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1985 Chevy M1009 (CK5 build thread part 2)

Soft Top Season!
I was waiting on a new bulb seal that attaches to the cab from Softopper before I could get the top installed. I removed the old one to paint behind it.
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The paint is definitely still curing, the Rapco data sheet says 1-3 weeks. I noticed as it continues to cure, it flattens out even more, further hiding my sins.
I failed to mention previously that I painted behind the grill and top of the core support, the fuel tank and skid, wing window metal, and wiper arms all black for that finishing touch. I also painted the inside of the passenger fender green, because it was white. And, I think I am going to leave the bridge plate off, it looks cleaner without it.
Looks so good
 
How long do those soft toppers last? I’d like to get the truck topper version but $1000 is salty when I can buy a fiberglass cap for that that will basically last forever.
 
How long do those soft toppers last? I’d like to get the truck topper version but $1000 is salty when I can buy a fiberglass cap for that that will basically last forever.
I guess it all depends on your environment. This one is still in great shape at 3 years old but I take it off for the winter. I know some guys on the site here have replaced them after a while.
Funny enough, I've had a camper shell where the wood inside the fiberglass on the bed rail completely rotted out and made the cap useless.
 
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Headlight Swap:
The M1009 had a pair of super bright LED headlights when I got it, and while they worked excellently, I was never a fan of the futuristic styling.
IMG_20260511_160859500.jpg
I wanted more of a classic headlight look, and I found a pair of glass H4 style headlights on Amazon, that came with replaceable LED bulbs.
IMG_20260511_172412339_HDR.jpg
They definitely don't have the same crisp pattern as the old lights, and the new lights came with a 12000LM bulb set, which I can step that up to a 50000LM set or better if I want. One drawback of the new lights is they fit kind of loose, and I had to wrap electrical tape around the edge of the body (where the retainer ring goes) a few times so they fit better.
Now for a highly scientific comparison:
Old Low Beams:
IMG_20260511_161000867_HDR.jpg
New Low Beams:
IMG_20260511_164259880_HDR.jpg
Old High Beams:
IMG_20260511_161005484_HDR.jpg
New High Beams:
IMG_20260511_164305414_HDR.jpg
You can see the new set has a less focused beam, and could be a bit brighter, although they seem way brighter than a standard incandenscent set.
But, I really don't drive this rig that much at night.
I certainly do like the new look:
IMG_20260511_165806577.jpg
 
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I like the light cut off of the old set, the new ones are the ones that blind you coming the other way, even if they do look better

The paint, wheels and soft top look awesome though!
 
I like the light cut off of the old set, the new ones are the ones that blind you coming the other way, even if they do look better
You know, that's a good point, as I was thinking about the way the new headlights have that wedge shaped different pattern built in that faces the drivers side. Like these are made for driving on the other side of the road in Europe, and that wedge shape lights up the ditch. I'm gonna have to try them out and see.
The paint, wheels and soft top look awesome though!
Thanks man!
 
You know, that's a good point, as I was thinking about the way the new headlights have that wedge shaped different pattern built in that faces the drivers side. Like these are made for driving on the other side of the road in Europe, and that wedge shape lights up the ditch. I'm gonna have to try them out and see.

Thanks man!
In Europe they drive on the same side we do.
It's islands all over the world that drive on the opposite side side.
England, Japan, Cyprus, Australia, New Zealand to name a few
 
Vacuum Pump Gasket:
Fun Fact! The GM part number from the CUCV Parts and Illustration Catalog is still good, after all these years. I ordered a few from RockAuto, at $0.81 each. They are not listed under any 6.2 diesel parts tree on RockAuto, you have to search by part number. Maybe this will help somebody in the future.
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IMG_20260529_092242690.jpg
 
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I have used regular Chevy distributor gaskets for my vacuum pump. I never looked up the part numbers but the gasser distributor gasket fits perfect.
Thats very interesting, as I've seen conficting info on this subject. So, I pulled the gasket from a spare HEI I have for a comparo: (its the red one)
IMG_20260529_104352445.jpg
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The HEI gasket is a very tight fit on the distributor.
Now I need to go pull the vacuum pump on the 6.2!
 
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Wow. I never put them next to each other. I just had a broken vacuum pump gasket and looked through my gasser stash of gaskets hoping to get things back together that day. The distributor gasket fit under the shoulder of the vacuum pump so I used it. No leaks 40K miles later. I also probably used 3M weather stripping, the yellow stuff in the tube, to glue the gasket to the vacuum pump. I was taught to do that with distributors waaayy back when. But, I can see how the too big gasket could fall or work its way out one side if not glued.

Thanks for getting that photo. I won’t write about it anymore.
 

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