2011.01.07 - UPDATE! - 3 YEARS LATER.....
Today marks a moment for introspection and reflection. It was
exactly 3 years ago today that I drove the K5 for the last time. I pulled it into the garage and put it up on jackstands to rebuild it the way I'd been imagining it in my own mind for several years.
This date also marks the 10 YEAR anniversary (give or take a few weeks) of the day I first bought this truck and drove it home from Oregon.... time sure flies!
It seems hard to believe that this project has been going for that long.
In my own defense, I will say that this journey has not been solely about rebuilding a truck. Looking back to the garage photos from those earliest days of the build, I didn't own a lot of the nice tools that I have now and the shop itself was poorly insulated, with very limited storage space. A great deal of time has been spent acquiring new knowledge and skills that I'd never had before.
Metalworking - I have to admit that learning about rust repair was one of the more humbling aspects of the build so far. Doing this type of repair is very tedious and time consuming and really tested my patience. Becoming familiar with hammer and dolly work proved to be a very satisfying part of that process, and even though I've only learned the basics so far it has greatly expanded my confidence and ability to tackle future projects.
Tube Bending - The building of the hydraulic bender attachment and the acquisition of the BendTech PRO software was another huge step in my personal development toward more professional-type rollcage fabrication. Being able to land my bends EXACTLY where I wanted them and with the exact number of degrees was a huge victory. Now I know that if I can imagine something, I can truly render it with tubing.
Suspension - I made a major revision to the old "ExcelCAD" program about a year ago when I was home with the flu. That allowed me to refresh my memory about suspension design considerations and allowed me to start on the bracketry for the rear 4-link setup. Getting the axle and links in place was a huge inspirational step in the build.
Mog-9 Axles - These have been probably the single most expensive and scariest part of the build so far. With so little information available on the web, there is almost nobody to get answers from or builds to study. This has forced me to learn a lot of it myself with VERY slow, deliberate studying of parts, diagrams and simply taking stuff apart to see how it was designed. Lots of specialty tools were required as well....large sockets, 20-ton press, breaker bars, metric wrenches and custom-made pullers. The final result will be awesome, but I will certainly have "earned my stripes" by the time they are complete and operational.
Frame - The time spent welding two complete frame together to form a boxed one was something I'd never thought of prior to actually getting into the build. I guess you could say it was one of those things that just happens during an inspirational moment during the build process. It wasn't nearly as difficult as I'd first thought, and I'm really glad I just went for it when the thought came to me.
Build Supplies - Over these last few years, I was slow to embrace the idea of having "extra" stuff stockpiled for convenience. For at least the first year, I'd go into an old box of grubby, rusted take-off bolts to find fasteners I needed for the build....and then one day when I finally had enough, I went online and spent $500 on a complete starter set of GR-8 bolts, nuts and washers, and probably another $200 for nice bins to hold them all. I can't express what a difference this has made in the satisfaction of the build, and how much time it saves me on a "build day" by not having to stop and make a trip to a hardware store for bolts I don't have. Lately, I've also stockpiled flapdiscs, red Scotchbrite pads, Roloc discs, Brakeleen, and those boxes of blue mechanics towels. Having a surplus of consumables really keeps things moving along more effiently.
CK5 - Of course the single most important aspect of this build has been getting support and advice from the guys here. Long-term builds can be a real test of patience and it is easy to get frustrated and burnt-out when the dollars are pouring out and the project just seems to be going nowhere. It's always inspirational to see other people's builds moving along, and to share photos. Sometimes just getting a few encouraging words or getting some tips that will save time or frustration is enough to get me fired up again. So thanks to all of you who have participated in this thread over the past 3 years.... I've got no idea how many more years we'll be gathering here, but I'll keep posting the photos if you'll keep checking in.
I'm sure the lingering question on everyone's mind is: "When will it be finished?". The simple answer is that it will be done when I've done each step as correctly and completely as I know how. That is not a date-constrained target, it is a quality-constrained one.... the truck needs to be completely assembled, then completely disassembled for all the final painting and plating work. THEN, I can reassemble it for the last time and take it for a drive.
I've said it many times: For me, this build is as much about the journey and the enjoyment of the build and time spent in my shop, as it is the final product. I hope that those of you watching don't get too frustrated at the slow pace at times... because in reality I'm enjoying this every step of the way.
I hope that in a few years time, my own son will be able to come out to the shop and help me put the final touches on this build, so that when the sun is shining and the weather is warm, we'll be able to roll up the garage door and finally take it out for a drive!
This is truly a badass build. Keep it up brother! 
