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SquareD Part 4: Paint, topper, Roof rack, and continued change!
« on: October 11, 2014, 10:46:23 AM »
During this part, we will pick up as the truck closes in on its OD Green paint job. It will start to take on uniquely military attributes.

At this point I am no longer thinking this truck is any back up sort of vehicle, but a primary go to truck should things turn horribly bad quickly. Knowing the vulnerability to the electronic Duramax truck, I could not really rely on it in all situations. A major EMP event would render it and all my efforts there useless, so this simple and old, yet modernized survival truck is now being given full attention.

Further as I am asked to demonstrate and teach on survival subjects, I have need of a "Technology Demonstrator," And SquareD will fill that role.

Not a high technology demonstrator, mind you, but rather a "Smart and Practical" technology demonstrator

Watch and enjoy in the pages to follow the coming departure from everything stock and a major transformation which will actually have the truck shedding many of it's former "repairs and fixes" in lieu of rock solid utterly reliability infused with some of the things I learned over 5+ years serving in combat theaters around the world.

Enjoy!
« Last Edit: November 22, 2014, 06:39:16 PM by Flyin6 »
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #1 on: October 11, 2014, 11:08:34 AM »
Some more areas needing attention:
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #3 on: October 11, 2014, 11:10:25 AM »
And even more!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #4 on: October 11, 2014, 11:11:25 AM »
But then finally it was all done, and recoated in areas with the lacquer primer, then resanded yet again
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #5 on: October 11, 2014, 11:12:50 AM »
And F I N A L L Y after another sanding it is all done and ready for cleaning and paint!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #6 on: October 11, 2014, 11:13:44 AM »
The Tailgate finally got some attention, getting sanded and primed. I'll sand it in the morning
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #7 on: October 11, 2014, 11:14:25 AM »
And here it is at the end of build day 118, probably the last day before it gets the OD Green color top coat
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #8 on: October 11, 2014, 11:17:28 AM »
Gents, this was paint day. It is 2200 and I can say, it's still paint day!

The whole truck is now wearing a single coat of OD Green!!!!!!!!!!

Thing is, I have at least 2 more coats to shoot. Say 40 min between coats and 30 min to shoot, and I'll be into the wee hours of the morn before I see any shut eye.
I did a full court press today. 8-9 hours straight so far without a break. I just want to get this thing painted and give me that all important psychological boost as the truck takes the turn from coming apart toward starting to look like something!

Welp, time to get out there and get that second coat on...

My head is buzzing and I'm using a good respirator!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #9 on: October 11, 2014, 11:17:57 AM »
Quote:
Originally Posted by lutzjk913 View Post
Push forward man!

OK time now is 2243...
The second coat is on and only one small run on the back corner of the cab.

This whole coat really evened out the color...It looks pretty good

And I think I caught the first flying bug of the season in the bed right side. Something with wings is embedded in the paint...

Screw it, it will help break up the pattern some

one more coat...one more coat...one more coat....gotta maintain...one mo...
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #10 on: October 11, 2014, 11:18:39 AM »
OK, 2329 and I'm going out to lay down the last coat...

Here goes nothing!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #11 on: October 11, 2014, 11:19:01 AM »
OK, 0009 and it's done

It was all shiny when I left it, but by tomorrow it should get all satin lookin'

I'm wasted...too tired to post up pics today, I'll get them up tomorrow morning, then get some pics of it during the daylight to show how it dried
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #12 on: October 11, 2014, 11:20:33 AM »
OK its 0910 (which is 9:10 AM for all you mustard seed, Kool-Aid pumping heart, jelly filled civies out there)

OK had a night to sleep off the thinner headache. Honestly, people actually inhale paint fumes because they want to? Heck, just employ them as laborers at a paint shop connected to a crematorium, so when they get enough, then just take their remains down a hall. Helps with unemployment, keeps them happy and helps two businesses, all the while increasing the national IQ!

Just call me the idea man!

OK, lots of purdy pics so lets get started.

Painting is a process, just like it was getting to this point.

One must clean, clean, and clean some more.

I started by cleaning the shop and blowing off the truck with compressed air
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #13 on: October 11, 2014, 11:21:17 AM »
It may be hard to detect, but with each progressive picture, the project is getting cleaner
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #14 on: October 11, 2014, 11:22:44 AM »
Then as you clean out the cavities of dust, you have to vacuum that up, clean some more, tape up a section, wash the floor and so forth.

You are working toward getting a clean vehicle to paint and in a clean environment.

The masking begins. Remember this was a 10+ effort on paint day to get from body work complete all the way to painted!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #16 on: October 11, 2014, 11:24:23 AM »
Just like the proverbial painter who paints himself into a corner and out of a floor, I am about to lose my work bench!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #17 on: October 11, 2014, 11:25:14 AM »
The masking and covering with drop cloths is endless...If you do this plan for how long you think it will take and double that. Fit that into your day and you'll be closer to realistic with respect to how much time all this takes
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #18 on: October 11, 2014, 11:26:22 AM »
Most of that masking and covering is really not necessary because I will be removing the engine, transmission and transfer case in the near future, but I did it anyway to protect some of the newer parts I put on there.

Even though the entire truck is covered in black primer, it should be sealed before painting to prevent any funny business such as wrinkles or other paint on paint reaction.

OK I did that, using a high quality Omni epoxy two part primer to prime and seal the entire vehicle before any color.

This was the first coat of material being sprayed onto the body today
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #19 on: October 11, 2014, 11:27:38 AM »
This was done with a dedicated primer HVLP gun and a .018 nozzle with the material also thinned a bit with Acrylic enamel reducer
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #20 on: October 11, 2014, 11:28:18 AM »
Coated!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #21 on: October 11, 2014, 11:29:22 AM »
Well, that turned out pretty good

I gave each coat 30-45 minutes to dry a bit before going on to the sugsequent coat

So

Finally

After all this time

It

is

Time

for

this color which is WW2 OD green. Again, I like it, but mostly I am using because it was the color of Dad's B-17G bomber that he flew as a 21 year old on 35 missions over Nazi Germany.

Dad I hope you like it

...He's in heaven...
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #22 on: October 11, 2014, 11:30:18 AM »
And here's the first coat:
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #23 on: October 11, 2014, 11:31:29 AM »
And about an hour later...Here's the second coat just having been sprayed.

The paint is semi gloss so it will not look like this (Shiny) when it's dry
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #24 on: October 11, 2014, 11:32:22 AM »
The body work is mostly invisible. Good enough for my work...I am no professional, just a seasoned amateur really.

There is a lot of detail painting that goes on. For areas on the firewall, you have to adjust the fan pattern to a tighter cone, then open it up on the big flat planes. That all takes time
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #25 on: October 11, 2014, 11:33:26 AM »
And an hour or so later, here is the third and final coat.

Remember, this paint is single stage old school stuff. It sprays on about 1/4" thick with each pass, so three coats is about equivalent of 8 normal modern Dodge truck paint jobs. I think at this point I am bullet resistant to at least .22LR based on paint alone
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #26 on: October 11, 2014, 11:35:10 AM »
And here it is after 8.5 hours of dry time, the following morning.

It is still not dry, so I think I'll keep the garage locked down the whole day, which just happens to be Saturday, the Sabbath, so that worked out nicely
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #27 on: October 11, 2014, 11:36:54 AM »
Some more.

Some sheen actually due to how well the paint flowed out and actually is continuing to flow out. Imagine what it would have looked like if I had added hardener, which glosses up things.
I might have lost the whole effect. I do like the semi gloss vs full on flat OD
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #28 on: October 11, 2014, 11:59:04 AM »
From the outside

I guess it turned out OK
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #29 on: October 11, 2014, 11:59:56 AM »
Quote:
Originally Posted by nmeyer414 View Post
Awesome color, that was a lot of work.


Nate,

You know, most people (Myself included) choose a vehicle color because we like the way it looks, agree?

But this color had depth and meaning to me. It connects me to my dad's plane, to him and in a way of millions of warriors past. That was the color of their uniforms...dirt and blood stained uniforms. And I wore a similar color as well. Yup a young lad I was but I wore an Army green before I wore a BDU, or a Nomex green or desert tan or any of the modern digital camos.

I don't know, hard to explain, but I definitely feel a kinship with that color and all that it means to me and those who have the eyes to see it...
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #30 on: October 11, 2014, 12:05:30 PM »
Quote:
Originally Posted by FBJR View Post
Yep, don't want to totally derail this thing  Don is doing so well


Don Note: JR has a great old burb, 1/2 ton
He wants to convert itto a 3/4 ton diesel with a 6BT
He lives in the communist kalifornia collective...
Nuff said....


Still need a tranny/tcase and possibly another sub. If I can't upgrade mine to 3/4 legally I can't swap this motor in here. I could a 6.2 though as 1500s came with them then when exempt (98 under diesel) drop in the 6bt.

JR

You ought to read this stuff through my eyes sitting in Kentucky

You just said that if some idiot who has no clue, never had a girlfriend or had his first fight, gives you, a proper man, permission to change your suburban to a 3/4 ton

OK, some Don sense here. Screw them. It's not their truck, it's yours. It's no dammed business what so ever. If you want to change into the lunar rover , then by golly do it!

So that geek is with holding that piece of freedom from you! (Here's the part I don't understand...Why isn't the state capitol burning? Why is anything still functioning of that center of supreme stupidity? Well that's your problem, since you real men out there have been pacified to the point of allowing this silliness to exist)

Allow me to continue. So if this geek clerk gives you permission to change the truck into a 3/4 ton then you get his permission to install a motor that makes sense...And if this G-man who holds the power of regulation over a man who could crush his skinny neck with your pinky doesn't give his permission, then your recourse is to bolt in an absolutely awful problematic motor that makes no power just so you can start to get better mileage.

Does this sound crazy folks or what? People who are living in communist states left and right please do not comment, you have allowed this to happen.
This is absurd, the total stupidity of it is beyond comprehension. Now all the while a good man is asking geek boy for permission to live his life, Mexicans and gangs and drugs are flooding the streets. While we control water levels to save the life of some salamander tens of thousands, well, hundreds of thousands of acres of farmland lay fallow because farmers can't use the water since it will mess with the sexual mis-adventures of those fish/bug things.

Suggestion, flood all the streams with DDT, kill all life down to the viral level, flush them out to sea or pump the waste into mexico and since no life exists in the streams, maybe the farmers can use the water to grow, cabbage, corn, wheat, rice and the rest...crazy, but just an idea.

Man, I'm goin' off here, but reading of how S T U P I D California has become just gets me angry! I don't want people in charge out there to have any influence what so ever over what is left of free America. If I could I would, in the words of one of my earlier commanding generals, build a 15 foot tall fence around the whole place and put a good lock on it and check that lock once every 5 years.

JR...M O V E

In the mean time sell me the sub...

And the 6BT
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #31 on: October 11, 2014, 12:06:52 PM »
OK folks if I can borrow my thread just a moment

After drying all weekend, here is what it looks like with all the tape and paper removed:
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #32 on: October 11, 2014, 12:07:32 PM »
I got a run!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #33 on: October 11, 2014, 12:08:37 PM »
Not much overspray in the door jambs
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #34 on: October 11, 2014, 12:09:22 PM »
Firewall detail:
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #35 on: October 11, 2014, 12:10:07 PM »
Quote:
Originally Posted by FBJR View Post
Couldn't have a run on the back or somewhere else. No, the one spot you will look at every time you go near or get into the SD.

Murphy,,,,,,,,,,,,,,,,,,,,,,,,,,but great work 

I'd give it a B to possibly a B+

But one thing is, it looks like someone did it themselves, pretty good but not as good as professional work.

Now from 10-15 feet it looks about as good as it gets.

I'll have to add it all up, but I should have somewhere less than $400 in that paint job!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #36 on: October 11, 2014, 12:11:01 PM »
I had to drive all over today, but I finally scored two, ten foot sections of 1/2" hydraulic line, so hopefully, I can have those mounted up tomorrow onto the back of the cab. The goal this week is to get the truck bed mounted back onto the frame and get it looking a bit more like a truck once more.

Hopefully I might even get the access door started on the bed floor. Once that is finished, the bed liner spray will start flying, and the roof will be prepped for the roof rack finish and install.

I ordered some Duplicolor spray can bed coating which I plan to use on the fuel access doors, the snorkel, and the roof rack. I have used it before and it gives the appropriate texture I am looking for on those parts.

I also ordered the weathertite 1,2,3,4,5, and 6 wire electrical connectors and a whole bunch of different dolor wire spools, since I will need to lay in some of the wiring for various things before closing off the roof.

Finally the new windshield installation is scheduled for next Wednesday

Forgot...that wasn't all. Today I started the conversation with Throughbred Diesel Not too awful far from Lexington, KY. I want to partner up with their considerable knowledge and vendor base for the engine and the transmission.

During the initial conversations, when we were talking about running multi fuels, being waste motor oil, Wade basically put the kabash on running the rotary pump.

He is a Cummins dealer and suggested we just go straight for the 7100 inline P-Pump and start at 600 HP. He thought that might be a bit difficult to handle, but at that level, he was good with keeping the bottom end stock, but in good condition.

That saves money for sure. His plan will be to convert the motor to the inline pump, play with the injectors, use the existing turbos, fire-ring and port the head and reinstall it with studs. That setup will be 100-150 HP and 300+ ft/lbs more than what I was considering, so he is bringing in a transmission expert to talk about what direction we need to go.

I/we will also be converting the alternator to a generator and basically, eliminating all electronics on the motor. THis thing is going tractor/stone age cool!

Actually we did talk about one other thing...sort of out there...But we started talking about converting my 2011 Duramax truck to a 12 valve Cummins as well, basically taking it backward a couple of decades so an EMP effect won't affect it either.

Thinking about it, with a 12 valve delivering 700HP/1500 torque and 20 MPG, that truck would have a max range of about 1,440 miles unrefueled!
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #37 on: October 11, 2014, 12:11:52 PM »
Quote:
Originally Posted by rugbyman87 View Post
Glad i finally had time to catch up and.....you never fail to amaze me Don lol.
Great job on the paint, i know what a pain that is and it came out pretty darn good, besides that one pesky run. It happens, were not professionals, and even professionals have runs.
Also....wow on the drivetrain, your really going all out! I honestly didn't expect any less from you though. The next project you start you just need to go at it like you are doing a complete tear down and you will probably save some time!
I have made some progress on the boat finally, i'm about to update my build thread for the not so survival built boat.

Thanks

I'm just trying to do a good job showing what someone can do in their garage. I am pretty sure some folks can do better, I have done better, and worse.

The project has indeed evolved. So might as well rebuild everything. There is an advantage to doing it part by part over a lot of time, that being you get lots of eyes on. And lots of wisdom, and lots of good and some not so good recommendations.

From the conversation last night with Wade over at Thourghbred Diesel, I learned about changing out the internals of that alternator to make it self regulating. That's his great idea. Now I'll add to that Don's idea and add a second unit, but that unit will be a simple generator. THat will feed an isolated electrical system that could start the engine or only used to power accessories.

The interaction of smart people oftentimes spawns brilliance and advances in design. So far we don't actually have advances in design per see, just refinement. But what has been created is a novel change in concept. Go back through SEMA, auto shows and engineering conventions and show me vehicles designed to operate after civilization. Yup, big black hole, nada. The military has such things but they tend to be way over engineered and way too bulky and heavy. Hence the creation of Combat Max and Square D. In the end I believe Combat Max will see the most significant change when it too becomes a 12 valve tractor powered vehicle.

As for looking down the road at the next project, well, let's just say that if JR of this thread lived next door to me it would make things much easier. I see me building a square fender Chevy Suburban or Chevy V3500 and giving it the treatment.

Perhaps in the future I might build these things for customers, we'll have to see. I owned a hot rod shop in the past, and it did well, but there was one problem I could not surmount...People!

Customers all want everything for free, and labor is generally very poor. But given the right combination of some talented souls and by focusing the market toward serious people (read: No star mag folks) it could work, but that's another subject for another day
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #38 on: October 11, 2014, 12:12:49 PM »
Quote:
Originally Posted by rugbyman87 View Post
I agree with everything you said there Don. It has been a learning experience for me and i'm sure alot of us to watch you do this build and the dmax. When i do finally actually buy a house and have a garage of my own, it shall spawn some interesting builds as well. haha


There's a lot more to this and my other build thread
That being

Christ

TO me, these trucks matter but not to the extent that Jesus does. If they ever approach idol status, I hope they are removed from my life, because I do not need them. I hope that that simple message is loud and clear here on these pages to all who come.

In addition to showing what one can do in their garage, I hope to show that God loving and fearing men can do the things they like and fellowship at the same time here.

I want father God to be the eternal glue that holds this and all my threads together, and for Nate's Kookin Corner as well. This is for him. Think of it as a single light on a darkened desert plain that draws on in. The light of course is him, not me. I am simply a messenger who is thankfully being used at the moment to spread the word...
Site owner    IS 6:8  Psalm 91 
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #39 on: October 11, 2014, 12:14:02 PM »
From a pesky DOT:

Was outta pocket for awhile- but thought of you all when I saw this; WE'RE EVERYWHERE DON!

Great progress, really like the color- immediately wanted to sneak over and paint a big white star on each door, three white vertical stripes on the bed and a pin-up girl on the front fenders! Your dad is truly honored!

Don Note: Sad discovery
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #40 on: October 11, 2014, 12:15:57 PM »
From Dustoff35:

Quote:
Originally Posted by BobbyB View Post
I think Harward performance should make a come back..

I found a couple of these in my toolbox, I think he will need to update the decals...
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #41 on: October 11, 2014, 12:16:55 PM »
Quote:
Originally Posted by FBJR View Post
$400 in paint for a $4000 job is pretty good. Remember all the prep and detail no one else would have thought of or done.


Ohh, do I see spare 5.9 parts laying around!! Got mine unloaded last night and into a little LUV utility trailer I have. Now she gets a good cleaning while I look for the trannys.

I think I have a bunch of brand new VE pump parts I'm not going to use.

The boyz down at thoroughbred want me to do a P-Pump swap so they can easily dial in 600HP.
They don't think the rotary pump will eat waste oil as easily as a Bosch inline pump will. Plus the inline pump pushes 10 to 20 times the fuel of a rotary pump. All those VE pump goodies will either be going on Duane's truck or yours???
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #42 on: October 11, 2014, 12:17:31 PM »
Got some more done today.

THe goal is to get the bed installed onto the truck frame this week. That means all the stuff hiding underneath needs to get done now. That was the goal for today. It is possible I might actually spray the bed liner tomorrow evening, but more likely, that will happen on Thursday and the big lift happen on Fritag.

I started with running the transmission cooler hard lines. I purchased hydraulic line, .500" O.D. with a .035 wall thickness to make up the lines.

I began the process by marking the first bend point
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #43 on: October 11, 2014, 12:18:00 PM »
The use of this simple device insures a nice uniform bend with no kinking
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #44 on: October 11, 2014, 12:18:45 PM »
And here is what it can do
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #45 on: October 11, 2014, 12:19:31 PM »
After taping the area up to prevent dings, I proceeded on one bend at a time. I made one tube, then duplicated it with the other pipe section on the floor
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #46 on: October 11, 2014, 12:20:06 PM »
That all only took a few minutes, then I had the tubing bent properly
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #47 on: October 11, 2014, 12:20:58 PM »
Next up I cleaned it up and primed it with the acid etching U-Pol primer
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #48 on: October 11, 2014, 12:21:32 PM »
Then I broke out my favorite John Deere Blitz black to paint the lines
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Re: SquareD Part 6: Paint, topper, Roof rack, and continued change!
« Reply #49 on: October 11, 2014, 12:22:08 PM »
Believe it or not, those lines were not easy to assemble. They kept wiggling all over and falling through and moving in all directions until I got a few of the clamps tightened
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