Author Topic: SquareD Part 3: Body work, paint, roof rack, and farther off course ... (Read 166609 times)

Flyin6 · « **Reply #400 on:** October 10, 2014, 02:02:30 PM »

Next the master cylinder and brake booster were removed. They will not be reused as the truck will be converted to a full hydraulic brake system powered by a larger power steering pump

Flyin6 · « **Reply #401 on:** October 10, 2014, 02:03:18 PM »

With that gone, the firewall got pretty vacant and sanded up nicely

Flyin6 · « **Reply #402 on:** October 10, 2014, 02:04:07 PM »

Then everything was taped up and wiped down with solvent after the sanding

Flyin6 · « **Reply #403 on:** October 10, 2014, 02:05:10 PM »

Then it got two heavy coats of quality lacquer primer

Flyin6 · « **Reply #404 on:** October 10, 2014, 02:06:01 PM »

Just the doors remain to be primed and checked for straightness before the color coat

Flyin6 · « **Reply #405 on:** October 10, 2014, 02:06:41 PM »

Off subject, I seem to have a leak I can't find in this tire. It goes flat in 3-4 days

Flyin6 · « **Reply #406 on:** October 10, 2014, 02:08:36 PM »

this is where it sits at the end of build day 105

Flyin6 · « **Reply #407 on:** October 10, 2014, 02:09:30 PM »

Quote:
Originally Posted by kaslduramax View Post
This is exciting, you're getting closer and closer to the engine build! The part I am most anxious to see!

Also, wondering why you're doing all the paintwork first? I've always seen people attack the engine bay and other mechanical issues first before starting on paintwork.

I'm betting it was to give yourself time to think about how to change the oil?

You eat an elephant one bite at a time...Right?

Same-Same

When I pulled the bed and this thing got serious, I entered a new game (Frame off full restoration/oil change), but I entered it at the wrong point in a normal build schedule. So the cab is happening now because I want to put the bed back on. I could have just painted the back of the cab, slid the painted bed on and called it done, then painted the cab later.
But I thought I might as well, just bag the cab painting all at once and be done with it.
So it all ends up getting done in this convoluted fashion. Linear??Hardly! But Done correctly? I think so...So I get to the same place but I started climbing Mt. Everest by helicopter on the third day ascent. Then I had to trek back down to base camp to get supplies to set up the second base camp so that I could make a descent run at where I am right now. But at some point all that will be laid out and I'll be making for the summit...

Motor? After the cab/bed I will pull the head and ship it off for mods. While that is gone you will see the front suspension going in, and near cylinder head return day, I will be pulling down the motor further to detail and rebuild each part except for the long block which is easily good for another quarter million miles or more. Then the head will go back on and then the twin setup

Flyin6 · « **Reply #408 on:** October 10, 2014, 02:10:36 PM »

OK, done with that
We did good and not so good today.
THe ball did get pushed downfield more so that was good

I started with pulling the old rubber trim off the door glass...I really should have done that earlier, but in the backwards sometimes sideways methods I am employing it all makes sense

Flyin6 · « **Reply #409 on:** October 10, 2014, 02:11:42 PM »

I wasn't sure if I had new rubber seals. Turned out I do, so I'll just repaint this area with the color coat

Flyin6 · « **Reply #410 on:** October 10, 2014, 02:12:30 PM »

Then I went taping everything and a few things nearby (Red Dog!)

Flyin6 · « **Reply #411 on:** October 10, 2014, 02:13:21 PM »

And I remembered to pull off the last pieces of trim and sand behind them

Flyin6 · « **Reply #412 on:** October 10, 2014, 02:13:58 PM »

OOps forgot the sanded pic...

Flyin6 · « **Reply #413 on:** October 10, 2014, 02:14:57 PM »

That's it for the silver except for the hood and the fenders and a few small parts. It all turns black in the next few frames.
I finished the taping inside and out

Flyin6 · « **Reply #414 on:** October 10, 2014, 02:15:54 PM »

Yes, I'm painting the door handles on the truck. I sanded the snot and chrome out of them so they are needing something to coat them.
So I mixed up more of that cool black primer

Flyin6 · « **Reply #415 on:** October 10, 2014, 02:17:44 PM »

Then commenced spraying after wiping down everything with solvent

Flyin6 · « **Reply #416 on:** October 10, 2014, 02:18:26 PM »

better

Flyin6 · « **Reply #417 on:** October 10, 2014, 02:19:07 PM »

Next up: Windows, front and rear.
Here I am about to pull the rear glass.
I decided to do it this way to minimize the dust that would get into the interior, and because I did not suspect I had any major issue at all

Flyin6 · « **Reply #418 on:** October 10, 2014, 02:20:19 PM »

To pull the glass, find the rubber insert, pry it out, then pull it out completely

Flyin6 · « **Reply #419 on:** October 10, 2014, 02:21:26 PM »

Then starting at a corner, Slowly work the rubber gasket to the outside of the lip that retains it

Flyin6 · « **Reply #420 on:** October 10, 2014, 02:22:32 PM »

Then even pressure will pop it right out

Flyin6 · « **Reply #421 on:** October 10, 2014, 02:23:53 PM »

I soaked that old awful window tint with liqueur thinner for about an hour before going after it with a razor blade

Flyin6 · « **Reply #422 on:** October 10, 2014, 02:24:31 PM »

The rubber gasket was perfect so I'll reuse it.

While that was drying I wire-brushed the window flange, scuffed it down and painted it

Flyin6 · « **Reply #423 on:** October 10, 2014, 02:25:33 PM »

Next up: The windshield

It comes out the same way, well, almost...

Flyin6 · « **Reply #424 on:** October 10, 2014, 02:26:17 PM »

I was only worried about this one spot:

Flyin6 · « **Reply #425 on:** October 10, 2014, 02:27:04 PM »

Then as I was GENTLY prying this happened

Flyin6 · « **Reply #426 on:** October 10, 2014, 02:27:40 PM »

Yep, that is a crack, actually a few of them.

So I made some more to match:

Flyin6 · « **Reply #427 on:** October 10, 2014, 02:28:26 PM »

I started having a good time...I was thinking about the red dog and that d!MM#$! bird the whole time...

Well, to hell with prying, I beat the thing until it yielded in ten trillion little pieces

Flyin6 · « **Reply #428 on:** October 10, 2014, 02:29:05 PM »

Good news is no rust to speak of, bad news should be obvious!

So with the rear painted and after an hour of vacuuming all the glass shards up, I ran out of time!

Flyin6 · « **Reply #429 on:** October 10, 2014, 02:31:00 PM »

Today after knocking it out at the gym it was like 1230 by the time I left there.

I had to buy some sanding discs in various grits and had to run to a number of stores before scoring what I needed (and cheap too) at HF.

Then I went gold shopping...I am, and you should be too...buying some bullion for the upcoming crash. it comes in ounces and tenth ounces, and for Nate, millionths of an ounce, and for Bobby, they will give you a picture of what it looks like! (Sorry Menses)

Then off on my quest for todays parts.

Made some great purchases. I decided to keep the brake system Dodge for the most part, so I purchased a brand new 1999 Dodge 2500/3500 hydro-brake booster. This gem runs off the power steering pump and provides nearly 300% more braking than the terrible stock vacuum setup.

After reading various swaps, I figured I can modify this one and make it fit in tight by fabbing up a mounting plate and adapting the too long push rod to the factory brake pedal. I also purchased a brand new 1999 master cylinder.

Next up was the quest for hydraulic hard line, 1/2" thank you very much. I ended up in a hydraulic shop with all sorts of stuff and purchased a 20' stick of hard line for $20!!!!!!!!!!

I will install compression fittings on either end and a hose fitting that will attach on one end to the factory cooler lines under the truck, and on the other end to a new roof mounted transmission cooler, uber-big in size. These hard lines will be mounted on the back of the cab on the right side in pillow blocks and give the truck a more pronounced "Back to the Future" look.

All that business had me arriving back at casa Don at 1712, far too late for any building shenanigans, so the real work will have to wait until tomorrow...

Flyin6 · « **Reply #430 on:** October 10, 2014, 02:32:22 PM »

Sitting here chewing on some cashews and figuring out how to get the various paints, plastics, body sealer and dust out of my hair and off my skin...Gas?

Well this happened again

Flyin6 · « **Reply #431 on:** October 10, 2014, 02:32:59 PM »

So I bought these:

Flyin6 · « **Reply #432 on:** October 10, 2014, 02:33:53 PM »

Lost the small one already...Threw it at the red dog and missed. She swooped in, snatched it up and carried it off...
How do you spell dead dog???

Anyway, with the heater blowing hot air on my leg I wrestled with the last tire/wheel...sort of a chores thing. But with this one I used different and better grade 8 hardware.

Flyin6 · « **Reply #433 on:** October 10, 2014, 02:34:30 PM »

It came out just fine!

Flyin6 · « **Reply #434 on:** October 10, 2014, 02:35:27 PM »

Someone asked me earlier just how much all that weighed,

Well, here's your answer:

Flyin6 · « **Reply #435 on:** October 10, 2014, 02:36:09 PM »

That explains why I am having to work so hard moving these things around...so it's actually good news!

While rolling it back to the pile I noticed this!

When I pried it out, the whole screw was maybe 1/2" long, so no patchin' required...Yippee

Flyin6 · « **Reply #436 on:** October 10, 2014, 02:37:22 PM »

The planned major task for the day was the prep and primer of the windshield area.
Using the handy cup grinder I definitely got rid of all the old gooey sealer stuff. I also buffed the plastic trim on the inside of the cab into a billion pieces and sent part of my new headliner to an early grave.

I spent some time doing a litany of sailor blessings, then continued the mission

Flyin6 · « **Reply #437 on:** October 10, 2014, 02:38:21 PM »

The primer found it's new permanent residence and I put that one in the bag!

Flyin6 · « **Reply #438 on:** October 10, 2014, 02:39:18 PM »

Next up is the final body work. There are a few small dents I will be repairing starting today, then after that the bed and the cab will be showin' some purdy OD Green color

TO help me along, I added this fine piece to the tool chest. Cost me all of $19 today at HF!

Flyin6 · « **Reply #439 on:** October 10, 2014, 02:40:32 PM »

And it works:

Flyin6 · « **Reply #440 on:** October 10, 2014, 02:42:04 PM »

Then Dr. Bondo paid a much anticipated visit

Flyin6 · « **Reply #441 on:** October 10, 2014, 02:43:00 PM »

After some coarse leveling with the file, it is about ready to sand

Flyin6 · « **Reply #442 on:** October 10, 2014, 02:44:32 PM »

The brake parts came in today:

Flyin6 · « **Reply #443 on:** October 10, 2014, 02:45:18 PM »

The old vacuum booster dwarfs the new hydro-boost brake maker betterer thing

Flyin6 · « **Reply #444 on:** October 10, 2014, 02:48:37 PM »

Spent today ordering pieces parts including a Canik 9mm pistol. Got carried away on the fittings and hoses I guess...
Anyway $319 for a new 0mm plastic pistol with a couple 18 round mags, two holsters, a cleaning kit, storage case and something else...You kiddin'!!

OK anyway, after that I guess I continued to be carried away ordering some fresh Danish 5.56 ammo and another super cool Surefire 60 round magazine

Sorry...drifting

So finally I got out into casa garage and did mostly body work.

Even though 1. the roof can't be seen by most non mutant people, and 2. It is going to receive a thick coat of bed liner, I decided to smooth out those roof plates and hard points I welded in earlier

Flyin6 · « **Reply #445 on:** October 10, 2014, 02:56:23 PM »

After more sanding and more primer

Flyin6 · « **Reply #446 on:** October 10, 2014, 02:57:19 PM »

I got the fuel door openings done

Flyin6 · « **Reply #447 on:** October 10, 2014, 02:58:12 PM »

The other side of the bed required another skim coat of filler, so that got slapped on and left to dry

I am working the area with a long board and 80 grit so it is very laborious and time consuming

Flyin6 · « **Reply #448 on:** October 10, 2014, 02:59:10 PM »

Some of the smaller dents were completed all the way to 120 grit sanding and a coat of primer

Flyin6 · « **Reply #449 on:** October 10, 2014, 03:00:13 PM »

After the dents are finished, I'll scuff everything with 400 grit, then prep and paint with the epoxy sealer, and follow that in an hour with the color coat

The cab is coming around, nearing completion