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1972 K5 4x4 modified build
I have had this blazer for a few years now, and I have posted some pics and questions, but I thought I would start an 'official' build thread to track work I have done and work I will be doing.
Started out as a 1972 CST, single wall top, AC, tilt, tach and so on. I had been looking for a plain jane for a while since I had planned on modifying it, but the price on this was too good to pass up. It literally came in pieces with boxes of unlabeled bolts, wires and parts. This is not a purest build, I modified the truck to suit me, I am sure I will upset some members by desecrating this vehicle, but I like it. This will be a camping, exploring, snow playing, ice cream getting truck. I want it to be strong and simple-ish, but fun. I have a few pics, so here goes! What I am ruining: ;) http://i178.photobucket.com/albums/w...r/DSCN3203.jpg First time in the shop with my son helping: http://i178.photobucket.com/albums/w...r/DSCN3194.jpg PO had an aftermarket tank in addition to the stock unit. I will be removing it and putting one in the original spot http://i178.photobucket.com/albums/w...r/DSCN3195.jpg Filler hole on body http://i178.photobucket.com/albums/w...r/DSCN3196.jpg Fairly straight body http://i178.photobucket.com/albums/w...r/DSCN3197.jpg Supposedly rebuilt 350/350/205 combo. At this point I was thinking a fuel injection setup on this engine, punching it out to a 383 and going to a 700R4 http://i178.photobucket.com/albums/w...r/DSCN3198.jpg Super awesome coil-over setup on all four corners: http://i178.photobucket.com/albums/w...r/DSCN3199.jpg |
Re: 1972 K5 4x4 modified build
It looked like a decent minimal rust body:
http://i178.photobucket.com/albums/w...r/DSCN3200.jpg But, digging deeper: http://i178.photobucket.com/albums/w...r/DSCN3201.jpg http://i178.photobucket.com/albums/w...r/DSCN3209.jpg http://i178.photobucket.com/albums/w...r/DSCN3207.jpg Both rockers had rust and were paper thin in spots. So, I figured I would hang the doors and the front sheetmetal then install an Energy Suspension body mount kit that came with the project so I could start ripping out the bad spots. http://i178.photobucket.com/albums/w...r/DSCN3215.jpg http://i178.photobucket.com/albums/w...r/DSCN3211.jpg http://i178.photobucket.com/albums/w...r/DSCN3219.jpg http://i178.photobucket.com/albums/w...r/DSCN3223.jpg http://i178.photobucket.com/albums/w...r/DSCN3228.jpg http://i178.photobucket.com/albums/w...r/DSCN3224.jpg |
Re: 1972 K5 4x4 modified build
More rust removal and repair pics:
http://i178.photobucket.com/albums/w...r/DSCN3255.jpg I started on the passenger side rocker. The A pillar and part of the lower kick were toast, as was part of the floor support: http://i178.photobucket.com/albums/w...r/DSCN3253.jpg http://i178.photobucket.com/albums/w...r/DSCN3256.jpg http://i178.photobucket.com/albums/w...r/DSCN3254.jpg I realize the floor isn't perfect, but it is sound for welding, and I plan to bed lie the tub, so it will hide any small imperfections Cleaned up a bit: http://i178.photobucket.com/albums/w...r/DSCN3258.jpg Test fit the inner: http://i178.photobucket.com/albums/w...r/DSCN3259.jpg Slight depression http://i178.photobucket.com/albums/w...r/DSCN3265.jpg Raised it up to match repair panel: http://i178.photobucket.com/albums/w...r/DSCN3268.jpg No pictures, but I prep washed the rocker box and any exposed surface to get rid of surface rust and painted it before assembly. Crappy alignment of panel: http://i178.photobucket.com/albums/w...r/DSCN3266.jpg So I cut and moved the slice up to match the floor. http://i178.photobucket.com/albums/w...r/DSCN3269.jpg |
Re: 1972 K5 4x4 modified build
More passenger rocker repairs:
I lied; I did have a picture of the painted area: http://i178.photobucket.com/albums/w...r/DSCN3262.jpg I had to really massage the patch panel to get it to somewhat jive with the original steel: http://i178.photobucket.com/albums/w...r/DSCN3270.jpg http://i178.photobucket.com/albums/w...r/DSCN3271.jpg http://i178.photobucket.com/albums/w...r/DSCN3273.jpg Welded for outer rocker http://i178.photobucket.com/albums/w...r/DSCN3274.jpg Pillar repair http://i178.photobucket.com/albums/w...r/DSCN3275.jpg http://i178.photobucket.com/albums/w...r/DSCN3276.jpg I bent and welded a repair panel for the lower B piller http://i178.photobucket.com/albums/w...r/DSCN3280.jpg The new outer rocker radius was atrocious, no where near the original http://i178.photobucket.com/albums/w...r/DSCN3282.jpg So I cut the end to get it tighter http://i178.photobucket.com/albums/w...r/DSCN3283.jpg |
Re: 1972 K5 4x4 modified build
I cut the old rocker end off and welded it to the end of the new one:
http://i178.photobucket.com/albums/w...r/DSCN3285.jpg http://i178.photobucket.com/albums/w...r/DSCN3286.jpg http://i178.photobucket.com/albums/w...r/DSCN3287.jpg I also had to cut and massage the rocker/pillar intersections: http://i178.photobucket.com/albums/w...r/DSCN3288.jpg http://i178.photobucket.com/albums/w...r/DSCN3289.jpg http://i178.photobucket.com/albums/w...r/DSCN3290.jpg Rear of rocker: http://i178.photobucket.com/albums/w...r/DSCN3291.jpg And that will finish passenger rocker: http://i178.photobucket.com/albums/w...r/DSCN3292.jpg |
Re: 1972 K5 4x4 modified build
Driver’s rocker was a little farther gone:
http://i178.photobucket.com/albums/w...r/DSCN3295.jpg Cut line for removal: http://i178.photobucket.com/albums/w...r/DSCN3296.jpg http://i178.photobucket.com/albums/w...r/DSCN3297.jpg Floor support was shot: http://i178.photobucket.com/albums/w...r/DSCN3298.jpg I think the only picture of me working: http://i178.photobucket.com/albums/w...r/DSCN3308.jpg Removed the support: http://i178.photobucket.com/albums/w...r/DSCN3311.jpg Pretty bad but not as worse as some I’ve seen on the boards here: http://i178.photobucket.com/albums/w...r/DSCN3312.jpg I built a new outer piece and welded it on: http://i178.photobucket.com/albums/w...r/DSCN3313.jpg http://i178.photobucket.com/albums/w...r/DSCN3314.jpg The rest was a copy of the passenger side, with the same amount of work: http://i178.photobucket.com/albums/w...r/DSCN3315.jpg http://i178.photobucket.com/albums/w...r/DSCN3317.jpg |
Re: 1972 K5 4x4 modified build
During this time frame, my power plant wishes changed, so I bought a Duramax/Allison combo, but it was a super tight fit, and I did not want a body lift. I sold it and found a L92/6l80E combo out of a Hummer H2 with 13K miles on it:
http://i178.photobucket.com/albums/w...r/DSCN3401.jpg I had purchased the DIY4X engine cross member for the small block I had, but it was not going to work with the LS engine: http://i178.photobucket.com/albums/w...r/DSCN3412.jpg http://i178.photobucket.com/albums/w...r/DSCN3413.jpg So a quick slice and the engine settled into place: http://i178.photobucket.com/albums/w...r/DSCN3417.jpg http://i178.photobucket.com/albums/w...r/DSCN3415.jpg http://i178.photobucket.com/albums/w...r/DSCN3416.jpg Tight fit: http://i178.photobucket.com/albums/w...r/DSCN3420.jpg As far back to the firewall as I wanted it: http://i178.photobucket.com/albums/w...r/DSCN3421.jpg I bought a 1990 NP241 passenger drop transfer case and changed the input shaft to a 32 spline to match the 6L80 and installed a slip yoke eliminator kit (no pics for some reason) http://i178.photobucket.com/albums/w...r/DSCN3418.jpg http://i178.photobucket.com/albums/w...r/DSCN3419.jpg Transmission/transfer in location for cross member: http://i178.photobucket.com/albums/w...r/DSCN3423.jpg |
Re: 1972 K5 4x4 modified build
Tunnel space looks great:
http://i178.photobucket.com/albums/w...r/DSCN3424.jpg http://i178.photobucket.com/albums/w...r/DSCN3425.jpg I will need to build some protection for the 241: http://i178.photobucket.com/albums/w...r/DSCN3428.jpg I also changed over to a hydroboost system. I cleaned and painted the brake pedal assembly: http://i178.photobucket.com/albums/w...r/DSCN3429.jpg I built a plate to adapt the hyroboost unit to the firewall. Unit is from an 86 Chevy diesel: http://i178.photobucket.com/albums/w...r/DSCN3430.jpg |
Re: 1972 K5 4x4 modified build
I modified the brake actuating rod for adjustment:
http://i178.photobucket.com/albums/w...r/DSCN3432.jpg Cut off end: http://i178.photobucket.com/albums/w...r/DSCN3433.jpg Turned a chunk of steel down and threaded on end for a rod end: http://i178.photobucket.com/albums/w...r/DSCN3434.jpg http://i178.photobucket.com/albums/w...r/DSCN3435.jpg http://i178.photobucket.com/albums/w...r/DSCN3436.jpg Cut two flats for a wrench: http://i178.photobucket.com/albums/w...r/DSCN3437.jpg Installed on rod: http://i178.photobucket.com/albums/w...r/DSCN3438.jpg Steel spacer for lock nut clearance: http://i178.photobucket.com/albums/w...r/DSCN3440.jpg In place: http://i178.photobucket.com/albums/w...r/DSCN3441.jpg |
Re: 1972 K5 4x4 modified build
Next I built a mount for the truck throttle pedal assembly:
http://i178.photobucket.com/albums/w...DSCN3443-1.jpg http://i178.photobucket.com/albums/w...DSCN3444-1.jpg This put the pedal in nearly the same area and angle as the original: http://i178.photobucket.com/albums/w...DSCN3445-1.jpg I also built the cross members for the transmission/transfer case: http://i178.photobucket.com/albums/w...r/DSCN3448.jpg Disregard the disc, I am building a better one for the parking brake: http://i178.photobucket.com/albums/w...r/DSCN3449.jpg http://i178.photobucket.com/albums/w...r/DSCN3450.jpg I purchased a Painless wiring harness so I needed to fill in the firewall to cut a new hole for the bulkhead. I am also deleting the foot activated parking brake, so those holes can be filled also: http://i178.photobucket.com/albums/w...r/DSCN3451.jpg http://i178.photobucket.com/albums/w...r/DSCN3455.jpg I also deleted the AC and planned on using an after-market heater, so I filled in the passenger side of the dash: http://i178.photobucket.com/albums/w...r/DSCN3452.jpg http://i178.photobucket.com/albums/w...r/DSCN3453.jpg http://i178.photobucket.com/albums/w...r/DSCN3456.jpg |
Re: 1972 K5 4x4 modified build
Wow, what a lot of work, nice though seems to be going fine, better choice for the engine, good time to switch to what you want. Will be a very nice truck when done, keep us posted.
Rick/ Mudman. |
Re: 1972 K5 4x4 modified build
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Re: 1972 K5 4x4 modified build
Somehow, I lost all of my in progress roll cage and axle swap pictures, however you can see them in the pictures from now on. I followed a member on here, Sand King’s cage as a guide, with a few modifications so it could be removable if required. I also acquired a 1991 Dana 60 front axle and a 1973 Corporate 14 bolt out of a van (to match track width) I went through both axles, re-geared to 5.13, Auburn up front and a Detroit in back. Also went to rear disc and cross-over steering.
I used DIY4X’s B52 kit to run 52” front springs, and also their shackle flip in the rear. These were pretty much bolt on swaps. I am running 4” lift springs with a zero rate block in back to push the rear axle back to it’s original spot. Here is a few shots of my console under construction: http://i178.photobucket.com/albums/w...r/DSCN3489.jpg I am using a Winters cable shifter for the transmission, and I built my own cable shifter for the transfer case. http://i178.photobucket.com/albums/w...r/DSCN3493.jpg http://i178.photobucket.com/albums/w...r/DSCN3494.jpg I finally received my Doug Thorley Headers after waiting three months. Only to find they hit the frame rails. So I made a small slice on each side by the motor mounts and reinforced it: http://i178.photobucket.com/albums/w...r/DSCN3491.jpg http://i178.photobucket.com/albums/w...r/DSCN3492.jpg I picked up a rear roll pan at the Portland Swap Meet. I am going to run a tube rear bumper, and wanted to have it clean looking behind it. This worked great. http://i178.photobucket.com/albums/w...r/DSCN3490.jpg I mounted my tires onto the rims, and rolled it outside for a picture. Tires are 38x14.5x17 BFG KM2 and the rims are Trailready beadlocks: http://i178.photobucket.com/albums/w...r/DSCN3495.jpg |
Re: 1972 K5 4x4 modified build
Back inside to star on the bumpers. I cut the fangs on the front fenders and rolled them to match the grill surround. I actually got the idea from a member on here, I just can’t seem to remember his name.
http://i178.photobucket.com/albums/w...r/DSCN3497.jpg I wasn’t sure how I was going to have the front lay out, so I decided to build the rear: http://i178.photobucket.com/albums/w...r/DSCN3505.jpg http://i178.photobucket.com/albums/w...r/DSCN3506.jpg http://i178.photobucket.com/albums/w...r/DSCN3510.jpg Then I started the front. I tied the bumper to the frame and the B52 front spring perch so I could use it as a pull point:: http://i178.photobucket.com/albums/w...r/DSCN3507.jpg http://i178.photobucket.com/albums/w...r/DSCN3511.jpg http://i178.photobucket.com/albums/w...r/DSCN3512.jpg I wanted to incorporate the front bumper/engine cage/roll cage so I needed to install the steering column and shaft. Since the truck did not come with a column, I grabbed an aftermarket tilt and used it: http://i178.photobucket.com/albums/w...r/DSCN3509.jpg http://i178.photobucket.com/albums/w...r/DSCN3508.jpg I milled an existing steering column shaft to a double D adapter for the column: http://i178.photobucket.com/albums/w...r/DSCN3513.jpg I installed my Entropy radiator: http://i178.photobucket.com/albums/w...r/DSCN3517.jpg This allowed me to bend up a simple cage for the engine: http://i178.photobucket.com/albums/w...r/DSCN3519.jpg |
Re: 1972 K5 4x4 modified build
Really coming together nice, well thought out too. The shifter setup on both is a nice touch, looks handy. The Dana 60 front being a 91 does that make it a ball joint diff, just wondering, mine is a dana 60 Currie front and has kingpins and was told a 77-86 setup with kingpin. Sure sits nice in the outdoor pic looks:sumo:..mean.
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Re: 1972 K5 4x4 modified build
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Re: 1972 K5 4x4 modified build
I bent up a couple of tubes to layout the connection from bumper to cage:
http://i178.photobucket.com/albums/w...r/DSCN3520.jpg http://i178.photobucket.com/albums/w...r/DSCN3521.jpg I built an attachment point for the connector tubes. You can also see the cage tied to the frame in this picture: http://i178.photobucket.com/albums/w...r/DSCN3522.jpg http://i178.photobucket.com/albums/w...r/DSCN3526.jpg http://i178.photobucket.com/albums/w...r/DSCN3527.jpg I used tube clamps to the bumper to allow me to disassemble everything: http://i178.photobucket.com/albums/w...r/DSCN3523.jpg And what it looks like done: http://i178.photobucket.com/albums/w...r/DSCN3524.jpg http://i178.photobucket.com/albums/w...r/DSCN3525.jpg http://i178.photobucket.com/albums/w...r/DSCN3528.jpg I built my front shock mounts while I was there: http://i178.photobucket.com/albums/w...r/DSCN3544.jpg http://i178.photobucket.com/albums/w...r/DSCN3545.jpg |
Re: 1972 K5 4x4 modified build
I took my rear spring shackles apart, cleaned them up and tied them together:
http://i178.photobucket.com/albums/w...r/DSCN3547.jpg http://i178.photobucket.com/albums/w...r/DSCN3548.jpg I bought a TIG welder so I am teaching myself how to use it: http://i178.photobucket.com/albums/w...r/DSCN3549.jpg I had purchased a NWMF 37gallon fuel tank early in the build, but when I decided to go EFI, it made the tank not worth the hassle to modify. Besides, it hung VERY low. So, I decided to fab my own tank. I drew it out in a CAD program and had a local guy cut the pieces out of 16g cold rolled sheet on his plasma table. Here I drilled and threaded the adapter for the fuel level sender: http://i178.photobucket.com/albums/w...r/DSCN3550.jpg http://i178.photobucket.com/albums/w...r/DSCN3551.jpg http://i178.photobucket.com/albums/w...r/DSCN3552.jpg And the fuel pump opening: http://i178.photobucket.com/albums/w...r/DSCN3556.jpg Everything was tabbed and slotted, so it went together easily: http://i178.photobucket.com/albums/w...r/DSCN3555.jpg I dimpled the baffles for rigidity: http://i178.photobucket.com/albums/w...r/DSCN3557.jpg http://i178.photobucket.com/albums/w...r/DSCN3558.jpg I started to bend up and tack everything together: http://i178.photobucket.com/albums/w...r/DSCN3554.jpg http://i178.photobucket.com/albums/w...r/DSCN3559.jpg Keeping it square: http://i178.photobucket.com/albums/w...r/DSCN3560.jpg http://i178.photobucket.com/albums/w...r/DSCN3561.jpg |
Re: 1972 K5 4x4 modified build
WOW! I wanna see this thing on a trail crawling over something big... Nice work!
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Re: 1972 K5 4x4 modified build
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Re: 1972 K5 4x4 modified build
I welded the lid on and checking for leaks. I pressurized the tank and sprayed soapy water to help locate the spots I missed: http://i178.photobucket.com/albums/w...r/DSCN3564.jpg
http://i178.photobucket.com/albums/w...r/DSCN3566.jpg http://i178.photobucket.com/albums/w...r/DSCN3568.jpg I then stuck it up in the truck to check fitment: http://i178.photobucket.com/albums/w...r/DSCN3570.jpg Nice and clean. This allowed me to make the stops for the tank: http://i178.photobucket.com/albums/w...r/DSCN3571.jpg http://i178.photobucket.com/albums/w...r/DSCN3572.jpg Here you can see the shackle reversal: http://i178.photobucket.com/albums/w...r/DSCN3573.jpg Good clearance which is what I wanted, and still should net 36~ gallons: http://i178.photobucket.com/albums/w...r/DSCN3574.jpg Shot from the back: http://i178.photobucket.com/albums/w...r/DSCN3575.jpg I also had the liberty of moving the filler neck and vent to the rear of the tank, this made a straight shot over to the tank instead of forward like the original: http://i178.photobucket.com/albums/w...r/DSCN3577.jpg http://i178.photobucket.com/albums/w...r/DSCN3578.jpg I built the blurry rear axle shock mounts and welded them on. They look clearer in real life: http://i178.photobucket.com/albums/w...r/DSCN3569.jpg |
Re: 1972 K5 4x4 modified build
I didn’t have a glove box interior, and since I used an aftermarket heater, I built my own out of 18g sheet:
http://i178.photobucket.com/albums/w...ps1999b7c1.jpg http://i178.photobucket.com/albums/w...ps3b1eb017.jpg At this point, I started to break it down for paint. I pulled the cage and finshed welding it: http://i178.photobucket.com/albums/w...ps911abe02.jpg http://i178.photobucket.com/albums/w...ps55994887.jpg Here’s a shot of the dash I modified for the Carling switches: http://i178.photobucket.com/albums/w...psfc42d666.jpg My tailgate hinges looked horrid, so I decided to rebuild them. I first cut off the original hinge mount wheel thing: http://i178.photobucket.com/albums/w...ps18e6c7a7.jpg I then turned a couple of axle shafts out of steel: http://i178.photobucket.com/albums/w...ps8c8edf75.jpg I cut two new wheel hinge mount bearing things out of some HMW plastic that fit over the axles: http://i178.photobucket.com/albums/w...ps44cc86ea.jpg Welded the axles in from the back and bolted the bearing mount hinged wheel things to that: http://i178.photobucket.com/albums/w...ps199de570.jpg And installed. They work great. No slop and easily rebuildable if the HMW plastic ever wears out: http://i178.photobucket.com/albums/w...psef0062c9.jpg |
Re: 1972 K5 4x4 modified build
Body has been detached, on the rotisserie and is heading for the sandblasters. It has been about 2 years to this point since we started:
http://i178.photobucket.com/albums/w...ps3d01c4aa.jpg http://i178.photobucket.com/albums/w...psf9cdd8b0.jpg My frame looks so alone. You can see here the rear crossmember I had to fab to fit the fuel tank: http://i178.photobucket.com/albums/w...ps66b6aaa7.jpg Body back from the blasters and has been sprayed with epoxy primer: http://i178.photobucket.com/albums/w...psf6e51ab2.jpg http://i178.photobucket.com/albums/w...ps19704718.jpg My son helping with the sanding: http://i178.photobucket.com/albums/w...ps8c9d05aa.jpg When I started this project, I wanted to do most if not all of the work, fabricating what I needed instead of buying, building instead of farming it out and that included painting. I am by no means a body /paint guy, so this is not a high zoot job, but it’s great for our use. It is primed and ready for paint. I guess: http://i178.photobucket.com/albums/w...ps46137278.jpg http://i178.photobucket.com/albums/w...psc2fcf35e.jpg http://i178.photobucket.com/albums/w...ps794feaee.jpg http://i178.photobucket.com/albums/w...psffe041c8.jpg |
Re: 1972 K5 4x4 modified build
Paint is on. It turned out okay. I reshot the tub and tailgate twice as I had a couple of runs:
http://i178.photobucket.com/albums/w...psd8276f4b.jpg http://i178.photobucket.com/albums/w...ps012d5a8f.jpg I sanded the tub down to spray Monsta-liner bed liner. I used a Shutz gun and it came out awesome! http://i178.photobucket.com/albums/w...ps20b07109.jpg http://i178.photobucket.com/albums/w...psc2e45aee.jpg http://i178.photobucket.com/albums/w...ps8df960b1.jpg http://i178.photobucket.com/albums/w...ps031cea65.jpg http://i178.photobucket.com/albums/w...ps28559b66.jpg I didn’t want black liner. I really wanted to keep the black to a minimum, and I thing the dark grey next to the orange looks good: http://i178.photobucket.com/albums/w...ps819fec38.jpg http://i178.photobucket.com/albums/w...pscf4e9b2d.jpg |
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