big plans, some progress, noob welder!

[rgilmartin]

So I've had this 87 sub for about a year now. Its been a bit used and abused. Now I'm working to
get it ready for winter and begin some modifications. I plan on it being my dd and a camping / support rig,
eventually I'd love to build a full on rock rig, but start with something shorter wheelbase wise, then dedicate the sub to towing. In the meantime I KNOW it going to be BEAT..

The intake manifold has been leaking from the front. Its been removed, and at the mach shop getting
Boiled and glass bead blasted.

There's a big crack in the ps exhaust manifold...Got some headers from summit..
.$100 with bolts collectors and gaskets found a pair of cats on cl.

Picked up a couple of leather power seats from an infinity at the junkyard, currently they're
Only held in with two bolts,

I had chopped a bit out of the dash a while ago, haven't gotten around to building
A custom yet, but planning it out. Also ripped out the ac / heater.

Got a hobart handler 135 110v mig for 275 off of cl, currently running w/ flux wire no gas.
I've never welded until today. I fitted a panel over the big holes in the firewall. Ill see about posting
Some pics here shortly.

 

[rgilmartin]

SO, I'm new to this forum, thanks for having all the great info here! There are so many talented members that have inspired me. I've been trying to gather as much info as possible. I'm putting this here in the hopes that someone finds it useful. Please ask any and all questions. Also, please add your comments I'm trying not to be a complete hack!

 

[rgilmartin]

OK should be able to add some pics now...

The Holy Firewall

Now after I've cut and welded it.

This was my first attempt at welding, and I guess its holding itself in there, but its pretty ugly, there are probably 6 places where I blew through the metal. I used 22g steel and am thinking it was too thin. I also cut the piece a little bigger than the hole, should I have tried to match it, then weld the gap?
Overall Im prouder of this than if Id have used sheet metal screws or POP rivets!

 

[rgilmartin]

So Im house sitting for my parents, got to borrow a car for 10 days, thats whats driving all of this..Trying to clean up the following:

Leaky Intake Manifold, the puddle on top is from pulling the thermostat before realizing I should snap a shot, but the stuff on the front was there before.

Cracked Exhaust Manifold

In an attempt to repair my poor-running truck I removed the catalytic converter...there was nothing wrong with it!... but it was welded right to the bend in the Y-pipe, my brother's welded it on a couple of times, but it keeps falling off. Since I've found this crack, I'm going to go headers, and full duals w/ cats.

PS, Ive wanted to have a set of headers since my first vehicle, an S10 2wd PU....but never actually did it, now that I have a welder, I wont have to pay someone a TON of $ to build the exhaust I want!

Here's my chopped up dash:

I had this idea to make a custom dash, and did a bit of cutting about 6mo ago, but haven't done much with it yet. I removed the rest of the heater wiring and vac lines today, and got the big hole plugged, now Ive gotta plug the blower hole. Then I'll start mocking in my new heater and putting together a plan for the dash, Id like to get that heater mounted and the right 2/3 of the dash completed this week.

The Rear AC is still up, and the plumbing underneath the truck waiting to get hung up on something...

If it goes as planned this will be out by the end of the week too.

 

[K85 Octane]

nice man, keep it up
try not to bite off too much at once
that way you can drive it from time to time and remind yourself how much fun it is.

 

[rgilmartin]

Thanks man, Im trying not to let it turn into a "while I was there" build, and have decided to leave the heads / timing chain / cam alone for now!

 

[rgilmartin]

Got the blower hole filled in, had just as much trouble with blowing through the metal, i had a hard time keeping the arc going, it would start, then stop, repeatedly. I kept having to turn the feed speed up to get it to stay 'lit'... some of the problem was the way I was routing the line to the gun, kinda kinked it a little and made it hard to feed. My brother said I also likely had a poor ground which was also probably true.

Cleaned up the intake manifold and valve cover gasket mating surfaces...WHAT TEDIOUS WORK...tried hitting it with a wire wheel, but it left a lot behind. I spent 2 or 3 hours with a razor blade cleaning them up. But they look ready to seal!!! THERE HAS GOT TO BE A BETTER WAY..Anyone??

Think Ive got a good plan together for the exhaust, like a Marine's haircut...High and tight...for the most part, Ill let you know how it goes.

got out of work after 1/2 day today, tomorrow off, I spent the other 1/2 chasing parts, and running errands, then most of the evening cooking / eating / talking with my GF...She's a little jealous of the truck, and the time I devote to IT..RRGGHH thats the MOST FRUSTRATING PART of this whole project!!!

Will post more pics tomorrow!

 

[K85 Octane]

there is no better way to take off old gaskets than a razorblade. It's just how it is. If you use the wirewheel or something similar, there's a chance you could pit or put waves in the sealing surface. Some stuff is ok, like heavy irons in places that don't require thin gaskets to seal on, but I jump feet first with a razor.

good progress

 

[texas4x4rebel]

Cleaned up the intake manifold and valve cover gasket mating surfaces...WHAT TEDIOUS WORK...tried hitting it with a wire wheel, but it left a lot behind. I spent 2 or 3 hours with a razor blade cleaning them up. But they look ready to seal!!! THERE HAS GOT TO BE A BETTER WAY..Anyone??

I used this type of pad does a good job have to be carefull on aluminum.

 

[rgilmartin]

K85 - Thanks for the encouragment, glad to hear Im not the only one who has callosed up their fingertips cleaning gasket surfaces..

TEXAS, where'd you find a wheel like that, what's it made out of.. it looks like it might work well...
I happened to see some today that had a kind of stiff plastic bristle on them, but have got it cleaned now, ill have to file that stuff for the future!!

 

[rgilmartin]

OOPS, a little setback ..

I left the piece that clamps the collector on over the O2 sensor bung...Had to cut it off, then re-weld it, an extras hour or so of work b/c I didnt pay attention.

TBI Fuel Lines

The ones on the left are from my 87, the end towards the throttle is about 18" or so of hard lines, they are a PITA, make the difficult job of loosening the distributor hold down even harder. The ones on the right are from an 88, THANKS FOR THE TIP, wish I remembered who mentioned it...
The feed line hooked right up, just routed a little different. Instead of running straight down then alone the frame, it goes over the transmission. The return line is short by about 24", got a patch piece from the parts store.

The intake is all cleaned up, and it and the valve covers are intstalled.

Got to take the dog to the vet, then start figuring out the new heater:

 

[rgilmartin]

done for now...

didnt get the heater done, but got the exhaust all plumbed and working.

I had to get an oil filter bypass, the header wouldn't clear the oil filter, because of the adapter to go to the oil cooler. It also turned out I need ford filters now, b/.c of the oil filter bypass...

I feel like I wasted a lot of time fetching parts, but am happy with what I got done. The exhaust sounds sweet, I just got to find some turndowns in the right size. The cough at idle is gone, and the POWER is back, OK its still a tired 87 motor, but its much better than it was.

I ended up having to route the passenger side on the outside of the frame, to clear the transfer case, and keep it away from the fuel lines. I'll just have to be careful over rocks where it crosses under the frame, overall I think its unlikely to get hung up..

After driving it for a few days it ran great, but would stall out at random times, ie stopped at a light, cruising down a hill, shifting into reverse...The PO had a hypertech chip installed, and had left the stock chip in the truck. I swapped them out, and the truck seems to run much smoother. It hasn't died since swapping to stock, and seems to accelerate similarly or better. BUT the big difference I noticed, and didnt think the chip would effect was the way the truck shifts between gears. I thought the tranny might have been on its way out b/c of the way it would SLAM into 2nd gear, but w/ the stock chip, its a nice solid shift. Im going to post my chip experience in the TBI forum, but has anyone had similar experiences?

 

[K85 Octane]

really nice outcomes
congrats!

 

[Big6ft6]

rgil, nice work! Looks like you're having fun and I can hear the pride in your voice (typing)! That is what is important.

You did just fine on your welding. Overlapping the metal is the best things to do when you'res starting trying to butt weld is very hard before you get the hang of the best setting for your welder.

The most important thing with welding is to clean both pieces of metal SUPER clean. when you are welding at low voltage required for thin metal, even the smallest contaminate can cause your arc to die and restart over adn over.

I just got done welding A TON of sheet metal on my truck (my first time too) after about 5 feet of seems and some reassurance from a neighbor I started getting better. But even when I ground of rust with a grinding wheel, if it was 90% clean but had some small rust pits, the arc would pop and sputter across those pits. If you leave any paint or anything it will make it hard to keep your bead at low voltage.

Also have to keep the two pieces of metal touching eachother. As you weld, they usually start to warp a little and the top piece will lift away. Then it becomes super easy to blow through that top piece and it gets messy quick.

Just keep welding...you'll get better and better.