What's new
CK5
Register an account today to become a member! Once signed in, you'll be able to participate on this site by adding your own topics and posts, as well as connect with other members.

Saying Good-bye to the 90 and Hello to the 72 Build. NEW:Hidden Exhaust

SBD. Searched your posts looking for where you cut but didn't find anything. Do you feel better now that you admitted not bracing the door? Admition is the first step in recovery. :haha:

Greg. Thanks. Just need to decide to cut it all apart or not. It is an off road truck after all, but doing it right and fixing the problem has always been a down fall for me.

TP85. The gap is at the top of the door and the bottom of the fender to door.
 
Holy cow! It looks like I need to go back and brace better so I don't run ito the same issue.
 
Well I may disappoint some, but I needed to move on! I decided I was not going to rip up the floor, remove/replace rocker (inner/outer) replace the front cab support,Replace rocker box, repaint with green, then Al's liner with 2 colors.

Here's how I fixed the problem area.

I removed the front rocker box lid by grinding off the welds on the top and removing the 3 spot welds on the side. I then carefully bent the cover down. I also removed the rear box cover. I then removed all the shims from the passenger side. I used the porta power to push the firewall forward to open up the door gap. To make sure the gap between the front fender and door was going to work out I placed the jack under the front corner of the rocker box and lifted the side up by it. I then mounted all the sheet metal for a test fit. The gaps where workable.

I cleaned up all the cancer and surface rust on the existing cab support and rocker box area. I used some 1/8" plate and welded it to the cab support and 3 sides of the rocker box. I removed the porta power and jack from the front corner and rehung the sheet metal for another test fit. It looked good, not perfect but workable. I pushed the front cover back up and re-welded it.
Although this was not the proper way to fix it I am very satisfied with the results.

I had to remember this is a trail rig and will get used as such. It was not worth the time or expense to make it driver quality.

grinch door repair.JPG

grinch door repair.JPG
 
How much easier is it to move the firewall with that rocker box flap peeled up? Was there a noticable difference in effort required? Mine needs a little of the same treatment.
 
I'm not sure it moved any easier. Hard to tell with the porta power. I do know my rocker box front cover ended up in a different spot. It could have been from bending it out of the way and then back up or the box itself actually got tweaked during the process.
 
Nice work. I wouldn't have torn it all apart for a trail truck either. The bodies on these rigs are flexible, when you wheel them hard the bodies seem to move around quite a bit anyway. Takes a bunch of sweating to get the top back on after wheeling it for the summer. Cage helps a bunch but :dunno:
 
Just some "feel good" progress pics showing off my cool fender badges. Windstar fan and of course the 500.

Now the fenders are mounted I can work on the rest of the wiring

P1010083.JPG

P1010084.JPG

P1010085.JPG

P1010083.JPG

P1010084.JPG

P1010085.JPG
 
Whoa Dennis!!!

Looks like you pushed a tad too hard with that PortaPower.... the distributor ended up on the front of the motor!!! :D

When you get a chance, see if you can take a photo of the whole truck from a distance....pulled out of the garage or whatever. We'd like to get an overall look at the paint, cage, stance, wheels, etc.



:usaflag:
 
Hey let's not get to excited here! :woot:

I'm still a ways out from mounting the tires and hood.

I need to fab up some battery trays. When I built the brackets for the Windstar fan I forgot about the battery tray mounting on the inside edge of the core support. See what happens when a project takes years.

Next will be the wiring under the hood, front and rear bumpers, fuel lines, brake lines and finally exhaust. Then I finally get to fire this thing up.
 
Last edited:
Decided to take a break from the wiring and see what the bumper off my 90 would look like on the 72.
It sort of fits pretty good. Only problems I can see is the winch is close to the grill because of the V of the 72. I will also have to add about a 1/4 shim to each side of the mounting brackets. The frame is about 1/2 narrower.

Since I pulled the bumper out further I will also have to add to the mounting brackets, the 72 frame does not come out as far as the 90 did.

Well what say you? Run it?

Greg: You're getting to see some it, but not the whole thing yet.

P1010087.JPG

P1010090.JPG

P1010092.JPG

P1010094.JPG

P1010091.JPG

P1010087.JPG

P1010090.JPG

P1010092.JPG

P1010094.JPG

P1010091.JPG
 
why not cut a section of the lower grill out and push the winch/bunper back more and get loose some of that front overhang?
 
MNorby said:
why not cut a section of the lower grill out and push the winch/bunper back more and get loose some of that front overhang?
Click to expand...

Thought about it. But I could only go in about 2 more inches before the ends would hit the fenders. Then I would also have to firgure out some way to beef up the grill. No support once you cut it.

Any ideas for parking lights/turn signals?

Thought about some behind the grill like an 84 (I think). I could recess some in the bumper (More fab work). I found some flush mounts that only stick out 3/4" . :dunno:
 
Here was my 71 with the grill cut for the winch. I was always gonna weld tabs for the front marker/turns like I have currently on my sonoma but never did on the k5
IMG_0158.jpg
 
You must log in or register to reply here.

Latest Posts

Top Bottom