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Author Topic: SquareD Build Thread, Part 1: The beginning  (Read 140745 times)

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Offline Flyin6

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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #150 on: September 21, 2014, 07:33:52 AM »
OK, let's get some more stuff fixed here

Keeping in mind a couple facts and my premises for this build, I know Diesels like air and a lot of it, and I am doing a thrifty build at this point. More of a restorative effort than expanding the envelope, again at this point in time.

So I was looking at the air box and I had an idea...
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Offline Flyin6

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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #151 on: September 21, 2014, 07:35:26 AM »
 like how and where the factory air box mounts. It's out of the way and cavernous. But it has only one duct to draw from leading from the front grill. The area there is not totally unobstructed so I decided to alleviate that restriction some while keeping the stock parts.
I will add a K&N or similar filter in a couple days, but it how can choose from which hole to breath through
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #152 on: September 21, 2014, 07:36:30 AM »
 think that more than doubled the air flow possibility from that nicely designed factory setup.

While that was out I scrubbed and cleaned yet again to get it looking all brandly newish like (BNL)
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #153 on: September 21, 2014, 07:38:04 AM »
Next I rebuilt the heater control valve assembly
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #154 on: September 21, 2014, 07:39:00 AM »
Then reinstalled that pretty coolant hard line assembly
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #155 on: September 21, 2014, 07:40:14 AM »
Next I pulled off the old oil filter and installed a quality WIX unit and 13 quarts of Rotella-T 15W-40

I went cost effective this time, but next time I will be using Willie's Amsoil products, most likely with a remote dual bypass filter setup
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #156 on: September 21, 2014, 07:41:45 AM »
Finally, I pulled and cleaned the radiator overflow tank and added a quart of properly mixed fluid, then topped up the radiator
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #157 on: September 21, 2014, 07:42:32 AM »
The engine compartment is starting to look descent for such an old, err, vintage ride!
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #158 on: September 21, 2014, 07:43:23 AM »
Here's the infamous "Lizard Skin" which is soon to skin various body parts of this truck.
This gets us current through today...hopefully more tomorrow!
Site owner    Isaiah 6:8, Psalm 91 
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #159 on: September 21, 2014, 07:43:47 AM »
BTW, so far the total cost of the project is $6,906
That includes the truck, the tires and wheels, and all the parts sitting on the shelf awaiting installation...
I won't consider it safe to operate until the brakes are totally overhauled and all the steering components are replaced or upgraded, and the shocks are replaced.
I think I'll keep the 6" lift for now and sort that out later.
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #160 on: September 21, 2014, 07:44:34 AM »
Quote:
Originally Posted by nmeyer414 View Post
Just imagine, if the orignal owner had actually maintained it like you are doing now how much he would have actually asked fforit or possibly kept it.

Indeed!
But I look at this as my gain
I would have purchased one of these a long time ago if I had realized what it was. One of these in a crew-cab version is actually a better survival vehicle than the Duramax for a number of reasons.
Straight front axle
No electronics
Same horsepower capability
Less expensive
Will run on B100, WVO, Vegetable oil, homemade fuel, anything really
Everything is extremely simple and easy to fix
Fewer gadgets to break
Real shift lever transfer case
Parts are cheaper and on and on...
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #161 on: September 21, 2014, 07:45:36 AM »
Quote:
Originally Posted by Armalite View Post
Looking newer each day Don. I like it...

Ash, it sounds good as well...Even with a rotted out muffler!
Just wait till I show everyone the so called exhaust, all six feet of it.
I just haven't cut all that off yet, but maybe this week, I'll get to it.
Even with the crappy exhaust, it sounds good, tight, well tuned.
And it always fires up with the slightest bump of the starter.

I was talking to a guy who owns a couple of these last night. He said he is finding all of them with retarded timing. He said to advance it a couple degrees and turn up the fuel screw and it makes at least another 100 horsepower!
Just hearsay, I can't verify any of that, but you do hear it a bunch
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #162 on: September 21, 2014, 07:46:59 AM »
Quote:
Originally Posted by je942010 View Post
What is the plan on this one for storage and sleeping quarters?


None at the moment
Keep in mind we are very early into this project.
The short term goal is simply to provide transportation while the LML gets a Dana 60.
Subsequent to that, this truck will continue to see daily service, and become more and more of a real back up to the D-Max truck.

I see this truck with some aggressive bumpers, pioneer equipment, perhaps and exo-skeleton, some roof storage, and maybe a cap. It will be able to pull any of the trailers I choose to use. the 35 foot camper, the 18 foot utility, or the yet to be built emergency off road shelter unit.
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #163 on: September 21, 2014, 07:47:33 AM »
It's sunday, and a day of rest, but I have been very busy ordering parts for the coming week
So far today I have ordered
front Skyjacker shocks
Rear Skyjacker shocks
New shock bolts
Steering gear box
Power steering lines
K&N air filter
Left/right motor mounts
Transmission rubber mounts
Tail light lenses
Parking light lenses
Door hinge and bushing kit to repair sloppy door hinge
Air conditioner master control module
Air conditioner clutch solenoid
Air Conditioner dryer and accumulator
Steering damper
Sway bar bushings
Voltage regulator
and a scad of other pieces parts

The concept here is to baseline the vehicle to a like new mechanical condition, replacing all wear items with good quality reman stuff.

What that gets me is probable reliability and the opportunity to drive it to see what I have and what it needs. I suspect everything will take a couple more weeks, then I'll have a reliable and serviceable ugly truck...perfect really!
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #164 on: September 21, 2014, 07:50:07 AM »
lets get some interior completed on Square D.

First up was to remove enough trim to get the headliner out. That was fairly easy and happened PDQ
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #165 on: September 21, 2014, 07:51:28 AM »
You can see that wrinkled mess was failing all over the place!

After the trim was out, I pulled the remaining seat belts
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #166 on: September 21, 2014, 07:52:11 AM »
Again, I was finding everything in pretty good condition.

With that out, the headliner pulled right down
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #167 on: September 21, 2014, 07:53:15 AM »
With some light tugging, the old material came right off exposing the foam shell
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #168 on: September 21, 2014, 07:54:11 AM »
The underside of the factory top looked as good as it did the day it was built!
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #169 on: September 21, 2014, 07:55:29 AM »
I pulled a few pieces parts from the interior while I was up in there, but not for long as I wanted to see how that new headliner would turn out
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #170 on: September 21, 2014, 07:56:37 AM »
The old glue (darker brown areas) came off easily by using a brush on a vacuum and a sawing motion
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #171 on: September 21, 2014, 07:57:36 AM »
The new headliner is a lightweight charcoal colored felt like fabric with some thin foam rubber open cell material attached to it's backside.

Attaching the new material is with some super-duper spray wasp encapsulater! Really, anyone ever shot a wasp out of the air with this stuff? It's cool and instant. Man if the Taliban shot that stuff at me, someone else would be writing about this truck, showing off it's new single 12" stack and star mags!
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #172 on: September 21, 2014, 07:58:44 AM »
First roll out the new material and square it up to where it's about right, of if you follow Duane, then 1.354" off center on a corrected 54.2 degrees (Measured at a standard day and calibrated for recent solar activity!)
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #173 on: September 21, 2014, 08:00:14 AM »
Start in the middle somewhere (or id you're like Duane exactly 26.886" from the left side and up 14.646" from the bottom edge) and spray some of the wasp and mud dauber anti aircraft spray in a small area (or if Duane, from a dead flat, certified surface of hard granite up 12" exactly plus or minus .002" spraying at an angle of 23.6 degrees for 1.34 seconds while applying 4.5 inch pounds of pressure to the spray cap to produce approximately 39 joules of energy which minimizes overspray to within the 2.34" cone of active spraying you have surveyed and done an exhaustive study on)
Of if me just spray it a bit and check left and right for a possible target and press the material down
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #174 on: September 21, 2014, 08:01:54 AM »
Keep working away from the center for the next few minutes until it's all glued down if using my technique or slowly over the next thirteen weeks if using Duane's method.

Either way, it ends up looking like this:
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #175 on: September 21, 2014, 08:03:16 AM »
At this point you can trim it up close and personal to the edge or glue a short strip up the backside to hold it better. I also cover the edge with masking tape to prevent from critter infiltration.
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #176 on: September 21, 2014, 08:04:19 AM »
And here it is completed and ready to reinstall:
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #178 on: September 21, 2014, 08:07:15 AM »
I was going to pull the actual dash out, but the farther I dug, the more I discovered I was going to have to disconnect to actually get it out!
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #179 on: September 21, 2014, 08:08:55 AM »
So I sez to myself, "Self, what the hay are we doin' here? Note: You can talk to yourself, that's OK! You can even answer yourself, still OK, But if you say "Hugh?" you have a problem.
So anyways I am having this one person conversation and it occurs to part of me that the other part doesn't really want to fuss with pulling every screw, including the rear bumper license plate lamp mount just to get that sucker out.
So the other part of me decides that both of us can paint that quill right where it lives! Problem solved and we are now getting along once again!

Anyway, the both of me pulled both door panels and interior removal was officially concluded
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #180 on: September 21, 2014, 08:45:15 AM »
Now I remember...I masked off the stuff I only wanted some overspray on! I used pretty blue tape because Kentucky is busy getting beat up on the SEC gridiron, and I wanted to honor them!
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #181 on: September 21, 2014, 08:45:56 AM »
SEM makes some great paint products. Their interior paint for plastic and vinyl comes in a perfect color which is called landau black. Not glossy, but with a touch of flattening, but not dull either
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #182 on: September 21, 2014, 08:46:59 AM »
The first, then the second coats produced a great finish, don't you agree?
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #183 on: September 21, 2014, 08:47:56 AM »
Then I started on each piece, one at a time. First scrubbing with detergent, then wiping with prep sol, then rubbing with this adhesion promoter, washing again, another wipe down, then spraying the color
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #184 on: September 21, 2014, 08:49:23 AM »
From the previous pic, you can see the instrument cluster bezel and trim going through the process...
It continues here"
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #185 on: September 21, 2014, 08:50:12 AM »
Some trim pieces had cracked and were in need of repair. I scratched up the back side and applied some layers of fiberglass cloth and resin
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #186 on: September 21, 2014, 08:50:51 AM »
But they patched up just fine!
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #187 on: September 21, 2014, 08:52:27 AM »
The door panels took some time and finished the clock out for the day.
Tomorrow I am in good shape to reassemble some of the interior, and maybe get el lizard skinimus sprayed all over creation!
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #188 on: September 21, 2014, 08:53:40 AM »
From Cudakidd53:

Had my doubts about the spray dye, but WOW really nice results. You could put it on the concourse at one of Duane's car shows -

Don at SEMA with both trucks, parlaying that into a Build Thread TV show, kind of "OverHaulin'" meets Duck Dynasty......you all may laugh, but who'd have thought a show about a Duck Call manufacturing family would catch on AND a network shows a family eating together each night and saying a blessing mentioning "Jesus" at the close of each episode?!
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #189 on: September 21, 2014, 08:54:02 AM »
I think it's turning out quite nicely!

I need to find a drivers armrest...Parts geek was a strike out. then I wanted to order new weather-strip, but again parts geek struck out, because they can only ship it truck freight!
Truck freight for a coil of rubber? Seriously, they wanted $135 truck freight for a $28 part that weighed 3 pounds!
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #190 on: September 21, 2014, 08:56:05 AM »
Didn't get a chance to post up last night

I started in the lizard skin process, but it was getting dark and I only got one thin coat on.

The reason I got started late was that I thought this stuff sprayed. I mean it says a spray gun, and references of up to 80 psi. So I put some in one of my cheapo spray guns and immediately clogged that thing up...

You see Lizard skin has the consistency of paste, not really liquid, unless you consider lard liquid...

So I quickly clogged up my good gun, then in a panic had to clean those guns out while the stuff was thickening (Read: Ruining my guns!)

About this time I also discovered those nitrile rubber gloves are useless. Yep, they were sitting about 15 feet away in their box and provided absolutely no protection for my hands.

I can report that there is a reason they call this stuff "Skin"
It has to do with the fact that is sticks to skin, it acts like skin, is about as easy to pull off as your real skin, and when you do pull it off, you pull the real stuff off as well. Apparently wearing shorts is not recommended when working with this stuff as well...

About this time, while I was piling on my winter and spring layers of new synthetic skin to my hands, forearms and legs, something the Marines always say came to mind, "Improvise, Adapt, and Overcome."

Well that universal statement works on just about any instance including failed lizard skin first attempts. Is I decided to grab up a cheapo paint roller. First thing I noticed was that when I placed the roller on and yes, I mean to say, on the lizard skin, it just sits there. It does not sink and the stuff does not slowly ooze around the roller, nope, it just sits there.

So it's thick...

That means no splatter when you're rolling overhead. But that means it falls off in stick muddy blobs which if not attended to quickly will dry on one's face and hair. What the heck, time for a hair cut anyway...

After wrestling with this paste for awhile I had rolled out a first coat mostly in the dark which accounted for my rolling it over my opposing hand, consolidating the previously unattached blobs into another non removable layer of epidermis.

Actually I exaggerate the stuff readily comes off as long as you hold your hand under live steam and scrub with tooth brushes and wire brushes... for awhile. No worries.
But if you also discover the nitrile gloves don't work sitting in the box, be sure to schedule two hours in the emergency room before supper
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #191 on: September 21, 2014, 08:58:05 AM »
Notice in the first set of pics it is daylight

Notice here it is night

If you do the math you will find many degrees of sun movement missing. That would account for trying to salvage the spray guns, both of them...

So now, before I applied another layer or three of skin to me, here is the frantic work to roll out what one cannot see!
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #192 on: September 21, 2014, 08:59:27 AM »
Not too pretty but

1. Not the final coat
2. Everything here is covered up and (gladly) never to be seen
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #193 on: September 21, 2014, 09:01:17 AM »
Oddly enough that stuff is a fairly close match to the color of the truck!

Well, all the stuff I ordered on Monday is starting to filter in

Here's the front shocks

Talk about nostalgic! But those old gas shocks did an OK job in their day, and that's what I'm looking for, OK!

And cost effective

These shocks were $45 each, $180 for the set

Bu comparison, the set of shocks I just ordered for the Duramax build totaled $3,300!!!!
Site owner    Isaiah 6:8, Psalm 91 
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Offline Dustoff35

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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #194 on: September 21, 2014, 11:21:03 AM »
The radiator repair took all of 5 minutes. I cleaned up he area with a brass brush, then cleaned the penny, then just soldered it into place...Simple

All Fixed:


So that penny that was soldered to the radiator, What vintage was it?  The reason I ask is that the newer pennies are actually copper-plated zinc, not copper through and through.  I know that it won't give you any problems in the future, but it might give me some...

Offline Flyin6

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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #195 on: September 21, 2014, 01:21:39 PM »
I actually discovered that it takes pre 1982 pennies (Pure copper, so I chose one that was like 1950 something
You're good to go!
Site owner    Isaiah 6:8, Psalm 91 
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Offline Flyin6

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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #196 on: September 21, 2014, 01:22:28 PM »
That baked on white shoe polish was known to crack, flake, and rust. I plan to scratch these down, then recoat with a layer of zinc followed by a clear coat. All so I can get one week of rust proofing this winter.
Kentucky uses the 2:1 rule

Meaning dump twice the thickness in salt as snow.

We seldom have more than 1/4" of snow which the highway department immediately responds to with 1/2" of salt. The fact that the salt is dirty, also containing some grit is what really gives us the traction we need to drive off to the nearest thirty car pileup!
Site owner    Isaiah 6:8, Psalm 91 
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #197 on: September 21, 2014, 01:23:18 PM »
Those suckers are thick, measuring some 2.4" O.D.
Site owner    Isaiah 6:8, Psalm 91 
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #198 on: September 21, 2014, 01:24:06 PM »
I even purchased some pretty new hardware which cannot be seen!
Site owner    Isaiah 6:8, Psalm 91 
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Re: SquareD Build Thread, Part 2: The build Continues...
« Reply #199 on: September 21, 2014, 01:25:50 PM »
Finished most of the interior reconditioning.

Should be reassembling tomorrow...finally!

It takes a lot of time to repair every piece which had multiple cracks in it from age and a million hot/cold cycles.

But they are all repaired and painted at this moment.

First a look at some of the parts which are now trickling in.

First is the Rancho steering stabilizer.
Site owner    Isaiah 6:8, Psalm 91 
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