New to me 91 Jimmy
 

Well, I first came to this forum because of the extensive knowledge of first generation K5"s. Now diving into a couple 3rd gen K5"s and hope for the same knowledge base or help to build it. New in the driveway 1991 K5. I do have some work to do on this truck (not a southern truck). I have to do rear floor (at tail gate) and rear floor support, outer and inner rockers both sides, drivers outer floor, body mounts. But here is a pic

Re: New to me 91 Jimmy
 

subscribed welcome

Re: New to me 91 Jimmy
 

You wouldn't guess it needed that much metal work looking at the picture. Congrats on the purchase. What are your plans for it?

Re: New to me 91 Jimmy
 

Gut the truck day. 1991 K5 Jimmy under the knife. Gutted the inside, all side panels, seats, carpet, kick panels, center console, glove box, removed nasty running boards, retracted rear window and removed tail gate. And yes there is rust and rot (this was planned for). Next step order body parts, cut and weld in new. FYI this is what salt does to your vehicles and this truck has been heavily undercoated since new. So yes rust from the top side down.

Re: New to me 91 Jimmy
 

I'm liking it. Just dig in full bore.

Re: New to me 91 Jimmy
 

Small update. All body bolts out. Body panels ordered.

Re: New to me 91 Jimmy
 

That's a dagone shame right there. I guess you northern guys are completely used to it though. It can be nice again.

Re: New to me 91 Jimmy
 

Pulled the wheels. New brake pads and rotors up front. New shoes in the rear. Waiting on drums. Welded in patch at passenger kick plate. Removed the broken power mirrors. Have manual stainless ones to install. Wouldn't you know the bolt pattern to mount the mirrors are different. So I will have to drill new holes and fill the old ones. Seat bases were rotten. Ended up buying a complete interior from another k5 just to get the seat bases.

Re: New to me 91 Jimmy
 

Plan is function. This will be my winter beater. I have a son who will turn 16 this next year, so a slightly imperfect truck for him to learn with is okay.

Re: New to me 91 Jimmy
 

I guess you call this progress. New mirrors installed. A couple kick plate patches in (not super pretty but nobody will see this area ever). Cutting out more rot and more rot and more rot. My new friend is air chisel. He makes removal fast and easy. Any body that knows these k5's the rear step area/ back seat is the bad spot. I made the funny rectangle pieces that goes from the cab floor brace to front of the rear bed floor. Install after I get the new floor in. All new floor pans etc are to be here by Wednesday. Tail gate repair started. Cut out the bondo area. Welded in new patches on the top left and right corners. Picture 4 shows a hole. Thats the seat belt mount! more metal going in there later.

Re: New to me 91 Jimmy
 

A few more pictures

Re: New to me 91 Jimmy
 

Ain't rust fun? ;-)

Re: New to me 91 Jimmy
 

Rust sucks! But I am getting it beat down. its nice to have a rust free k5 beside it so I can see what its suppose to look like.

Re: New to me 91 Jimmy
 

Power mirrors removed and manual mirrors installed.

Re: New to me 91 Jimmy
 

Tail gate patch welded in place. Some more details to work out on that. Rear tail support- using a spot weld drill bit. Works awesome and fast. More knife cutting and a test fit. No particular order.

Re: New to me 91 Jimmy
 

Bottom of drivers door metal repaired. This area gets covered with carpet so nothing pretty here. Need some body sealer and paint. first pic was test cut to see how much I needed to cut out.

Re: New to me 91 Jimmy
 

At least the frame looks like it is decent!

Re: New to me 91 Jimmy
 

This truck was heavily undercoated since new. All cab supports are like new. Rot is all top down other than the dreaded rear sill support.

Re: New to me 91 Jimmy
 

Progress tonight! Rear part of the passenger floor pan welded into place.

Re: New to me 91 Jimmy
 

Some work done tonight. Front passenger floor pan and cab support floor brace replaced.

Re: New to me 91 Jimmy
 

More work tonight. Welded in new seat belt patch - thicker metal than the original. Inner and outer rocker in place some more stitching to do but ran out of time.

Re: New to me 91 Jimmy
 

Been watching your posts and you're a better man than me. That was a parts truck to me.
I bow down to your patients, sir!
Rare truck for sure.
Only made 3026 or so Jimmy in 1991.
Just got a 91 SLX Jimmy myself. Cant stop buying these things!

Re: New to me 91 Jimmy
 

Nice work! :metal:

Re: New to me 91 Jimmy
 

That's some high quality tedious work. Good stuff.

Re: New to me 91 Jimmy
 

Thanks guys. Its my first crack at this kind of work. Sometimes I feel like I am over my head but just have to keep at it. Hope to have it on the road by the end of the weekend- but that wishful thinking.