CK5
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The Shop Truck

1971 Chevy C20 with a custom flat bed.
When I did the aam 10.5 on my truck, I stuck w/ the d60 calipers as they were the same piston area as the 2500 that the doner had. I also did the 2500 master. It will lock up the 37's if I ask them. I did have to mount a newer booster as my 80 truck had a smaller diameter mount surface.
 
I’m still using the stock brakes on my 82 c10, swapped in a front 10b and a aam 10.5 it locks the 35’s up.
 
I'm at a loss right now honestly. I bought some calipers but when I looked at them compared to the AAM calipers I started to wonder. After a ton of google searching and calculations this is what I came up with:
C20 front calipers - 2.93" piston bore - 6.74sqin surface area
K20 front calipers - 2/93" piston bore - 6.746sqin surface area

2500 rear calipers - 2x2" piston bore - 6.28sqin surface area.

These calipers should work just fine. Now I'm digging into the master cylinder, POL says it's a 1" master cylinder, but the factory one is 1.25" so that's a huge difference (.78sqin vs 1.22sqin). I'm not sure why POL went with a SMALLER than factory master cylinder, but I think that's my problem. The P30 master would give me a 1.312" master cylinder with 1.35sqin piston.
 
Well, this just reinforces my statement of never purchasing from POL again. We picked up a stock replacement master cylinder from NAPA, of course the front/rear lines are reversed on the C20/30s so I had to make new lines to go from the master to the proportioning valve. I hate making small lines like this, but somehow I managed to knock both of them out first try and they actually look decent!

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The test drive went well, it stops great, locks the tires up if needed (which is hard with the big 275s on there). Now on to more fun things, I think my wife and I spent at least 3 full days trying to make the "bolt on" POL brake master cylinder work, which included replacing half the parts that came with it...
 
It's alive!
IMG_20240603_175801624.jpg


We took it on quite a long test run yesterday with no issues (related to the recent changes anyway). We started smelling fuel so I stopped to check, the high pressure line quick disconnect came off of the Corvette filter/regulator inlet and dumped 8 or 9 gallons out as I was driving. It somehow was keeping enough pressure that it didn't have any engine related issues. I clearly didn't get that clipped on right last time I had it apart and for some reason it finally decided to let go.
 
It's alive!
IMG_20240603_175801624.jpg


We took it on quite a long test run yesterday with no issues (related to the recent changes anyway). We started smelling fuel so I stopped to check, the high pressure line quick disconnect came off of the Corvette filter/regulator inlet and dumped 8 or 9 gallons out as I was driving. It somehow was keeping enough pressure that it didn't have any engine related issues. I clearly didn't get that clipped on right last time I had it apart and for some reason it finally decided to let go.
Looks cool as hell!
 
It's alive!
IMG_20240603_175801624.jpg


We took it on quite a long test run yesterday with no issues (related to the recent changes anyway). We started smelling fuel so I stopped to check, the high pressure line quick disconnect came off of the Corvette filter/regulator inlet and dumped 8 or 9 gallons out as I was driving. It somehow was keeping enough pressure that it didn't have any engine related issues. I clearly didn't get that clipped on right last time I had it apart and for some reason it finally decided to let go.
I did the same thing going down the I10 days before leaving for Moab.
 
Looks good, I especially like that you kept some sidewall instead of the low profile type tires!

It looks good with those wheels!

I spent a lot of time deciding what wheel and tire package I wanted. I also do not like the super low pro tires on an old truck, these are 17s so not much bigger than stock. I wanted a shorter, wider tire to get the truck a bit lower and with how wide the rear axle was my choice of wheels was limited (+25 offset). I took a chance on these and I love the way they look, I'm very happy with how it turned out.
 
We spent some more time working on the truck this weekend. It's hot here in AZ and this truck was never designed to do 80 down the freeway, so I'm trying to get it to cool better. The Delta PAG fans keep it nice and cool everywhere but on the highway, that's when temps start creeping up. Before I start adding more power, I want to get that taken care of. I picked up some filler plates from Classic Truck Products to prevent the air from going up and over the radiator rather than through.

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They make working under the hood much nicer as it gives you a nice shelf to set all your tools on there.

We've been fighting the A/C system in this truck since we installed it and we attempted to make it work properly again by swapping out the expansion valve. We keep wrestling with low suction pressures and high discharge so I was thinking possibly the expansion valve was clogged or faulty. Unfortunately swapping it out didn't help anything, we pulled some refrigerant back out and I removed the insulation from the expansion valve pigtail. This seems to help a bit, but once the whole system is heat soaked, it takes a bit to get back to steady state. At least the compressor isn't coming on and off every couple seconds now.

While we were fighting with the A/C, we noticed that the fans were making some noise, after looking into it they both had started to rub, not to encouraging for fans that aren't even a year old, with very few hours on them. The shrouds both seem to be a bit oval shape now, very close/rubbing on the sides with about 1/8" clearance on the top and bottom.

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I drilled a hole and bolted the shrouds together in the middle to give some clearance there, and I drilled a hole and put a screw in from the back side to push the outer edges out away from the fran.

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This fixed the issue for now, but I'll probably send Delta PAG an e-mail. I'm assuming they warped a bit from heat, but who builds a radiator fan that can't handle high temps?
 
Good call on sealing the airflow into the radiator. The filler panels look nice. I would add some filler foam or rubber sheets to make sure all the air coming into the grill has to go through the radiator. If the still doesn't do the trick, you might need some hood vents like on your Duramax.
 
Need a filler for dad's Ranchero gonna look and see.

Where did you have the sensing bulb for the thermal expansion valve
 

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