Project: Rust, White & Blue
 

Alright this build thread is way overdue and im finally getting one started. I started driving this truck in april of my freshman year of high school (2006) when I turned 16. I did different things to it like replace the exhaust system after getting tired of it being tied up with bailing wire and lots of other small things. Eventually I got a new set of 33/12.5/16.5 tires for a set of 16.5x 9.75 wheels, after that it just looked to low to the ground so I decided to make it 4x4.

Re: Project: Rust, White & Blue
 

So towards the end of my junior year I bought my 80 3/4 4x4 donor. A funny thing is that the engine that is in my truck originally came out of the 4x4 truck about 15 years ago and will be going back in it soon. The body was shot (literally):lol: but nothing hit the frame, transmission, or t-case. I then started taring it down to the frame getting ready to rebuild it. I probably scraped 30 pounds of flordia sand, mud and dirt off of that frame.

Re: Project: Rust, White & Blue
 

I wire wheeled mostly everything on thee frame and sand blasted everything I couldn't get to with the wheel. Then I primed it with rustoleum rusty metal primer. I flipped the frame over so I didn't have to work upside down but that all got primed and painted with rustoleum gloss black. Then I did the same to the 14 bolt, I only replaced the gaskets and seals because all the bearings were perfect. I still need to replace the pinion seal and swap out the the yoke for my other one because it has a chunk missing by one of the bolt holes.

Re: Project: Rust, White & Blue
 

New drums, brakes, sandblasted everything else then primed and painted everything everything but the cover, I painted that with engine enamel and then clear engine enamel. After a while the clear turned kinda yellow an crackled but I guess it just gives it character. I did the same for the front except I replaced all the outer bearings and races, ball joints and I got new Mile Marker lockouts to go on it.

Re: Project: Rust, White & Blue
 

one more

Re: Project: Rust, White & Blue
 

some more

Re: Project: Rust, White & Blue
 

Again I sandblasted, primed and painted everything except for the stuff that needs to be adjusted, Ill paint that later once everything is situated. I painted the cross member too but I don't have a picture of it. Then I started taring the truck down.

Re: Project: Rust, White & Blue
 

Stripped down the firewall with 80 grit on the DA and stand blaster, then epoxy primer. I also filled in some of the holes from the aftermarket AC system but i lost some of my pictures. Then i flipped the cab on the back and started cleaning it.

Oh, most of these pictures were taken on my phone and my dumb arse changed the settings to take crappier pictures so that's why the pictures get smaller, eventually I figured it out.

Re: Project: Rust, White & Blue
 

I took the hump out of my K30 to trace where the 4x4 hole goes. I cut the hole a 1/2" small then bent the edge down like it would be from the factory, then drilled the holes for the boot. The driver side door channel was a little rusted from 25 years of dirt/rain but it mainly was just rubbed through from the plastic gas tank rock shield rubbing it for so long. Then I cut out the bad spot.

Re: Project: Rust, White & Blue
 

Sand blasted the rust in the inside and bent a new patch panel from a old chevy fender, then welded it in.

Re: Project: Rust, White & Blue
 

I cut off the spot of the tank shield so it wouldn't rub anymore. I also removed the little heat shield where the factory manifold gets close to, no more manifolds :). It had a nice little crease on the rocker and cab corner where someone found a post or something. It was creased back to where dirt and water would collect in there so when I went to pull the dent the studs would just rip off. I just went ahead an cut out that area and replaced it.

Re: Project: Rust, White & Blue
 

More 80 grit on the DA, sandblasting, and epoxy, then I sprayed on this stuff called LINER X-TREEME from trkspecialist on ebay. I really like the stuff, but if I was to do it over i wouldn't add any of the rubber crumb and add all of the reducer from the start.

Re: Project: Rust, White & Blue
 

Some the spacers for the cab bushings were pretty bad so I made new ones to replace them. New urethane bushings from lmc to fit the '80 frame.

Re: Project: Rust, White & Blue
 

Looks like a very nice project, cant wait to see how this goes!

Re: Project: Rust, White & Blue
 

Thanks!

Re: Project: Rust, White & Blue
 

Awesome.

Re: Project: Rust, White & Blue
 

Thanks Jonny Cash! :lol:

Re: Project: Rust, White & Blue
 

Looking very good, I really like what you did with the diff covers ;)

What size lift did you go with?

Re: Project: Rust, White & Blue
 

Thanks! I forgot to mention that, I went with a 4" Rough country lift.

Re: Project: Rust, White & Blue
 

daggone you are doing a lot of work im excited to see updates!!

Re: Project: Rust, White & Blue
 

Thanks, yeah its been a lot of work and im afraid im only half way there. :lol: Ive been real busy workin lately and taking care of other stuff too so I haven't had a chance work on this in a while. Its also getting dark around 6:30 now so that cuts out a lot of my time for this truck, if I had a bigger shop with better lighting I would work on it till 12 every night. Im gonna to try to get the cab on the frame within a week or so.

Re: Project: Rust, White & Blue
 

Dang, I just came across your build thread and I'm glad I did! Great stuff, you and I think very much alike. I just wish I had more space to work and more patience. I want to drive my truck and work on it at the same time. I'm just going with the engine spray can rebuild for now.

I'm also going to go with a 4" lift. I want to keep my OEM wheels and narrow tires and dog dish hubcaps--love that look. What size tires are you going to run?

Texas, baby!

Re: Project: Rust, White & Blue
 

Thanks! Yeah there seems to be a lot of people on this site that think like me :crazy: :lol:. Im going to run the 33's for now but im afraid there going to look too small so I might go with 37" hummer tires. I have a new set of gmc hubcaps to go on it also.

You like the diff covers? ;)

Re: Project: Rust, White & Blue
 

Yeah, the covers are sweet! Any photos of the truck with the 4" lift right now? Did you go with springs or blocks in the rear? Those Rough Country lifts are priced right, are they pretty complete?

Re: Project: Rust, White & Blue
 

Nice project and sweet job on the diff covers! That's original and cool!