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Author Topic: SquareD Build Thread, Part 1: The beginning  (Read 58005 times)

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Re: SquareD
« Reply #50 on: September 20, 2014, 09:37:56 PM »
I scrubbed the rubber floor mats, the Cummins has two layers and a felt pad as well. I saturated everything with detergent, allowing it to soak, the scrubbed and finally pressure washing everything.
I got the bright idea to launder the felt pad in the wash machine...Don't wash your felt pad in a wash machine.
So tomorrow, I'll be ordering a new felt pad...
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Re: SquareD
« Reply #51 on: September 20, 2014, 09:39:36 PM »
The rust is really not so bad, just scale really.
Tomorrow I'll take a wire cup grinder to it, then wipe down and coat it with the rust converter.
I think I might spray a layer of Lizard skin over that to seal it and provide some sound deadening as well
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Re: SquareD
« Reply #52 on: September 20, 2014, 09:40:54 PM »
I went a little crazy at this point.
I was looking at the seat, and I was looking at the pressure washer and wondering, what if???

So I mixed up a half gallon of carpet and upholstery cleaner and saturated the seat and again did the wax on/wax off thing for some time. Then I sprayed it with all 3200 psi of water not caring what happened since I was planning on re-skinning the seat anyway.
Well surprisingly all those years of really nasty stains went ah flyin' and I was left with a pretty good looking seat.
If the fan can manage to dry out the 250 gallons of water still trapped in the foam, I just might reuse it!
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Re: SquareD
« Reply #53 on: September 20, 2014, 09:43:03 PM »
Originally Posted by duramaxdarren View Post
no no no that will never dry out lol!!! a week in the sun maybe

Well, I've got a week, no worries!
Just checked on it...It's drying right out
And it actually looks pretty clean

Just ordered the lizard skin sound deadener, 2 gallons

My plan there is to spray the stuff up the back wall, on the floor, up in the roof and inside the fenders
I have heard that does a great job of keeping all those mechanical sounds at bay...We'll see!
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Re: SquareD
« Reply #54 on: September 20, 2014, 09:43:28 PM »
Originally Posted by Armalite View Post
Loving the progress!! Especially the seat preparation...

Yea, this thing is surprising me. It is in pretty good shape everywhere I look...Just dirty and covered up with moss, lichen, pine needles, leaves, dirt, 25 years of junk in the toolbox, crusty oil and grease, finger prints, more moss, and all manner of trash.
Now that I am starting to get to the bottom of all this, I am starting to see one pretty solid truck!
Yippee
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Re: SquareD
« Reply #55 on: September 20, 2014, 09:44:28 PM »
Originally Posted by Armalite View Post
I agree. So, what exactly are the plans for the front of the truck, after the removal of that Armageddon bumper??

Going with a factory bumper and a winch, or another road armor style??

I don't know just yet
Tomorrow I plan to saw off the upright cattle gate part and leave the bottom intact so I'll have something on there while I decide what to do.

I like the look of stock, but it wouldn't handle running into kias and Hyundai's so something more substantial will be required.
Since this is a budget build, I might just fab up something myself and drop a 12K winch in there for good measure!
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Re: SquareD
« Reply #56 on: September 20, 2014, 09:45:46 PM »
From Ashley

Originally Posted by flyin6 View Post
I don't know just yet
Tomorrow I plan to saw off the upright cattle gate part and leave the bottom intact so I'll have something on there while I decide what to do
.

I like the look of stock, but it wouldn't handle running into kias and Hyundai's so something more substantial will be required.
Since this is a budget build, I might just fab up something myself and drop a 12K winch in there for good measure!

I agree. Just cut off all that excess, and reuse the lower portion. Use those handy welding skills, and maybe even some of the cut offs, and build a bumper that will serve a better purpose, I mean prettier purpose.

You cant tell me that the current set up could get any better at protecting that front end...
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Re: SquareD
« Reply #57 on: September 20, 2014, 09:46:29 PM »
Originally Posted by flyin6 View Post
I don't know just yet
Tomorrow I plan to saw off the upright cattle gate part and leave the bottom intact so I'll have something on there while I decide what to do
.

I like the look of stock, but it wouldn't handle running into kias and Hyundai's so something more substantial will be required.
Since this is a budget build, I might just fab up something myself and drop a 12K winch in there for good measure!

I agree. Just cut off all that excess, and reuse the lower portion. Use those handy welding skills, and maybe even some of the cut offs, and build a bumper that will serve a better purpose, I mean prettier purpose.

You cant tell me that the current set up could get any better at protecting that front end...
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Re: SquareD
« Reply #58 on: September 20, 2014, 09:47:37 PM »
Quote:
Originally Posted by duramaxdarren View Post
Now what about sprayin that raptor liner on the floor then put the dynomat down. not to expensive and should make for a water tight and quiet cab..

Dunno...Was thinking of spraying the ceramic heat shield stuff over the sound deadener and calling it a day but undecided at the moment. It takes all of 10 min to pull out the interior, so not a big concern if I don't get it right the first time...

Just ordered a black headliner, well just the material and glue. I figure I'll yank the old one off, then glue up a new one
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Re: SquareD
« Reply #59 on: September 20, 2014, 09:48:40 PM »
OK, let's get this thing pushed another couple yards down field.

Today was a productive one. The wiring mess got removed, as did the ugly steps, lights, tool box, switches, wiring harnesses, and that cattle gate front end. Additionally the interior metal all got treated as did some of the exterior metal.

First up was removing of the birds nest from under the hood, front grill, along the frame, inside the cab, and in the bed.
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Re: SquareD
« Reply #60 on: September 20, 2014, 09:49:27 PM »
Next I pulled out the battery to see what shape all of that was in. Surprisingly, for a 22 year old living in the rust belt, there wasn't much rust or corrosion hanging out there
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Re: SquareD
« Reply #61 on: September 20, 2014, 09:50:38 PM »
In no particular order, next all the switches and myriad of wires came out of the cab
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Re: SquareD
« Reply #62 on: September 20, 2014, 09:51:42 PM »
Back to the battery tray, I used a cup brush and some hand wire and brass brushes to clean up things to get ready for the rust converter
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Re: SquareD
« Reply #63 on: September 20, 2014, 09:52:58 PM »
This stuff is around $40 a gallon and once you remove the bulk of the rust, basically the loose and flaky stuff, you simply brush on this water soluble liquid and over about an hour it does it's magic
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Re: SquareD
« Reply #64 on: September 20, 2014, 09:54:36 PM »
With things on slow cook under the hood, it was on to the bad areas in the cab. Again first with the wire cup and a way-powerful grinder
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Re: SquareD
« Reply #65 on: September 20, 2014, 09:55:54 PM »
I scratched up everything since it is all going to get coated with the Lizard Skin tomorrow or Wednesday
Then the surface was given a cleaning with lacquer thinner
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Re: SquareD
« Reply #66 on: September 20, 2014, 09:57:19 PM »
I scratched up everything since it is all going to get coated with the Lizard Skin tomorrow or Wednesday
Then the surface was given a cleaning with lacquer thinner
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Re: SquareD
« Reply #67 on: September 20, 2014, 09:58:30 PM »
After the battery tray and spot on the radiator dried, not quite in these pics, I coated those areas with some rust treatment paint
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Re: SquareD
« Reply #68 on: September 20, 2014, 10:03:45 PM »
Next, with the assistance of my handy plasma torch, I tore down the cattle gate.
Then I thought what the heck, I'll just leave the bottom half on there temporarily until I get more time to build a proper bumper, so I ground down the stubs, wire brushed it and shot it with some rattle can black, cheapo stuff that I purchased for wasps.
You know about that trick?
Blast them with it and first they can't see to sting you, then very quickly it seals their skin up suffocating them...Pretty effective if you don't mind having some black spots here and there!
I just tell folks it's black mold and I never have to deal with company!
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Re: SquareD
« Reply #69 on: September 20, 2014, 10:04:49 PM »
Cattle gate all gone, I checked on the cab floor...Lookin' good
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Re: SquareD
« Reply #70 on: September 20, 2014, 10:05:59 PM »
Trash piles getting even bigger!
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Re: SquareD
« Reply #71 on: September 20, 2014, 10:07:20 PM »
Next those creepy looking side mini steps and the offensive eyeball lights met with the flame torch...They lost
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Re: SquareD
« Reply #72 on: September 20, 2014, 10:09:36 PM »
I pulled the tool box off and treated the rusty spots beneath where it had sat for years. That all turned out great.
I might reuse the toolbox...have to think about it. But it will be John Deere Black if it goes back in there!
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Re: SquareD
« Reply #73 on: September 20, 2014, 10:10:48 PM »
Running short on time I pulled the rotary wire brush out once more, tackling a 10" wide strip across the rusty roof.
After removing most of the scale I applied two coats of the rust converter, and it converted the roof into a radish garden!
Well, not really...
It blacked that sucker right up giving me ideas about the exterior color of the truck to come...
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Re: SquareD
« Reply #74 on: September 20, 2014, 10:11:42 PM »
It's starting to look more and more like a normal 80's-90's truck!
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Re: SquareD
« Reply #75 on: September 20, 2014, 10:12:32 PM »
I'm going to go get them this morning after my workout

I don't need to put them on, though, until after installing the new brakes and steering.
Very soon it will be coming into the shop for the first round of major parts replacement
So far on the list is:
Interior: New Headliner
New Carpet
All pieces parts dyed or painted black

Steering: Borgensen steering shaft
New Drag link
New Tie Rod ends
Possible replacement steering box

Engine: Detail cleaning
Oil change
Fuel filter
Accessory belt
Heater hoses
Radiator hoses
All clamps

Transmission: Fluid and filter change

Brakes: Rebuilt Calipers
High performance brake pads
Rear brake shoes and cylinders
or Rear disc brakes
All new brake hoses everywhere
All new hardware, everywhere

Body: Replace weather strip, both doors
Replace Windshield gasket
Replace rear window gasket
Install bushings and new pins in drivers door
Repair tail gate so that it will stay closed

So, anyway, when all that stuff gets done, and it won't take as long as you may think, Then I'll install the new prudy wheels and tires!
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Re: SquareD
« Reply #76 on: September 20, 2014, 10:12:57 PM »
 had a crazy/stupid idea last night that actually might make some sense.

THe idea is to not paint the truck!

Hang on Ash, get back in your chair, catch your breath and control your heart rate.

It has a certain Patina, that I am adding to daily. Soon it will have black splotches all over surrounded by areas where various layers of paint has been ground or brushed away. It already has the faded blotchy silver, which has worn off in spots.
It already looks like it would be in home in the second row of the local junk yard.

So suppose I sprayed a low gloss clear coat all over it, preserving this moment in time so to speak. Then I could park it anywhere near wrecked cars or debris and it might look right at home...

Modern industrial camouflage...

Think about it

I might be on to something here...!!!
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Re: SquareD
« Reply #77 on: September 20, 2014, 10:14:31 PM »
From Ashley:

Quote:
Originally Posted by stlaser View Post
You seem to easily forget the intended use of this build. I think it better to blend in with the local scenery than to build another flashy "hey look at me" type truck. Ever been to KY? It's a fairly poor state and I'm guessing his farm is located in that type of area. Think smart, stay alive..........

I don't want flashy... Just give it a decent paint job. Back to solid grey, or flat black maybe...

Or just leave the rust spots. The more I think about it, the more different it is, and Don is all about different...

Hmmm, now its growing on me...

You two using some secret army technique to convert my decision making process??
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Re: SquareD
« Reply #78 on: September 20, 2014, 10:15:01 PM »
Process,
Well First I suggested it,
Then Shawn liked it
Then Bobby shored up the reasoning,
Then You saw the light!

I definitely haven't decided on what to do with the outside as it is not a priority. All it really needs is rust proffing and maybe some protection against getting banged up.

In the Kintucky scheme of things, the worn out and faded look works well, but so does a factory style paint job.

Reasoning here is:

1. Statewide, Kintucky is a poorer state and most people keep vehicles forever. uite a few take pride in what the DO own (Which isn't much) and keep it painted up or waxed up.

2. Another crowd just doesn't care and welds cattle gates to the front bumper and calls it a day

So either way works...

Now that is the hiding in plain sight concept which is a good one.

Another concept is to stay in the woods, in hideouts and run at night, hopefully using NVG and no lights. For that scenario we're back to some blending camo pattern.

So the theme of this truck is
"Better" not best
Restored and not modified to look like a monster truck
Alternate and back up, not the primary vehicle
Be serviceable and useful as a "truck" to do all things truck
To be low cost to build and to maintain

I will build it around those parameters

No matter what the outside looks like the undercarriage will get the full on treatment. Completely renewed, painted, rust-proofed, and up to date...
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Re: SquareD
« Reply #79 on: September 20, 2014, 10:15:35 PM »
Quote:
Originally Posted by nmeyer414 View Post
Why not do it all in raptor liner?


Too obvious...
Too different...

The more I think about this idea of just neutralizing the deterioration then freeze it in time with some flat clear, the more I like it

It is really smart...Not saying that because I have some delusion of being smart, nossir, I live with me, I am far more capable of stupid than an occasional mistake toward the smart side.

But isn't this sort of smart?

It would take an attitude to pull this look off, but talk about trend setting...

And easy

And cheap

It's like done in a few simple steps!
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Re: SquareD
« Reply #80 on: September 20, 2014, 10:16:09 PM »
From Nate:

Heres my thinkin for sayin raptor line it.

The truck is from the time when the big 3 were having an issue with the new primer and technique they were using. What ended up happening to these vehicles was the paint would flake off and the primer would stay. Well after a while the primer would litteraly just wash away and you would have rust. This is an actual documented issue.

Now the reason I say raptor line it, is because there is something in the product that makes it truly stick to whatever it is applied to. Where as if don sands it down and applies a clear coat, the process will repeat itself and it will begin to ruat all over again.

Now lets face it, once don gets done with combat max, square d will most likely see most of the driving except for sundays and when ever the family goes someplace. I will also bet that square d will most likely see more farm time than combat max and why not have some sort of armor on her like raptor / linex / etc to keep it from getting worn even more.
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Re: SquareD
« Reply #81 on: September 20, 2014, 10:16:33 PM »
Well, my hood and roof sure prove out your statement about paint failing. Mine is completely gone, not even a flake of the stuff left
For now, it's death by wire cup and 1 horsepower and black, magic coating...
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Re: SquareD
« Reply #82 on: September 20, 2014, 10:18:15 PM »
Note: This was all happening back in the beginning. At this time, I was holding onto a much simpler concept of what this truck ought to be, and not the thing it has become that will show up a couple thousand posts from here.
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Re: SquareD
« Reply #83 on: September 20, 2014, 10:19:15 PM »
Quote:
Originally Posted by 6.0 BOWTIE HD View Post
Kinda mad maxish I think it would look rough and tough. Not too mention every chip or scratch will just add more character. Just do enough to keep it from rusting through on the back side.


Sent from AutoGuide.com Free App

Well, no decisions, but it is an idea I am actively thinking about

I just came from the paint store where I loaded up on restoration products to repaint the interior, frame, undercarriage and so forth.

We talked about capturing the patina.
They have a mat clear, but it's almost $100 a quart!
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Re: SquareD
« Reply #84 on: September 20, 2014, 10:19:49 PM »
No one is going to believe this one...

I just got back from the paint store and getting the tires and wheels.

Beneath the truck is a wet spot, actually beneath the radiator

I crawled under the truck and traced the fluid to the culprit spot.

Know what I found?

The previous owner had secured the transmission cooler hoses together with a nylon zip tie.

Well, that zip tie had been chaffing against the brass side of the radiator and wore a hole in the left side tank!!!

The anti chaffing stuff chaffed a hole in the tank

Now, I truly have seen everything

I have a great old trick though.

I'll have to pull the radiator, but you solder a penny over the hole and in 10 minutes, voila' no leak and it only cost 1 cent!
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Re: SquareD
« Reply #85 on: September 20, 2014, 10:20:33 PM »
Quote:
Originally Posted by 6.0 BOWTIE HD View Post
But it's a 20 year old radiator with 20 years of corrosion in the cores. I know you flushed it but strictly peace of mind knowing you won't have any issues with a new one in it. Hate to have to pull it out again in a short time.


Sent from AutoGuide.com Free App

Are you saying replace it???

That's psycho!

I mean how much do those things cost

Really big brass radiator, can't be cheap
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Re: SquareD
« Reply #86 on: September 20, 2014, 10:21:23 PM »
I actually got a lot more work done today than I have pictures of. I slipped on that logging chain and fell onto the fire extinguisher and screw jack. Darn near punched a hole in me, but I guess all this working out I do made me tougher than the fire extinguisher which I broke. The camera also broke (again) but I managed to snap most of the parts back together, but now it over-exposes on some frames. About half of the pics I had taken of various processes looked like I was standing on a white sand beach wearing all white while filming the surface of the sun!

Well, anyway, let's get started

Since we hurt Ashley's eyes looking at those ugly wheels and bald tires, here's a new tire and wheel rolled into place where it soon will reside
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Re: SquareD
« Reply #88 on: September 20, 2014, 10:23:54 PM »
I like the semi aggressive tread on the Hercules tires
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Re: SquareD
« Reply #89 on: September 20, 2014, 10:24:49 PM »
I made a trip to the paint store where we talked through what I was doing. I came out of there a quarter of a thousand dollars poorer, but with a big box of stuff to use.
They encouraged me to use the nitrile gloves which are a much more durable rubber, and sold me some metal surface prep which I put right to work cleaning stuff.
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Re: SquareD
« Reply #90 on: September 20, 2014, 10:25:53 PM »
Knowing I was about to get grinding on the hood, I removed the cowl.

Underneath I found a couple yards of mulch.
I used it to spread around a couple of my flower beds.
It used to be leaves, pine needles, bugs and the like, but it was only organic material about 2" deep everywhere in the recesses of the cowl area.

I removed all of it, then soaked the living sticks out of the area with simple green.
« Last Edit: September 20, 2014, 10:26:53 PM by Flyin6 »
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Re: SquareD
« Reply #91 on: September 20, 2014, 10:28:13 PM »
Next up, the hood met the wire cup and the rust went flying. Good thing, though almost none of it got on the ground. It all collected in my hair, eyes and face.
One quick shower, and I saved myself the time from washing down the driveway again
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Re: SquareD
« Reply #93 on: September 20, 2014, 10:30:52 PM »
Here's a look at how the roof turned out after curing with two coats applied
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Re: SquareD
« Reply #94 on: September 20, 2014, 10:31:25 PM »
You can see the area where rust had taken purchase is a total black, whereas in the areas of sanded paint it didn't change color all that much.

The surface is very hard now. So hard, that I am going to have to use some aggressive sand paper to rough it up for the primer which is the next step in the restoration process.
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Re: SquareD
« Reply #95 on: September 20, 2014, 10:32:34 PM »
Note: I first mention "The restoration process...Thinking back, I think I was mentally starting to turn the corner toward a much more aggressive teardown and rebuild...
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Re: SquareD
« Reply #96 on: September 20, 2014, 10:33:23 PM »
Beneath the cowl was an aluminum tag riveted in place with all the build codes for this truck. The photos didn't turn out, but everything is completely legible this time!
I'll post the codes in an edit to see if anyone can decode
I'm still waiting on Chrysler to respond to my query...

Edit: Here's the codes:
K2X
LPE
NBL
NCM
NMC
RCD
89
DGR
ETB
GPB
HAA
K1X
501
QAM90101 173 AD6L62
APC
PS7
QAC
M1S8
795
824391
XBS
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Re: SquareD
« Reply #97 on: September 20, 2014, 10:34:19 PM »
Thanks there Special K!

I just got the build data email from Chrysler, so I think I know what the truck has/is supposed to have!

Here it is:

Dear Donald:

Thank you for contacting the Ram Customer Assistance Center.

We are pleased to provide vehicle build information per your request for
your vehicle. According to our records, your vehicle was equipped from
the factory with the following:

Sales Code Description

ADAA Light Group
AHLS Heavy Duty Insulation Group
APC Center Band Two Tone Paint
BANS 120 Amp Alternator
BCLS 1100 Amp Maintenance Free Battery
BGKS 4-Wheel Anti-Lock Brakes
BKHS 12x2.5 Rear Drum Brakes
CBAP Straight Back Bench Seat
CDEP 6-Way Power Passenger Seat
CKJS Black Vinyl Floor Covering
CURP Rear Compartment Storage Tray
DGB All 4-Speed Automatic Transmissions
DGRS 4-Spd. Automatic 46RH Transmission
DHES Man Shift-on-the-Fly Transfer Case
DJFS Dana M60/248MM Front Axle
DMDS 3.55 Rear Axle Ratio
DRES Dana M70/267MM Rear Axle
ETB 5.9L I6 Cummins Turbo Diesel Engine
GACS Tinted Glass Windows
GBBS Tinted Windshield Glass
GCBS Front Door Tinted Glass
GFD Rear Sliding Window
GNAS Rear View Day/Night Mirror
GPBA Pwr Fldg Htd Drvr Memory Mirrors
GVAC All Vehicles W/O Power Mirrors
HAA Air Conditioning
JCDS 100 MPH Primary Speedometer
JHAA Var Intermittent Windshield Wipers
JJAS Cigar Lighter
JJFS Single Low Note Horn
JKAS Locking Glove Box
LAAP Ignition Time Delay Lamp
LAFS Key in Ign/Seat Belt Warning Buzzer
LAJS Headlamps On Warning Chimes
LBAP Map/Courtesy Lamp
LBCP Glove Box Lamp
LBDP Ash Tray Lamp
LDAP Underhood Lamp
LPEP Cargo Lamp
MBBS Bright Front Bumper
MBDA Argent Rear Bumper
MFDS Bright Grille
MHAS Black Windshield Moldings
MKAS E-Z Step
NBLS Delete EVAP Control System
NEMS Exterior Sound Control
NFEA 24 Gallon Fuel Tank
NHBS Auxiliary Transmission Oil Cooler
NHKS Engine Block Heater
NMCS Heavy Duty Engine Cooling
NZAS Diesel Emissions
PS7 Dark Silver Metallic
QAC Silver Star Metallic Clear Coat
RAAC All Radio Equipped Vehicles
RAS AM/FM Cassette Radio
RCDP 4 Speakers
SBAS Power Rack and Pinion Steering
SCBS 2-Spoke Steering Wheel
SFBS Front Heavy Duty Shock Absorbers
SGBS Rear Heavy Duty Shock Absorbers
TBB Full Size Spare Tire
TBMP Tire Carrier Winch
TZHP Michelin Brand Tires
WDAS 17X7.5 Steel Styled Wheels
WLBP Steel Spare Wheel
WLYC All Steel Wheels
WMAS Black Hub Caps
XBSA Pickup Box
XEFS Transfer Case Skid Plate Shield

Thanks again for your email.

Sincerely,

Christopher
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Re: SquareD
« Reply #98 on: September 20, 2014, 10:34:54 PM »
^^^^How cool is that!

I sort of doubt it had 17 X 7.5" wheels in 1991!
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Re: SquareD
« Reply #99 on: September 20, 2014, 10:35:47 PM »
From Duramaxdarren:


nice work boss!!!! lotta elbow grease went into that....not to derail the thread but since you are now the resident rust buster and i am torn on how best to spend my money and prep the underbelly of my bed. So you know i wanna use the raptor liner as my final coat....so after seeing your use and results of the rust converter stuff but i also saw this stuff called rust destroyer from advanced protective products. what should i use? can i use both? which is best as a base for the raptor. I have just a bit a scale on the bed crossmembers and on the pumpkin. the bed belly side is very clean and barely any rust spots and scale...whats your thought big don corleonie?
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