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The RedBurb

Every Part Is Replaceable
A little side project this weekend. My first legit welding project. Learned a few things. Things y’all will probably say “duh” to, things that I already knew aka was already told, but guess I had to relearn the hard way. Things like:

1. The welder is more efficient when it’s plugged directly into the outlet, and the extension cord is deleted. I only have one outlet in my shop so my power source is limited. However, this kind of work required retooling a bit so I could set the welder right in front of the outlet.

2. Metal HAS to be clean. Like super clean. Like cleaner than a wire wheel can do. This was one of my first welds, and it turned out terrible because of the two aforementioned mistakes:

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Ground that off and went back over it.

Once I started cleaning the metal appropriately, my welds turned out more like this:

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@AgDieseler is my inspiration and I’m hoping to be half as good as he is when I grow up.

Anyhow, y’all may or may not remember from my initial launch of this build, that I bought this K5 swing out tire carrier to mount my spare, and after installation immediately realized the tire was too big for the carrier and abandoned that plan. Kept the carrier on the truck though. Bought a new fuel can to put on it since it had provisions for one, only to realize it only worked with the vintage cans. Not to be undone, I bought a ‘69 USMC can, repainted it and installed. Still wanting to carry the other new can, though, I bought a basket-style carrier for it and bolted it to the driver barn door. Realized that was too much weight for the sheet metal and took it off and stored the can and basket.

Well, I still wanted to be able to carry both cans, since I had them, still wanted to use the basket since I had it, and wanted to make better use of the K5 swing out carrier than to carry just one can. I had avoided for a while this notion of altering this carrier, since they are kind of rare. But, in @campfire ’s spirit of “build it the way you want it”, I decided it was time to make better use of the carrier.

Bought another basket, picked up some quarter inch flat bar and got to work. I will say that I saved the original brackets in case they ever needed to be used again.

Here’s a brief play by play and then the final product:

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And the final product:

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So the framing for the baskets were welded to the carrier and the baskets were bolted to the new framing. Every crosspoint where metal touched metal was welded on all sides.

There were some adjustments made in the process:

- The cans sit higher than before so that the framing could stay between the carrier tubing.
- I also moved them over two inches toward driver so that the passenger brake light wouldn’t be as blocked.

Here’s the before and after:

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Some tweaks had to be made, but overall I’m satisfied with the final product. Got a few other small things I’ll be adding to it in the next couple weeks. More to come.

With all the different lines and angles, it’s hard to look at it and believe it’s sitting level, but it’s pretty close. The different shades of red don’t help either. These cans will eventually be repainted yellow. They do carry diesel fuel afterall.

Overall, it was a pretty decent first welding project.

Andy

Wowzers, that's a LOT of improvement between welds! Those later welds look good. PracticePracticePractice. You're on the right path.

I like the red cans. For aesthetic reasons I wouldn't repaint them yellow. The red is good.
 
One thing I did with my barn doors which I liked. Was I cut them out on the inside and made pockets sort of to hold things. A .223 ammo can fits really well a .50 cal almost fits.

I've thought about this, but I'm just now getting to the point where interior things can happen. And they will be happening soon, so ideas like this are timely and appreciated.

I would not have thought that a .50 cal can nearly fits. :thinking:
 
Yeah, I wish I had practiced more before starting, but didn’t have much scrap to work with. I have some now, so definitely will be putting in some hours.

This is a self-fixing problem. Bad welding produces scraps which facilitate practice which produces good welding. Problem solved! :thumb:
 
1: The wire from the solenoid to the ignition switch is purple, according to some diagrams and research I have done. Have not had a chance to look and confirm the wire color on my truck, but is this in fact the wire I’m looking for?

Yes, purple is what you want for this series of truck.

There is noooooooo way that I memorized this to facilitate hotwiring vehicles. None. Zero. :rolleyes:


:rotfl:
 
2: What amperage do I need for the fuse I’ll be installing? Some diagrams say 15amp, some say 30amp, the fuse panel has a 20amp fuse labeled “ignition”, so I’m thinking I need a 20amp fuse for this. Am I right?

Thanks in advance.

The fuse is sized according to the smallest wire gauge that will be downstream of it. Yes, it should be large enough to power your intended load (the relay), but the wiring is what it's protecting. If you need 5 amps to flip the relay, make sure your wiring is rated for more than 5 amps. Bad wiring kills vehicles. And houses. Worth doing right, because you may not get a second chance.
 
I've thought about this, but I'm just now getting to the point where interior things can happen. And they will be happening soon, so ideas like this are timely and appreciated.

I would not have thought that a .50 cal can nearly fits. :thinking:

Had I built mine with a bit more fore thought they would have fit nicely.
 
What range of temperatures do you see on your gauge?

Finally paid enough attention to this to write it down mentally. Here’s what I was seeing:

Idle EGT was at 500
Cruising EGT was 700-800
EGT under throttle/acceleration/grade climbing was at 900-1100.

Seems decent to me.
 
Wowzers, that's a LOT of improvement between welds! Those later welds look good. PracticePracticePractice. You're on the right path.

I like the red cans. For aesthetic reasons I wouldn't repaint them yellow. The red is good.

Thanks for the encouragement! Have been keeping a close eye on the carrier and no welds have broken yet so that’s good.

I’ll definitely be putting in some practice time before my next welding project. Which may be fixing the rust hole I discovered in my new to me barn door.

If I do repaint the cans yellow, it won’t be for a while, and it’ll be for two reasons: 1) for diesel-application appropriateness and 2) because I might be painting my truck red once the body work is done (of which I also have 2 personal reasons for choosing that color) so it almost makes sense to paint them a different color to stand out. But I have a lot more work to do before any of that becomes relevant.

Yes, purple is what you want for this series of truck.

There is noooooooo way that I memorized this to facilitate hotwiring vehicles. None. Zero. :rolleyes:


:rotfl:

Good thing I guessed correctly. Just kidding. I researched. And there are only two wires to choose from. Red and purple. The red goes to a junction block, supposedly, so purple it was.

The fuse is sized according to the smallest wire gauge that will be downstream of it. Yes, it should be large enough to power your intended load (the relay), but the wiring is what it's protecting. If you need 5 amps to flip the relay, make sure your wiring is rated for more than 5 amps. Bad wiring kills vehicles. And houses. Worth doing right, because you may not get a second chance.

The product description claims a “40A/30A high switching capability” if that means anything. However, the ignition fuse on the fuse panel is a 20amp, so that’s what I went with. 20amp to match what’s on the fuse panel. For what it’s worth, the wire from the “battery” (aka junction post fed by the batteries mounted in the rear of the truck) to the fuse, to the relay, to the purple wire, are all 12AWG, which appears to also match the purple wire.
 
Finally paid enough attention to this to write it down mentally. Here’s what I was seeing:

Idle EGT was at 500
Cruising EGT was 700-800
EGT under throttle/acceleration/grade climbing was at 900-1100.

Seems decent to me.
That seems pretty high, I have to tow a heavy trailer up a hill to get my egt's over 800. Idle they'll drop to 300 or less.
 
Thanks for the encouragement! Have been keeping a close eye on the carrier and no welds have broken yet so that’s good.

I’ll definitely be putting in some practice time before my next welding project. Which may be fixing the rust hole I discovered in my new to me barn door.

If I do repaint the cans yellow, it won’t be for a while, and it’ll be for two reasons: 1) for diesel-application appropriateness and 2) because I might be painting my truck red once the body work is done (of which I also have 2 personal reasons for choosing that color) so it almost makes sense to paint them a different color to stand out. But I have a lot more work to do before any of that becomes relevant.



Good thing I guessed correctly. Just kidding. I researched. And there are only two wires to choose from. Red and purple. The red goes to a junction block, supposedly, so purple it was.



The product description claims a “40A/30A high switching capability” if that means anything. However, the ignition fuse on the fuse panel is a 20amp, so that’s what I went with. 20amp to match what’s on the fuse panel. For what it’s worth, the wire from the “battery” (aka junction post fed by the batteries mounted in the rear of the truck) to the fuse, to the relay, to the purple wire, are all 12AWG, which appears to also match the purple wire.

Size the fuse for the weakest link, not the strongest. It's good that your relay can handle 30 amps. But 12AWG is only rated for 20 amps. So a 20 amp fuse is appropriate.
 
Been knocking out a lot of little projects the last couple days.

Replaced the push button for the manual glow plugs.

Replaced a toggle switch in the back of the truck that I installed a while back so I can turn the interior lights off when the barn doors are open for long stretches of time.

Mounted the back up LEDs (that were on the bumper) to the fuel carrier.

Installed a cheapo license plate bracket along with led light on one of the baskets.

Wired up said backup lights and license lights. (Harnesses were already present just needed to be extended).

Installed the black instrument bezel I picked up a while back from the junk yard. (Still need a decent stereo surround cover).

Replaced the driver’s 4-point window switch and harness. All windows work now.

Reworked the top mounting bracket of the fuel carrier so that it’s supported from the interior. No more warping sheet metal and it’s now perfectly aligned with the latch.

“Adjusted” the EGT gauge. I have a theory on why it was reading so high. The plastic lens is cracked and can get pushed down enough to catch the needle. With power off, the needle was stuck at 200 EGTs. Simple fix is uninstall and reinstall. Needle sits at 0 now when off. Will know tomorrow if this has any effect on the readings. Probably need to fix that lens someday.

None of this really NEEDS to be done before our trip next week, but I’m using it as an excuse to GET it done.

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Replaced a toggle switch in the back of the truck that I installed a while back so I can turn the interior lights off when the barn doors are open for long stretches of time.

Interesting. I only have dome light switches on my 2 front doors, not the other 4. I have always figured that this didn't seem right. Glad to know GM corrected the oversight eventually...
 

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