Re: 1972 K5 4x4 modified build
 

Looks awesome, I agree the gray / orange combo is great looking. Keep up the progress you be driving in no time.

Re: 1972 K5 4x4 modified build
 

Man oh man!

Re: 1972 K5 4x4 modified build
 

Thanks for the compliments! I am very close to driving. I will update with more pictures of my progress today.

Re: 1972 K5 4x4 modified build
 

Fantastic build - I wish I had your skills! One thing to consider, GM painted the upper part of the dash between the windshield and the dash pad in a flat color to reduce glare on the windshield. For an orange truck this would be black or I guess saddle depending on interior color but none were left orange. I did the same on my orange K20 build, which has a parchment interior and a black dash.

Re: 1972 K5 4x4 modified build
 

Wow nice build!

Re: 1972 K5 4x4 modified build
 

mad fab skills!!

Re: 1972 K5 4x4 modified build
 

Very nice.You got some skills.! :metal:

Re: 1972 K5 4x4 modified build
 

Man that is a beauty, did you do all that when I slept last night, I wonder if you work 24 hours a day.:metal:

Re: 1972 K5 4x4 modified build
 

Thank you, thank you! This is my first project, so I learn as I go. And no, I am not working 24/7 on this. This is more of a recap of my past work. I just never made time to sit down and post. But I have a cold, we have 7" of snow and ice on the ground, so I have time now. I am nearly done, just have a few more small items to address.

On to the pictures:

I got some help, manually lifted and put the body and cage in. It started raining right when we got done:
http://i178.photobucket.com/albums/w...ps3b6797f9.jpg http://i178.photobucket.com/albums/w...ps22d28d28.jpg
http://i178.photobucket.com/albums/w...psada372b8.jpg

Tailgate and roll pan going on. I had planned on using the original rubber items, but new was pretty inexpensive:
http://i178.photobucket.com/albums/w...ps01c29fa9.jpg http://i178.photobucket.com/albums/w...pse7475313.jpg

I put the dash pad on, bolted the glove box door on (yes, it clears the cage) and started the wiring. I had a large chunk of aluminum left over from another project, so I turned a couple of billet cup holders for the console. I had rough cut them for mock up, but finished them now:
http://i178.photobucket.com/albums/w...psc2362993.jpg
http://i178.photobucket.com/albums/w...ps6366d187.jpg http://i178.photobucket.com/albums/w...ps58fa18ab.jpg

I had a buddy give me a load of ¼” stainless button head bolts so I am trying to use them up: http://i178.photobucket.com/albums/w...psbfe4b88d.jpg

Re: 1972 K5 4x4 modified build
 

I installed the new sport mirrors and the window regulators on the doors and then hung them. I then taped off the tops to install the glass:
http://i178.photobucket.com/albums/w...psbdafc702.jpg
http://i178.photobucket.com/albums/w...ps0912cd99.jpg

I got the Danhard heater tucked into position:
http://i178.photobucket.com/albums/w...ps83712fbe.jpg

Then it was onto wiring. I love wiring; this is probably my favorite job. It can be tedious sometimes, though: http://i178.photobucket.com/albums/w...ps09575fde.jpg
http://i178.photobucket.com/albums/w...ps6c70ccd9.jpg

I looked for a decent dash panel to run the Autometer gauges I bought, but I decided to build my own. So I took some .125” aluminum and cut it out in the shape of the original, then welded a flat strap on the outside to get the original face angle and standoff.

The back wired up:
http://i178.photobucket.com/albums/w...psa3692b6e.jpg

The front. I like the Sport Comp II; if you squint, it looks like the Chevy bowtie symbol:
http://i178.photobucket.com/albums/w...ps6cb10d56.jpg

Here is where my project went askew. If you look under the console, you can see the placement of the ECM. I had purchased a new wiring harness from PSI which allowed me to put the ECM inside the tub:
http://i178.photobucket.com/albums/w...ps9f1b516d.jpg

Re: 1972 K5 4x4 modified build
 

Thanks! I do wish I knew to paint the dash black when I had it on the rotisserie, it would have made it a lot easier. I now need to figure out how to paint it where it's at.

Re: 1972 K5 4x4 modified build
 

You bet! I suspect in the long run you'll be glad you did and it's a nice OEM detail (and practical) that often seems to get overlooked. Have pics of mine in the link on my my signature below.

Re: 1972 K5 4x4 modified build
 

Well, I tried and tried to start it, but it would just backfire. After going round and round with PSI, I decided to use the original harness, which is what I should have done in the first place.

Since the harness is from an H2 Hummer, the ECM needed to be mounted in the engine bay. So I bent up a new one to sit on the driver’s inner fender:
http://i178.photobucket.com/albums/w...ps541e7878.jpg
http://i178.photobucket.com/albums/w...ps0747a26c.jpg

I took pics of the wiring I was extending so I wouldn’t screw it up:
http://i178.photobucket.com/albums/w...ps144d76a1.jpg
http://i178.photobucket.com/albums/w...ps9fb9b7da.jpg

I then extended the wiring for the fuses into the tub and mounted it above the throttle pedal:
http://i178.photobucket.com/albums/w...psb586bdb1.jpg

I was ready to start it, but I read I should clean the injectors, so I did. This is what came out of the fuel rail when I took it apart. And it STUNK. I still don’t know what it was:
http://i178.photobucket.com/albums/w...ps0cb44311.jpg
http://i178.photobucket.com/albums/w...ps9041f4e2.jpg
Put it back together and it fired right off! I was pumped.

Here is the ECM mount in the bay:
http://i178.photobucket.com/albums/w...psa0308da0.jpg
http://i178.photobucket.com/albums/w...psd1ef2c4d.jpg

Re: 1972 K5 4x4 modified build
 

Next I needed to build a battery box for the firewall, as the air cleaner was taking the normal battery position on the core support. I still had some aluminum scrap, so I decided to build it from that.

Sides cut:
http://i178.photobucket.com/albums/w...ps7744545f.jpg
For the bottom I cut and bent a flat sheet a little wider than the battery:
http://i178.photobucket.com/albums/w...ps8e7aa63b.jpg
The two sides with holes drilled. Good for 5-10 horsepower I’m told:
http://i178.photobucket.com/albums/w...psd692a1f6.jpg

Next I bent up a top hold down plate. The dimpled holes hold it nice and snug:
http://i178.photobucket.com/albums/w...psab51dca4.jpg
http://i178.photobucket.com/albums/w...ps43a83c94.jpg

Welded and mounted on the firewall:
http://i178.photobucket.com/albums/w...ps2fe9da03.jpg http://i178.photobucket.com/albums/w...pse95c0ede.jpg

Installed the fenders and grille surround. I painted the inner grille grey instead of the silver color it was, that way I can do touch-up if needed. I had to repair the grille surround with the TIG in a couple of spots then sanded it down to get a nickel finish look. I might have it nickel finished in the future:
http://i178.photobucket.com/albums/w...psf889f40f.jpg

Re: 1972 K5 4x4 modified build
 

Since I am using the Winters/Art Carr shifter, I needed to fab some kind of reverse switch. So I went to Radio Shack and picked up a micro roller switch and built a mount to attach to the shifter:
http://i178.photobucket.com/albums/w...ps8d096caa.jpg

My idea was to use the existing holes in the shifter plates to engage the switch as it comes around. So I turned some aluminum bar stock down as a ‘wheel”
http://i178.photobucket.com/albums/w...ps030e8e04.jpg

I cut two just in case I wanted to activate a switch in the future (park/neutral) The wheel will sit between the gold plates:
http://i178.photobucket.com/albums/w...ps433e93e0.jpg
I cut some aluminum angle scrap and mounted the switch. I can adjust it up/down and back/forward for proper engagement:
http://i178.photobucket.com/albums/w...ps85f694a0.jpg

Wired it up to a relay as a switched ground and it works great. Here a couple of close ups:
http://i178.photobucket.com/albums/w...psd6cd760e.jpg http://i178.photobucket.com/albums/w...psc57a6a2e.jpg

Re: 1972 K5 4x4 modified build
 

The cool work continues, need a friend. I do think the truck is a very nice achievement. Won't be any others around close to it for sure. What are your future plans with it when finished, any mud use, competition, or fun mud use or maybe just cruise around and enjoy it, could show it but that sounds boring. Took my beast out today and tore up some 2-3ft deep snow. Funny the big block with over 500hp just seems to need more power now, think I am just getting to used to it. It kicks but easily, will literally smoke the 40" Mud tires taking off in 2nd gear, think I may need to step it up to 600 plus. Won't make the gas mileage part of the forum.:lol:

Re: 1972 K5 4x4 modified build
 

Thanks again. Your truck sounds like a beast, I would love to have that horsepower- but 40" tires are expensive!! I think the future plans are the same as when i started it. I wanted a reliable, fun truck to camp, explore, run to the grocery store and definitely play in the snow- as a matter of fact, if I didn't feel like dog poo I would love to be out in it now. I am not a car show kinda person, I might go to a local show and shine once or twice, but I'd rather be out in the woods.

Re: 1972 K5 4x4 modified build
 

I got the ducting from the heater ran and installed the console side panels that I cut out of sheet aluminum:
http://i178.photobucket.com/albums/w...ps7fbb12f2.jpg http://i178.photobucket.com/albums/w...psd789106a.jpg

Threw together the front and rear skid plates:
http://i178.photobucket.com/albums/w...ps8b5c1d58.jpg http://i178.photobucket.com/albums/w...psd118b59e.jpg

I installed the shocks and bump stops:
http://i178.photobucket.com/albums/w...ps191e62a1.jpg
http://i178.photobucket.com/albums/w...ps90397e6e.jpg

Here is a better shot of the fuel filler adjustment. I forgot I did have to cut and turn the steel neck below the bed to make a straight shot to the tank. You can also see the cage to frame tie in point:
http://i178.photobucket.com/albums/w...ps3d264759.jpg

Another couple of pictures of the cage tie in points:
http://i178.photobucket.com/albums/w...pse76789a8.jpg
Above the rocker box:
http://i178.photobucket.com/albums/w...psf77c229e.jpg
http://i178.photobucket.com/albums/w...ps39cf8c1d.jpg

Re: 1972 K5 4x4 modified build
 

Well I am glad you will get some use out of it, I don't use mine as much as I would like to but have plans to in the future. I do a car show or 2 but mine is the rough one, not all shone up. I have been wanting to do some more updates and your thread is very encouraging to get back to my build instead of all the builds I do for everyone else, but theirs do fund mine, all takes time right. I like the console idea a lot so planning on an upgrade there after seeing yours.

Re: 1972 K5 4x4 modified build
 

I picked up a couple of slim LED turn signals and installed them in the grille:
http://i178.photobucket.com/albums/w...ps629db8df.jpg

Driveline and new parking disc installed:
http://i178.photobucket.com/albums/w...ps68e11d28.jpg

An AFE air cleaner installed:
http://i178.photobucket.com/albums/w...ps2ea0b7d6.jpg
I built a radiator recirculation tank:
http://i178.photobucket.com/albums/w...ps0dc0b73c.jpg

I also fabbed a relay holder and cover on the wiring bulkhead. Don’t mind the extra wires, just need to be cut and removed:
http://i178.photobucket.com/albums/w...ps00ec12ac.jpg

And this is where I am at today:
http://i178.photobucket.com/albums/w...psa2292227.jpg http://i178.photobucket.com/albums/w...ps61c38968.jpg http://i178.photobucket.com/albums/w...psaff2067c.jpg

To do list:
Door seals, fab some headlight and washer knobs, axle venting for both front and rear, windshield wipers and reservoir, some kind of stereo, fuel tank vent termination, maybe a steering damper.

Oh, ya. Drive it. A lot.

Re: 1972 K5 4x4 modified build
 

Love the fab work.

Re: 1972 K5 4x4 modified build
 

Sick sick sick, oh SICK!!!! Nuff said! You are one talented dude!

Re: 1972 K5 4x4 modified build
 

Did you really say "simple" when referring to the engine roll cage?:lol:
I would hate to see what you consider difficult!:metal:
As others have said, Dude! You have skills! Love how she turned out, hope you and your family enjoy for years to come!:metal:

Re: 1972 K5 4x4 modified build
 

WOW unreal build!

Re: 1972 K5 4x4 modified build
 

WOW! :jdp:

From a wanna be fabricator, how about some advice on shop equipment? What bender are you using? What are you using for making dimples? Etc. I need to start building a better shop and any advice would be much appreciated. I have zero for fabrication tools and my next project is going to be very similar to what you have created. Knowing what equipment is required up front would be great.