ok, gimme a bit to go back and read it, got a puppy playdate going on......
CK5
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71K5 - BP71K5's Just for fun build
- Thread starter bp71k5
- Start date
Man, that orange looks great. I love it.
bp71k5
3/4 ton status
Thanks!
ok, generally, that's a function of thickness and friction.. if the underside of the fasteners are smooth, you can often slather them with some bearing grease, tighten, than wipe away what squeezes out..
it isn't necessarily a product failure.. it's often why certain component/areas need to be refinished once assembled.... but overly thick can aid in failure for sure...
it isn't necessarily a product failure.. it's often why certain component/areas need to be refinished once assembled.... but overly thick can aid in failure for sure...
bp71k5
3/4 ton status
Thanks, good to know. Try to keep the coating thickness down in areas like that. The grease idea sounds like a good plan too.
bp71k5
3/4 ton status
Update 07/31/2016
Most difficult upgrade so far... New windshield. The old one was fogged, pitted with weld spatter, and had a couple spider cracks. Of course the day I picked felt like the hottest on record.
Installing wasn't bad if you know the process. I've done it a few times in my old VW, but this one was a bit trickier installing alone. Definitely would have been easier with a second person.
Finished the shifter boots as well. Using a 6-cyl shift boot for the nv4500. My old one lasted about 10 years and was cracked and split so I ordered up a new one.
My son also helped me bolt the cage back down. I cleaned up the hole in the dash that the bars go through before I painted it.
You can see a short stub that's protruding forward into the engine bay. Future cage/frame support. It has a bolt on disconnect on the end that can be accessed once the cowl cover is removed.
Aaaaaaand, the ugly doors back on. It feels difficult not to spend any time painting the doors since it would be easier, but I want to drive this thing again and that would add months to the process.
Should be back on the road in a couple weekends.
Most difficult upgrade so far... New windshield. The old one was fogged, pitted with weld spatter, and had a couple spider cracks. Of course the day I picked felt like the hottest on record.
Installing wasn't bad if you know the process. I've done it a few times in my old VW, but this one was a bit trickier installing alone. Definitely would have been easier with a second person.
Finished the shifter boots as well. Using a 6-cyl shift boot for the nv4500. My old one lasted about 10 years and was cracked and split so I ordered up a new one.
My son also helped me bolt the cage back down. I cleaned up the hole in the dash that the bars go through before I painted it.
You can see a short stub that's protruding forward into the engine bay. Future cage/frame support. It has a bolt on disconnect on the end that can be accessed once the cowl cover is removed.
Aaaaaaand, the ugly doors back on. It feels difficult not to spend any time painting the doors since it would be easier, but I want to drive this thing again and that would add months to the process.
Should be back on the road in a couple weekends.
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Again, nice work sir. Looks good.
Beautiful work man. I agree, get it on the road. Enjoy it for a bit, then tackle the next project.
bp71k5
3/4 ton status
Update 08/20/2016
Dash pad recovered and installed. This makes it feel a lot more finished than it is.
I had to trim about 2" off each end to fit between the cage bars. There was no good way to stretch vinyl in such a sharp shape so I had to patch the ends on with separate pieces. It's ok from 5 feet away but if anyone decides to do this the "right" way, stitching the ends into a compound shape would be a much nicer way.
Seats back in.
Doors, fenders, hood back on.
From the drivers seat. I can almost fool myself into thinking the entire truck is one color.
And to prove it drives...
Clicky...
Dash pad recovered and installed. This makes it feel a lot more finished than it is.
I had to trim about 2" off each end to fit between the cage bars. There was no good way to stretch vinyl in such a sharp shape so I had to patch the ends on with separate pieces. It's ok from 5 feet away but if anyone decides to do this the "right" way, stitching the ends into a compound shape would be a much nicer way.
Seats back in.
Doors, fenders, hood back on.
From the drivers seat. I can almost fool myself into thinking the entire truck is one color.
And to prove it drives...
Clicky...
Dash looks great! I bet 0% of people will notice the end.
I saw these in action a few weeks ago. I'm a ways off from being able to personally report on their performance, but figured you might be interested.
http://www.radrides.com/store/parts/product/126-rastners
As always, great work.
David
$13.95 for two screws 
bp71k5
3/4 ton status
$13.95 for two screws
Two screws AND two washers, in stainless steel. They are nice though.
"If you have to ask, you can't afford it pal"
That orange paint sure looks great! 
bp71k5
3/4 ton status
Update 09/23/2016
I noticed some damage to the inner fenders when I had it apart for paint. I keep finding the inner fender bolts on the front keep getting pulled out. I'm assuming it's from too much movement between the frame and cab. Since the cage it tied into the rear part of the frame, all the flexing happens in the front.
You can see I've welded up the holes before.
The holes in the firewall were filled with a short tube that bolts to the cage A pillar behind the dash.
That tube goes down and bolts onto the frame right next to the steering box.
Just used a big 1/2" bolt to tied a short stub to the frame and coped the long tube into that.
Had to cut out a bit of inner fender to make room for the tube.
I used some of the door-ding edging around the hole to seal it up a bit and help prevent any noise if the tube flexes and touches the cab. Used some tube couplers on the end. This tube is kinda short because it has to feed into the cab at an angle and then bolts to the cage with another coupler inside the cowl.
All bolted back in.
Also notice I covered up the heater box with a fun project. Made a wooden pattern and used a big round sledge to form the outside edge and then cut out the center so I could form a big "bump" to ridgidize it. Maybe not necessary but it was fun beating on some metal.
First rough forming.
Other side.
After a decent amount of hammer and dolly smoothing.
And a lot more.
And with some mounting holes in it.
Plan is to paint it black and find some black mounting bolts for it. Keep it that way until I decide what do do about AC/heat some day.
I noticed some damage to the inner fenders when I had it apart for paint. I keep finding the inner fender bolts on the front keep getting pulled out. I'm assuming it's from too much movement between the frame and cab. Since the cage it tied into the rear part of the frame, all the flexing happens in the front.
You can see I've welded up the holes before.
The holes in the firewall were filled with a short tube that bolts to the cage A pillar behind the dash.
That tube goes down and bolts onto the frame right next to the steering box.
Just used a big 1/2" bolt to tied a short stub to the frame and coped the long tube into that.
Had to cut out a bit of inner fender to make room for the tube.
I used some of the door-ding edging around the hole to seal it up a bit and help prevent any noise if the tube flexes and touches the cab. Used some tube couplers on the end. This tube is kinda short because it has to feed into the cab at an angle and then bolts to the cage with another coupler inside the cowl.
All bolted back in.
Also notice I covered up the heater box with a fun project. Made a wooden pattern and used a big round sledge to form the outside edge and then cut out the center so I could form a big "bump" to ridgidize it. Maybe not necessary but it was fun beating on some metal.
First rough forming.
Other side.
After a decent amount of hammer and dolly smoothing.
And a lot more.
And with some mounting holes in it.
Plan is to paint it black and find some black mounting bolts for it. Keep it that way until I decide what do do about AC/heat some day.
Great example of what the patient application of a hammy and dolley can achieve. Really nice work.
David
David
bp71k5
3/4 ton status
Thanks, it'll get a bunch more smoothing before final paint. Try to see how smooth I can get it without bondo.
bp71k5
3/4 ton status
Update 2/17/2017
Since I can't drive the k5 with all this rain, I managed a good deal on a new tool today at an employee auction at work. Did I mention I hate sanding...
Since I can't drive the k5 with all this rain, I managed a good deal on a new tool today at an employee auction at work. Did I mention I hate sanding...
Those are so nice to have access to
