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TailPan Swap (pics)

Discussion in '1973-1991 K5 Blazer | Truck | Suburban' started by Boss, Jul 10, 2001.

  1. Boss

    Boss 1/2 ton status Author

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    Hey,
    Several of yall PM'd me about this and I just remembered that I was suppose to make a post with pics and explanation on how it was done. Sorry for the memory lapse [​IMG].

    Anyhow Here it is:

    Ok, this was performed on my 75' K5. Here you can see why it needed to be done: (and please enlargen the pics to atleast "Normal" Webshot doesn't default to the proper size)
    http://community.webshots.com/photo/17164755/17167180iWsmImmmon

    Now, First, I removed the gas tank. No brainer here.
    Second remove the tailgate. They're held in by 8 bolts total that connect through the threaded hinges into the tailpan. This pic is just on one side of the hinge. You can see that the hinge support broke off the tailpan [​IMG]
    http://community.webshots.com/photo/17164755/17166822JWViQhnnEu

    Now, remove the 2 rear body bolts that goes through the bed to the frame (this holds the body mounts in place.)

    Now, you will have to break the spot welds. What I did was heat everything up one at a time and stuck my crowbar in between and broke the spot welds. You will ruin the rear part of the bed this way. So keep in mind you'll need new sheetmetal at for the rear. I bought like 3 or 4 pieces of 12x6" 16 guage sheetmetal.

    Now, jack up the body from the tailpan. I used a bottle jack and a 2x8" (if I remember right) and jacked the bed from the tailpan. I then took a 3lb sledge and pounded the tailpan down out from where it was attatched to the body. The tailpan broke off at a corner so I easily removed it from the truck (in 2 pieces).

    Here is a pic of the new vs the old:
    http://community.webshots.com/photo/17164755/17166889WsHXjVWjSr
    And then I put them in one at a time and rested them on the frame and welded them back up:
    http://community.webshots.com/photo/17164755/17164826fQkqiNCziM

    Now, with the new sheet metal (12x6" pieces), I welded them up one by one.
    http://community.webshots.com/photo/17164755/17164998gVbYMLsImf

    Then put your heavy ass tailgate back on and you're done [​IMG] Oh, and then put your gas tank back in and hook it up.

    Let me tell you....this was one of the biggest pain in the ass jobs I've done. But it only took me a weekend (say about 4 hours a day) and that included some rest inbetween and stuff. Once finished though, the tailgate was finally lined up perfectly. Before it was off a b/c of that broken hinge support I guess. But, it was something I'm glad I did. Good luck to you guys that have been PMing me :) And everyone else that needs to do this for that matter.
    Boss
    ps, oh, here is the page where you can see all the pics:
    <A target="_blank" HREF=http://community.webshots.com/album/17164755NHCvrebwyY>http://community.webshots.com/album/17164755NHCvrebwyY</A>

    89' 1 TON of FUN K5
     
  2. riz

    riz 3/4 ton status

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    <font color=purple> Thanks a ton for all of the info, I'm glad you guys are so helpful..........now it's my turn I guess.

    L8r,
    . Riz . <A target="_blank" HREF=http://www.geocities.com/rizmonkey>http://www.geocities.com/rizmonkey</A>
     
  3. wayne

    wayne 3/4 ton status

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    Hey Boss got a couple of ?'s for ya.
    1. Are you going to make it to Bloomsburg this weekend?
    2. I need the # for whare you got the stuff for your crossover steering stuff? I know the rods are RockStomper pieces but don't know where to get the rest.
    Thanks Wayne.
    BTW good write up on the tail pan.

    <font color=blue>Wayne<font color=blue>
     
  4. Itali83

    Itali83 1/2 ton status

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    Thanks Boss. Looks like a bunch of fun!!!! NOT, and Riz and I are gonna have even more fun because we are doing the whole floor!, not just the tail pan!! Yippee Skippee!!!!!!!! Well, thanks again and I'll probally be picking your brain when I get my truck riped apart! Lol
    Ben 87 Jimmy
    <font color=blue>Rust=Bad</font color=blue>
     
  5. riz

    riz 3/4 ton status

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    <font color=purple> No doubt.....thanks Boss ! Nice job !

    L8r,
    . Riz . <A target="_blank" HREF=http://www.geocities.com/rizmonkey>http://www.geocities.com/rizmonkey</A>
     
  6. Boss

    Boss 1/2 ton status Author

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    Wayne,

    Hey bud, Can't make it this weekend. Helping a friend build a deck still. We're running out of time and we both work a lot so we only have weekends to do it. Have to have it ready for the big killer Keg Bash in two weeks [​IMG][​IMG]

    Anyhow, take some pics for me....

    Pitman Arm is Superlift part # SUP 1104
    Steering arm from Parts Mike: (530)885-0673
    You can get the Pitman arm from him too if you like. You're going Crossover right away??? I told you should [​IMG]
    Boss
    ps, Riz, Itali...No prob dudes. Yeah, major suck. Well, I replaced patches on my bed(only the rotted parts, most of the bed was still tip top.......that sucked too, but not as much as replacing the whole bed!! Good luck

    89' 1 TON of FUN K5
     
  7. wayne

    wayne 3/4 ton status

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    Thanks for the info. I will take pics and post a link to them when we get back. Wish you could make it though. As far as doing the crossover I am not sure if I will do it at the same time but it is the next thing I want to do. If I have the money I will do it at the same time.

    <font color=blue>Wayne<font color=blue>
     
  8. Grim-Reaper

    Grim-Reaper 3/4 ton status Author

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    Wow I guess I got lucky. My floor was slavageable on mine. on 1 quarter size area that had a problem I needed to deal with. I drilled out all those fun pinch welds.

    It's not my damn planet monkey boy!
    <A target="_blank" HREF=http://communities.msn.com/OffroadK5s>http://communities.msn.com/OffroadK5s</A>

    Grim-Reaper
     
  9. Boss

    Boss 1/2 ton status Author

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    Hey Grim,

    You know, if I had my head on right, I could've just drilled out those spots welds, but no, went the hard way and torched and pryed and torched and pryed and practically ruined that end. But, I was planning on replacing the entire rear bed anyhow. Oh well. But suggestion to others, drill out the spot welds like Grim said [​IMG]
    Boss

    89' 1 TON of FUN K5
     

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