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Old 02-10-2020, 01:40 PM   #26
Bigdually
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Re: 1986 S10 Daily Driver Rollover Rebuild

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Originally Posted by Katrina/10 View Post
I have an 85 S15, 2.5 Duke with 700 trans and factory air. I bought a bunch of parts from Rock Auto and put it back on the road. It runs pretty good, but the engine has a rattle at low RPM. May be a bad piston, but I guess I'll run it till it dies.
The 2.5 is not a quiet motor. It's got a lot of things that make it noisy, mainly the valvetrain due to the fiber timing gear wearing and causing noise. Mines fairly quiet, but I had to have the head shaved to true it up when I did the head gasket and bolts a good while back. Under load the valves will chatter on low grade gasoline, if I use midgrade I never hear them.
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Old 02-10-2020, 10:22 PM   #27
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Re: 1986 S10 Daily Driver Rollover Rebuild

Switched back to the body work for this evening, I drilled the spot welds and cut the good cab corner out of the old cab. After a little trimming, this one snapped right into place and fit 100% better than the other one.

I bought a Harbor Freight air flange/punch tool on sale for $25, I used that to flange the top of the red cab corner to fit up under the cab metal on the new cab. I picked up a 3M panel bond glue cartridge and applicator gun combo on Amazon for almost what the glue alone costs locally. I'm no welder, so the glue is the only way to go for me.

I have it glued and clamped in place to cure now. This is my first attempt at any sort of body repair whatsoever, so I'm learning as I go here. If I don't get perfect results I'm not too worried, it's a work beater and in my opinion, not too bad a place to practice a little bodywork.
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Old 02-12-2020, 08:59 AM   #28
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Re: 1986 S10 Daily Driver Rollover Rebuild

I heard that timing gear could be a problem, so I ordered a steel gear set, then took the cover off. Guess what, the fiber gear was perfect! So I took the cam out to change it anyway, hoping that might help with something. I found the roller lifters had worn grooves in the the cam, so ordered another cam. Finally got everything put back together, and it still rattles. After going through the entire valve train, it must be something piston related.
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Old 02-12-2020, 02:26 PM   #29
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Re: 1986 S10 Daily Driver Rollover Rebuild

I love these Drive a 97 EC every day. Good work! Any link to the panel bond/gun combo?
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Old 02-12-2020, 05:05 PM   #30
Bigdually
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Re: 1986 S10 Daily Driver Rollover Rebuild

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I love these Drive a 97 EC every day. Good work! Any link to the panel bond/gun combo?
Thanks! They're definitely good little trucks.

https://www.amazon.com/3M-Adhesive-M...26468864&psc=1

I could get the glue locally for around $80 and the gun for $150. Definitely a better deal on Amazon. The gun is sturdy and very well built. It will probably last me for the rest of my life at my hobby level of vehicle repair.
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Old 02-12-2020, 11:25 PM   #31
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Re: 1986 S10 Daily Driver Rollover Rebuild

I filled the transmission with fluid this evening and changed the fuel filter while it's easy to reach. I did those things while waiting for the body filler on the cab corner to dry so I could sand.

I KNOW it isn't a great job, or even a good job. But it's my first time doing it, and I'm happy with the results. I used some seam sealer in the gap between the rocker and the cab corner, just like factory. I worried most about the side where it will be seen. The back isn't bad, but it isn't perfect either. The bed will always cover it there. At least it's better than if I'd just stuffed rags in the rust hole and bondo'd it up like most do to these trucks. A few coats of primer and some sanding, then some paint, and the cab will be completed.

I have high hopes my shifter will arrive tomorrow. Once it's on and my cab corner is painted I'm pretty much ready to set the cab on. I'm getting excited about that.
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Old 02-14-2020, 07:19 AM   #32
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Re: 1986 S10 Daily Driver Rollover Rebuild

Big progress yesterday!

My shifter came in the mail, got that bolted up and it seems to work nicely, I think I like it!

Got home from work early and threw on a few coats of primer and a few coats of blue paint that is SO much darker than the color on the lid. Oh well, at least it's not rust.

I also finished up some little things and got the new cab mounts on the frame, then fired up the tractor and rolled the frame outside to set the cab on. Once I got it on and back inside I hooked a few things up enough to see if I have power on everything that is different in this cab from the old one. I do, but there are some ground issues I think. It'll crank over but I get no fuel pump, but the relay is clicking. Also I have a whole slew of dash lights on, looks like a Christmas tree. Being that I don't have the cab bolts in yet and that there's not much grounding anything, I'm pretty sure it'll heal itself as I keep putting it together.

I didn't get a picture of it as it sits until I was about to walk out of the shop, I can see it looking like a truck again!
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Old 02-17-2020, 11:36 AM   #33
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Re: 1986 S10 Daily Driver Rollover Rebuild

Sucks how it 'started' but it's shaping up to be a nice resurrection of a cool little truck.

Nicely done patch repair for your first attempt. I'd just rock a rattle-can re-spray in a color that matches better. Use some finer grade Scotch-Brite or steel wool to help w/the blend.
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Building a small, high rpm engine
with the perfect bore, stroke and rod ratio is very impressive...
like a highly skilled Morrocan sword fighter with a Damascus Steel Scimitar.

Cubic inches is like Indiana Jones with a cheap pistol....
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Old 02-18-2020, 07:12 AM   #34
Bigdually
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Re: 1986 S10 Daily Driver Rollover Rebuild

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Sucks how it 'started' but it's shaping up to be a nice resurrection of a cool little truck.

Nicely done patch repair for your first attempt. I'd just rock a rattle-can re-spray in a color that matches better. Use some finer grade Scotch-Brite or steel wool to help w/the blend.
Thanks! Appreciate the comments, I didn't think it was horrible for a first try, I can definitely see getting better at it if it was something I did more often.

I've been considering either a spray bomb or buying a cheap Harbor Freight gun and spraying it myself. Either way I'm definitely going to drive it first and work the kinks out, getting it back to daily driver status is a priority




As far as progress goes, I worked on it this weekend some and got the clutch and brakes bled, plus fixed several electrical issues that were mainly due to grounding. It starts and runs now! Won't stay running very long and I have no rear lights whatsoever, but I'm closing the gap on the electrical gremlins.
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Old 02-18-2020, 11:53 AM   #35
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Re: 1986 S10 Daily Driver Rollover Rebuild

Good progress. I think the repair looks fine. An autobody supply house can mix up your exact paint code in a spraycan for you. Runs about $15.
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Old 02-21-2020, 06:11 PM   #36
Bigdually
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Re: 1986 S10 Daily Driver Rollover Rebuild

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Good progress. I think the repair looks fine. An autobody supply house can mix up your exact paint code in a spraycan for you. Runs about $15.
Thanks! I might get serious with the paint sometime after I get it roadworthy again, if I go the spraybomb route I'll have to remember that.



Haven't made any progress this week due to work, but this evening I came home and kinda just sat and looked at it. I had my battery sitting in the passenger floorboard and jumper cables run up front to hook things up. My issue had been everything out the back wasn't working and my fuel pump sounded funny. It hit me that all that stuff grounds to the frame, and I hadn't hooked up the wire that usually runs from B- down to the frame. A simple quick connection and now everything works!

Of course, this was the time the battery decided to give up and fill the floor with acid from a mystery leak on the case. Thank God I had a box of baking soda in the shop fridge, it came in handy

I think tomorrow I'll work on the front clip and maybe the interior. This evening I'll pick up a battery that actually fits the tray, my old one was too big and had a bungee for a hold down that was rollover tested and held up like a champ
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Old 02-21-2020, 07:17 PM   #37
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Re: 1986 S10 Daily Driver Rollover Rebuild

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Originally Posted by Bigdually View Post
Thanks! I might get serious with the paint sometime after I get it roadworthy again, if I go the spraybomb route I'll have to remember that.



Haven't made any progress this week due to work, but this evening I came home and kinda just sat and looked at it. I had my battery sitting in the passenger floorboard and jumper cables run up front to hook things up. My issue had been everything out the back wasn't working and my fuel pump sounded funny. It hit me that all that stuff grounds to the frame, and I hadn't hooked up the wire that usually runs from B- down to the frame. A simple quick connection and now everything works!

Of course, this was the time the battery decided to give up and fill the floor with acid from a mystery leak on the case. Thank God I had a box of baking soda in the shop fridge, it came in handy

I think tomorrow I'll work on the front clip and maybe the interior. This evening I'll pick up a battery that actually fits the tray, my old one was too big and had a bungee for a hold down that was rollover tested and held up like a champ
"Mystery leak" would suggest otherwise

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Building a small, high rpm engine
with the perfect bore, stroke and rod ratio is very impressive...
like a highly skilled Morrocan sword fighter with a Damascus Steel Scimitar.

Cubic inches is like Indiana Jones with a cheap pistol....
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Old Today, 01:29 AM   #38
Bigdually
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Re: 1986 S10 Daily Driver Rollover Rebuild

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"Mystery leak" would suggest otherwise



Odd thing was the leak is from the bottom of the case, I think where the battery was too wide and vibrated for a long time over the edge of the battery tray. Have a proper group 78 unit in there now with 800 CCA.




Worked on it for several hours today (Saturday) and got lots done. Reverse lights work now, had to wire my transmission reverse switch to the wiring that was inside the cab that used to go to the auto column. Switched over the brake light switch from the old auto pedal assembly to the manual one to make the brake lights work. Rewired all my aftermarket guages and my electric fan setup too. Hooked up and adjusted the parking brakes, and set on the front clip.

The new front clip was in really good shape, except the passenger inner fender and the battery tray were rotted. My old front end had a good inner and tray, so I did the old swaperoo and now the whole front clip on the truck is solid. Fenders need a shim on the top bolts, but I didn't have any so I'll have to adjust that later.

There were lots of wires and plumbing and cables to route, and they're all tucked away nicely now, I just have to bolt on the hood and stick in my LED headlights from before, then the bezels. Inside I need to pick the best floor mat and put that in and then bolt in my red seat because it's far more comfortable. Then it's door and window seals. As it sits now it moves on its own power. I need to bleed the brakes again, they're a tad soft, but otherwise everything works!
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Old Today, 05:13 PM   #39
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Re: 1986 S10 Daily Driver Rollover Rebuild

Lots of work on display!
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All Fleetsides

Building a small, high rpm engine
with the perfect bore, stroke and rod ratio is very impressive...
like a highly skilled Morrocan sword fighter with a Damascus Steel Scimitar.

Cubic inches is like Indiana Jones with a cheap pistol....
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Old Today, 05:25 PM   #40
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Re: 1986 S10 Daily Driver Rollover Rebuild

Wow! It almost looks like a truck again!
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