

looking forward to more on that one as well. i am liking that build.

i am looking forward to that stage very much. i have some ideas for how to build the crossmembers. not sure if it will turn out. i am going to use less tube on this than when i built my jeep and more sheet metal. we will see how it turns out. in my head, it will be awesome. i hope reality turns out somewhat close to that

Thanks!

Re: 72 k20 project
 

So, after a long and peculiar day i returned home with this.

67 front clip

http://i94.photobucket.com/albums/l8...ruck/pside.jpg

grill has a few dingers in it. nothing terrible

http://i94.photobucket.com/albums/l8...uck/grille.jpg

this is the battery box.

http://i94.photobucket.com/albums/l8...batterybox.jpg

fender cup is solid on the passenger side. there is some rust through on the drivers that will have to get fixed but nothing compared to the stuff on my original fenders. the core support is solid and strong. there a little spot on one of the inner fenders that is rusty. i'm not even sure i will repair it. i was pretty happy with my haul. so much better than the stuff i pulled off the truck

Ryan

Re: 72 k20 project
 

Looks nice and solid from here! :chevy:

Re: 72 k20 project
 

tacked in the drivers side

http://i94.photobucket.com/albums/l8...ruck/001-1.jpg

i hacked the old fuel pump relief out. i will plate that back in and then depending on the front accessories i end up with i will likely have to notch and replate the frame in that area for the A/C comp. i want to have a blank slate if that is the case so i am going to patch it all in first.

http://i94.photobucket.com/albums/l8...0truck/002.jpg

had a little extra bit in the front. i thought i took shots of both sides, but i guess not. the other looks like this one in a mirror. the frame has some awkwardness at the front. i have a few gaps to deal with, but when i am done it will be smooth.

http://i94.photobucket.com/albums/l8...ruck/005-1.jpg

drilled the holes for the bushing tubes, need to touch them up a little with a die grinder as the holesaw walked just a touch on the passenger side and the bushing tube is about .060" off on the inside. the saw left a little ridge that is holding it away from where i want it.

http://i94.photobucket.com/albums/l8...0truck/003.jpg

http://i94.photobucket.com/albums/l8...ruck/004-1.jpg

http://i94.photobucket.com/albums/l8...0truck/008.jpg

then i had to clean the garage as it was a horrid wreck. in the process i decided i would like some gratuitous test fit shots with the new front clip.

http://i94.photobucket.com/albums/l8...0truck/006.jpg

http://i94.photobucket.com/albums/l8...0truck/007.jpg

i am so excited to have the cab moved away from my workbench and out of my way. a weekend or two more and i think i can set it back on a welded frame

Ryan

Re: 72 k20 project
 

The 67 clip is sweet! I dont think that seat will be DOT approved though! Great job on the frame and thanks for all of the details and pics. I have a question: I see where you have an existing 4" lift on the truck in the first few pics, do you know if the K20 sits higher than the K10 with the same lift? I know sometimes the 3/4 ton trucks do have more ground clearance from the factory but I wasn't sure about the oldies. Thanks

Re: 72 k20 project
 

if they do it would be minimal. i know the frames are the same between the K10 and k20 and the springs will fit either. visually i have never noticed a difference i stock trucks.

ryan

Re: 72 k20 project
 

time for more pics

as promised, patch going in

http://i94.photobucket.com/albums/l8...0truck/010.jpg

the rough knock down on the welds

http://i94.photobucket.com/albums/l8...0truck/012.jpg

smoothed up. i could have spent alot more time in alot of places finishing this out to make it 100% awesome and beautiful, but i will save that effort for a build that it matters on. this truck is going to be used and will be dirty and dusty most of the time. so, this is enough

http://i94.photobucket.com/albums/l8...0truck/014.jpg

http://i94.photobucket.com/albums/l8...truck/0152.jpg

burned the bushing tubes in

http://i94.photobucket.com/albums/l8...truck/0162.jpg

http://i94.photobucket.com/albums/l8...truck/0172.jpg

i couldnt stand not having some paint on the frame somewhere. i will have to knock it off in a few places when i start doing crossmembers i'm sure but oh well. some times i cant be patient. you can also see that i have filled alot of the holes in the frame. i dont want/need them all filled but i have done alot of them. i have also left some of the front unpainted since i know i have alot of fab left up there. the back also for the same reason

http://i94.photobucket.com/albums/l8...truck/0182.jpg

http://i94.photobucket.com/albums/l8...truck/0192.jpg

http://i94.photobucket.com/albums/l8...truck/0202.jpg

hopefully i can get some cab mounts ordered and maybe next week set the cab back on the frame.

does anyone know if the 67-68 core support bushings are different than 69-72, and does it matter if you use one or the other on a conversion truck?

and on that note rubber or poly?

ryan

Re: 72 k20 project
 

got the front axle back in and put the cab and clip on for a look

http://i94.photobucket.com/albums/l8...truck/0012.jpg

http://i94.photobucket.com/albums/l8...uck/0022-1.jpg

Re: 72 k20 project
 

Looks tough! I like it!

Re: 72 k20 project
 

fiddled around today trying to learn some rust repair i also started stripping the paint off the fender. i can tell that process is going to be good for my mental wanderings

the offending hole

http://i94.photobucket.com/albums/l8...truck/0013.jpg

i am new to this stuff, but tape seemed like a good way to get strait lines for cutting

http://i94.photobucket.com/albums/l8...truck/0023.jpg

traced the old part onto the non rusted fender and chopped out what i needed

http://i94.photobucket.com/albums/l8...truck/0033.jpg

going in.

http://i94.photobucket.com/albums/l8...truck/0052.jpg

after some sanding

http://i94.photobucket.com/albums/l8...truck/0062.jpg

closer shot

http://i94.photobucket.com/albums/l8...truck/0092.jpg

as much paint removal as i got done before i had to stop and burn a slab of beef for dinner

http://i94.photobucket.com/albums/l8...truck/0102.jpg

the patch isn't as good as i had in my head before i started but i am going to make a dolly tool tomorrow that will hopefully get the low spots out. it will still need a little skimmer of bondo. i suppose it could be worse for the first time I've ever done it

Re: 72 k20 project
 

Looks like a fine job to me.

Re: 72 k20 project
 

ive been sanding paint whenever i felt like it after i get home from work and the gym during the week for the last couple of weeks. my wife was back for the last two weekends and the week in between, so i did absolutely nothing in regards to the truck (although i was rather forcibly told i needed to purchase my engine and i should also either buy a trans or some tool that i wanted as a valentines present :) ). anyhow, all that is left is the front right fender and the hood, although i may end up ditching this hood so i will be ignoring it for the time being. i also think that i will take the cab to the blaster and have the impossible spots and most of the interior blasted. that will happen after the engine gets placed though as i plan on modifying the firewall to allow me to set the engine back a touch further.

http://i94.photobucket.com/albums/l8...ruck/003-1.jpg

i also got the dent in the back of the cab that i have no idea how it happened to be pushed back in for the most part. im not sure if its noticable in the pic

ryan

Re: 72 k20 project
 

Nice progress and great work on that rust repair!

Re: 72 k20 project
 

Nice progress you have made,hope to see more picture soon.Keep the hard work going forward & keep on truckin'. :metal:

Re: 72 k20 project
 

i had a lot of plans for this weekend but, at 10 this a.m. i found out i need to build an ejector nozzle that has to be in the Mohave monday night or tuesday morning. so tomorrow i have to do that as well as hopefully get a little more done on the 72 stuff that i need the to do at work. hopefully i wont have to go in sunday and finish the nozzle.

anyhow, i cut some stock

http://i94.photobucket.com/albums/l8...truck/0014.jpg

this will end being the gooseneck ball mount. the tubes are 2"x4"x1/4" and they extend out to the stock frame rail web. my frame boxing plate will butt up to the 2"x4" tube and should make the overall product very stout. i will figure out how i am going to actually mount the ball later. i hope to be able to either rob a B&W system or copycat it.

as you can see the rear axle is out. more on that later this weekend i hope.

Ryan

Re: 72 k20 project
 

Wow, great stuff. Must be something about the name Ryan, since there is now 2 of you doing cummins conversions in 72 K20s. :lol: Cant wait to see it done!

Re: 72 k20 project
 

i take it you fabbed the boxing plates? how thick of plate did you use?

Re: 72 k20 project
 

also how much did you buy?

Re: 72 k20 project
 

i used 3/16" p&o plate for the boxing plate. i'm not sure how much i bought so far. i would guess what i have used at 12-14 ft^2 but i have no idea. i buy it from work and i bought a partial at first and used parts of it and then i cut the funny shaped parts from a different sheet we had laying around at work. i am quite sure that a full 4'x10' sheet would be more than you need. for what i've made so far i would say i have spent 80-90$. keeping in mind i get the steel for barely more than cost

Re: 72 k20 project
 

i ended up at work for about 12 hours saturday and 7-8 today so i didnt get nearly the progress i had hoped for. but i do have a little to show for my weekend

i started tacked up the rear section of frame rail that i am replacing due to some ugly rust pitting that i dont like.

i made some provisions for a bumper and receiver hitch mount

http://i94.photobucket.com/albums/l8...1112132935.jpg

http://i94.photobucket.com/albums/l8...1112134129.jpg

http://i94.photobucket.com/albums/l8...1121347421.jpg

the holes were drilled out to .75" and sleeved with .75"x.120" wall DOM. i countersunk the holes and welded in the groove and sanded it all flat

this is sitting on the frame that it will replace. i had intended to have this all welded up and the new shackle hangers in place this weekend. i didnt have the time to cut and tack up the hangers but they are ready for cutting on the table when i get around to it

http://i94.photobucket.com/albums/l8...ruck/001-2.jpg

ryan

Re: 72 k20 project
 

Very nice fab work! It looks great! I plan on doing a B&W style gooseneck in mine as well. Dang you. I keep seeing people box their frames and I think I'm going to have to do it now too. I have a different route I'm going with mine again so the extra strength can't hurt. :lol:

Re: 72 k20 project
 

Thanks! i think if i can get my machinist friend to do it for me i think i will make my own turnover ball dohicky. of course if i find a cheapsky B&W i would be time and probably money ahead to just use whatever of it i need to.

i wanted to box the frame partly because i like doing fabwork, and partly because i know that these frame are a little limp as is. if i end up getting stupid with the diesel power i want something solid to tie it too.

what is the current plan of attack?