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Progress on the Duck

75-K5

3/4 ton status
Joined
Apr 28, 2002
Posts
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Location
Anderson, Indiana
No pics to share from this past weekend, there was not a lot of progress that was visually oriented. Just wanted to share some of the progress that is being made with the fellow diesel guys here. Memorial Day weekend yielded the following:

1. Motor and tranny/case are completely mounted and bolted in! Just need to drill a couple holes for the crossmember (have the beefy style that goes through both frame rails)

2. Got fuel cell placed (not mounted yet) in truck, got all necessary fittings sourced, and fuel filters in place. Mounting firewall spin-on filter to back inside wall, any known problems with this?

3. Completely refurbished wiring harness. Robbed carbureted harness out of the '82 K20 that I disassembled, got all stock gauges to work, rear taillights work properly, all wiring completely cleaned and wrapped in electrical tape.

4. Reset odometer to 0 just for fun (title reads Exempt anyway, so no legal ramifications for this)

5. Set up switches for starter (used tractor switch mounted to floor and dash switch for power to floor switch to prevent accidental bumping), fuel pump and IP hot (on same switch), and cold advance.

6. Reinstalled gauge cluster and dashboard and tied up most of the wiring.

7. Installed zero-rates.

It's starting to look like a truck again! Now all that's left is finish the hydroboost, new brake lines, shoes, and rotors, plumb the fuel system, mount glow plug (Ford starter) solenoid, hydro clutch, wastegate control spring, shorten driveshafts, get exhaust done
, and about 10 billion hours of body work :crazy:. It sounds like a lot on paper, but after everything that's been done so far, it really seems like it's downhill from here. All the "hard stuff" is done!

Going back next week to do "catch up" and take care of a couple minor things before tackling the big list the following week. I'll try to snap a few pics then.
 
In case anybody is following this, I snapped a few pics this past weekend. Got a lot more done, to include 95% of wiring. Got the glow plug solenoid mounted and the plugs all wired up. All other wiring was hooked up and heat-shrinked (shrunk?). Decided to relocate the distribution block to the driver's side fender for better proximity to the driver's side battery. My buddy found me a badass battery cable from Deka (can be seen in one or two of the pics) that is set up for dual batteries and has leads for the starter and GP solenoid.

Speaking of starters, somehow I had a gear-reduction 6.5-style starter laying around, so we got that bolted in and ready to go!

Also made the bracket for the fuel cell made and got it all mounted, also finished all fuel and return line plumbing. It looks like I'll be able to use the stock steel apparatus that connects the injector return lines to the IP return, which is good because it was going to take a buttload of fittings to rig something like that up!

Got one of the doors switched out (my friend liked my power doors even though the skins weren't in the greatest of shape, so we traded straight up for his nice manual doors). I still need to pick up some weatherstripping, but other than that the door lines up and shuts awesome! Just a flick of the wrist and it closes with a nice firm sound.

Did a couple other things too, like finally install the rear-center body mounts and mount the seat, stuck the shocks under there, etc.

Going to order the wastegate controller (Heath TurboMaster), drop brake lines (BlackWidow), hydro clutch parts, hydroboost stuff, and power steering lines this week, and get the oil feed and return lines for the turbo custom made at a hydraulic shop. Then, I have to figure out my snorkel setup. Once that's all done and a few more minor things are taken care of, it will be ready to go to the exhaust shop to get the crossover pipe made and hopefully also get them to plumb the exhaust out the fender (not sure if they will since that would technically be the emissions side of the exhaust and this is anything but stock :crazy:)

Here are a few pics of last weekend:

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Gonna be awesome without fuel tank and exhaust in the way under here! And easy to work on too!
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Hopefully more pics in 2 weeks! Taking this weekend off :p:
 

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