Re: 86 Silverado K20 12V CUMMINS Build
 

I think if it were mine, I would just cut off the flat face piece that holds the master cylinder from the rest of the bracket and just weld it to the firewall. That is the way my '88 is set up but instead of welding it on the firewall the mechanic bolted it up. When I finally tear mine down to rewire and such, I plan on welding it in. It's looking good.

Re: 86 Silverado K20 12V CUMMINS Build
 

What your doing is very close to how I did mine . All the same parts . My pedal assy is under the floor tho. Used the same bracket as you are doing . They are fun to get out from under the stock daash eh ! I had trouble becouse the travel of the hyd assy was up before my pedal was out of travel. Thus I bent the rod going into the master when it was out of room but my foot was saying more ! Or giving more anyway . After this i did basically what Ryan mentioned and added a sleve over the remaining straight part and threaded rod on the other with a small heim joint . Works well now .

Re: 86 Silverado K20 12V CUMMINS Build
 

Thanks for the interest and feedback guys. I did some more checking and this I what I have come up with. I did consider cutting the face of the bracket and welding to the fire wall but decided against it for 2 reasons. Firewall flex due to all the push force and also with this style of master cylinder from a 1st gen, the way the seals work you would have to eliminate the large outer seal which I am sure would air leak and waterleak. I cut 2 pieces of angle and tacked them into position. I removed that very small piece that I used.
http://i1284.photobucket.com/albums/...psvu99imi5.jpg
I also trimmed some off the bracket to allow pedal clearance at full stroke.
http://i1284.photobucket.com/albums/...psubq4scqn.jpg
http://i1284.photobucket.com/albums/...psk0ud3e9d.jpg
I think I also have figured out a way to re-use the stock chev return spring on the pedal by welding the pin back on in a slightly different position. I have to still install it all back on the cab to re-test the strokes etc. then mock up the spring. I am also going to install a hardstop for the pedal because right now the only pedal stop is the master cylinder inself. I will get some more pictures also. Hopefully this will help others out as I struggled a little bit on figuring out this one myself.

Re: 86 Silverado K20 12V CUMMINS Build
 

That is looking stronger and that's a good deal about the return spring.

Re: 86 Silverado K20 12V CUMMINS Build
 

So I think I got the clutch pedal done. I have welded the bracket on the solid now.
http://i1284.photobucket.com/albums/...psxcklemry.jpg
I have a new hard stop that will contact just about full stroke on the master and a new return spring to hold the pedal.
http://i1284.photobucket.com/albums/...psb20caad6.jpg
Little splash of black and set it in place to try it out.
http://i1284.photobucket.com/albums/...psf07d9454.jpg
Full return and full stroke seems to be smooth and straight.
http://i1284.photobucket.com/albums/...ps7612f45a.jpg
http://i1284.photobucket.com/albums/...psb5c7bca8.jpg
The seal around the master looks good and no flex on the fire wall at all.
http://i1284.photobucket.com/albums/...ps5usrfdyv.jpg
Now onto body work. Cab rust :( Got alot to do before I can say its is ready for paint. Hopefully time and weather will be on my side ;)

Re: 86 Silverado K20 12V CUMMINS Build
 

It turned out really nice! Nice work.

Re: 86 Silverado K20 12V CUMMINS Build
 

All I can say is Way to hang in there! Great Info and attention to detail ! Too bad your not closer as I have a couple of divorced 205's one drivers side and the other passengers side drop!
Well spring should be about over up there and I'm looking forward to seeing more, so keep up the good work!

Cheers !!

Re: 86 Silverado K20 12V CUMMINS Build
 

Thanks for the comments. I too wish you were closer as there is nothing anywhere in a 205. Still searching kijiji every week but they are very rare and made of gold up here.

Re: 86 Silverado K20 12V CUMMINS Build
 

Wow. Been 5 months since last post. Couldn't find the build, way down pg.2
Well it has been a crappy and busy couple of months. We found out of the 4th of July that my father had cancer. We all found out the same day, even him. The next 6 weeks was a battle that I would not wish on my worst enemy. He only came home once for a few rough days the 2nd week of July and passed away on the 10th of August. That was a whir wind blur of a 6 week span.
One of the last things he said to me on one of the last nights when he was still responsive was that he still wanted to see "that truck run".
Needless to say, I haven't hardly worked on the truck. But I did do some cab work in the late spring and now in this last week I worked on the engine. After I get my uploads finished on my super slow internet Ill have some updates.

Re: 86 Silverado K20 12V CUMMINS Build
 

Last spring I cut out all the rust and patched up the floors with 18gauge. I rebuilt-replaced the two skis with 3/16 angle.

http://i1284.photobucket.com/albums/...psktmdgzww.jpg

http://i1284.photobucket.com/albums/...pstvzgzc0s.jpg

Got the doors hung and setup-replaced the rockers and cab corners.

http://i1284.photobucket.com/albums/...psgtnbijcr.jpg

http://i1284.photobucket.com/albums/...psdkdsqbjd.jpg

http://i1284.photobucket.com/albums/...psthgsujni.jpg

I have got the cab completely welded. Just needs some more finish sanding then it will be ready for the POR15 treatment.

Re: 86 Silverado K20 12V CUMMINS Build
 

So fast forward from last spring until mid October. I was thinking about all the times during the winter that I have time to work in the garage but just can't for more than a few min because I can't feel my fingers anymore.
So........................
I installed a zero cost reclaimed SS chimney out the back wall.

http://i1284.photobucket.com/albums/...psk3xjnvvp.jpg

and then installed a freebee wood stove/furnace.

http://i1284.photobucket.com/albums/...psqwcqqumg.jpg

So far it works awesome. :metal:

Re: 86 Silverado K20 12V CUMMINS Build
 

Drooling over the heated shop!

Re: 86 Silverado K20 12V CUMMINS Build
 

So last Sunday I fired up the stove in the Garage and un covered the Cummins. I picked up everything needed to button up the engine. Front crank seal and gaskets, valve cover gaskets, engine oil, filters etc, etc, etc.

http://i1284.photobucket.com/albums/...pslwfhv6zg.jpg

While I had it apart, I decided to re-do the KDP and loc tite and re-torque the front housing bolts.

http://i1284.photobucket.com/albums/...pspjn0quio.jpg

Made my own from the scrap drawer in the tool box

http://i1284.photobucket.com/albums/...psupvq2tgv.jpg

Tabbed for good. ( I hope )

http://i1284.photobucket.com/albums/...psqbam9lkc.jpg

Re: 86 Silverado K20 12V CUMMINS Build
 

I dont seem to have any pictures after I did the KDP. I guess I was so excited to work on the truck I never even thought about the camera.
Today I hooked up a battery, put some fuel in a can and primed the fuel system. I have ran out of diesel before and I have heard and read on the internet that it can be a real bear to prime, but it went real smooth. This engine has gone smoke free for approx 32months. I pulled the engine exactly 2 years ago this month from the Dodge. Here is a short small low quality walk around video of the "second" start in the new Chevy!! :metal::metal::metal:
Hopefully this works for everyone.

http://i1284.photobucket.com/albums/...pstcfevpds.mp4

Re: 86 Silverado K20 12V CUMMINS Build
 

I don't know why the big 3 manufacturers don't do this but on the stuff i build at work we use 3 motors only a qsb 6.7/4.5 cummins or a deutz but disregarding the deutz on the cummins we use a fuel filter that has a hand primer on it literally best invention i have seen i wish regular trucks had them because running out of fuel would be a thing of the past you unscrew the handle prime it till the handle is really hard to push in and they start right up. It has a regular quick disconnect line that goes to the pump not sure if its high pressure but the other line we use is regular rubber lines for the return.

If you want i can look for a part # on it i am sure its there somewhere.

Its somewhat similar to this picture

Re: 86 Silverado K20 12V CUMMINS Build
 

That is very interesting. Looks like a neat setup.
My current plan is to use the stock setup. When I get the truck drivable I will then start the mods on the fuel system.
The 2nd Gen Cummins lift pump has a "primer bulb" built in. It works very good. I use it at filter changes and one time I ran out of fuel on the side of the road.
I used this about 30 to 40 pumps today. It filled all the line, fuel canister and the IP.

http://i1284.photobucket.com/albums/...se372a1e5.jpeg

Old picture from tear down but the rubber boot thing on the side of the lift pump is the primer.

Re: 86 Silverado K20 12V CUMMINS Build
 

I'm still drooling too. Oh you have no idea. :metal:

Re: 86 Silverado K20 12V CUMMINS Build
 

Brian, Sorry to hear about your loss. Glad to see your making some good progress and that heater is going to come in handy. I have to drive about 16 miles, to use my friends heated shop. One day I will have my own heated shop. :lol:

Re: 86 Silverado K20 12V CUMMINS Build
 

So sorry to hear about your father! The engine sounds great. Nice rust repair, and I'm sure the heater will be used a lot there s winter, unfortunately.

Re: 86 Silverado K20 12V CUMMINS Build
 

Thanks guys.
Ya the engine does sound good. I was starting to get worried because it has sat so long plus I had the injection pump off. Guess I got the pin timing right. :lol:
After I get the truck drivable I want to upgrade the fuel system with better lines, filters, free mods etc. For now, just to know it runs, is good enough for me. Thinking about getting rid of the saddle tank as well and go with the rear burban style. Seams to be the popular way to go. I have been keeping an eye out in the classifieds etc for a 88 to 91 suburban for a parts wagon.

Re: 86 Silverado K20 12V CUMMINS Build
 

You need to find someone near you with the timing kit and add some timing. That is a well worth mod on these. Around 15 is great for a DD/tow rig with minimal mods.

Re: 86 Silverado K20 12V CUMMINS Build
 

I have done a fair bit of homework on this and yes timing will need to be done. I was looking at kits on-line when I was getting ready to install the pump but they are pricey. Not something that would be used very much but would make a very nice addition to the tool box collection for sure. I plan on doing all the adjustments and mods on the p7100 after I get it drivable. Then I can have a comparison for turning etc.
Your not that far from southern Ontario are you? ;)

Re: 86 Silverado K20 12V CUMMINS Build
 

You can get them from Snap-on for $189. When I purchased mine I paid $489. Yes, I'm more than bitter about that. :lol:

Re: 86 Silverado K20 12V CUMMINS Build
 

You and I are less than a hr apart . We can split on Ryan's travel costs and he can tweak my pump as well . lol. Truck is looking good . Like your new heater as well. Im just in the process of rigging up a waste oil heater . Go to YouTube some time and type in efficient waste oil heater. The guy in the vid looks like relic from beachcombers Heater is kick ass . He has done lots of homework to get it to this level

Re: 86 Silverado K20 12V CUMMINS Build
 

:lol: That could be a fun trip. Speaking of heaters, I managed to get a fuel oil/diesel burning furnace I have to get installed in my shop.

Re: 86 Silverado K20 12V CUMMINS Build
 

Ya I seen some on the internet and remembered thinking that was a lot of money. It would be cheaper than trying to get someone to do it at a diesel shop tho. 489 ya, that is a lot of money but I'm guessing you get to use it more than I would so eventually it would pay for itself.

If you had the p7100 pump we could just split the cost of the tool kit then figure out how to setup joint custody and which weekends etc :lol:

On the waste oil heaters, my buddy does alot of oil changes throughout the year and he stores the waste oil in a regular furnace oil tank and has it piped in to the heater. It puts out good heat. The fuel is free but he had high start up cost if I remember as he bought all new stuff. But if you could piece together some items from around the farm, shop, or kijiji you'd be laughing.

Re: 86 Silverado K20 12V CUMMINS Build
 

When you get to the point of adjusting your timing, let me know. We have two kits and I could probably send you one and let you borrow it.

Re: 86 Silverado K20 12V CUMMINS Build
 

If you can take a week off and come up here I am only another hour and a bit north of Brian. I can hire you to mount a cummins in my longhorn chassis. :)

Re: 86 Silverado K20 12V CUMMINS Build
 

2wd or 4wd?

Re: 86 Silverado K20 12V CUMMINS Build
 

Haven't decided yet. I would like to build 4wd but really don't want too big of a lift in it as its my daily work truck and I need access to the flat bed.

Re: 86 Silverado K20 12V CUMMINS Build
 

FWIW, back when I first got into my Cummins, the kits were still almost 500 bucks as well, made my own from instructions given to me on DTR, under 70 bucks complete. Works just as good as the pro kit :metal:

Here is the PM from a fellow dieselhead.

"Hey no problem, I dont mind helping.
Well, You can get a delivery valve socket from piers diesel for $30.
2. For the dial indicator, Harbor Freight sells them for $10, and it works just as good as an expensive one. It has been used ot the forum more than once. The only prob. with it is it is in inches. That isnt a big deal, because if you search on DTR people have converted the mm to in. measuremens.
3. For a dial indicator holder, you can use a drain plug from our cummins. I went to autozone and they had one for $5.00. You just drill out the center so the dial indicator slides in there. Then you need to drill and tap a small hole for a set screw in the side of the drain plug, so the indicator doesnt move.
4. For the gear puller, any cheap steering wheel puller will work. You can get them from auto parts stores, for under $20.

I did mine this way and it worked out great. I looked on ebay and came across a metric dial indicator for cheap, after I did it with the inch dial indicator.

There you go, under $70.

Also, I dont recommend it, but I have read on here people use a set of chanel-locks and a rag to get the delivery valve holder off. The only prob. with that, is re-torquing the holder, to much and you will tear the o-ring and you can only get it at a bosch dealer, I guess its some weird size."

I am sure prices have gone up a tick since then, but not that much.

Re: 86 Silverado K20 12V CUMMINS Build
 

well this is too funny. brimc, i just happened to stumble across this thread and thought that truck looked familiar. i remember that truck came up on kijiji years ago and i went up to see it twice as well! it was up in the wasaga beach area if i remember correctly? i was dragging my heels over the money and just when i was ready to pull the trigger and give the guy his asking price, i called him he told me that it had just left the driveway. man was i kicking myself haha. glad to see it went to a good home though!

Re: 86 Silverado K20 12V CUMMINS Build
 

Well that is funny. I too dragged my feet for sometime then after he reduced his asking price, I gave him a lowball offer he accepted. Thought I did alright because I actually just paid him and jumped in the truck and drove it home. It drove great. Wasn't till I found out about the dead cylinder that I felt I paid too much. All in all I'm glad I got it. It is taking me a very long time but I know it will be worth it in the end. Thanks for the interest. Hopefully have some updates soon!

Re: 86 Silverado K20 12V CUMMINS Build
 

Nothing really to update. Just getting the cab prepped. Final sanding on the bottom and finish prep the new cab corners and rockers. Plan on spraying the bottom first gravel guard sound deadner then paint. Flip it up then paint the entire cab. Want to have the entire body painted this spring.

Re: 86 Silverado K20 12V CUMMINS Build
 

Tired of winter yet. Much more tolerable than last year tho. How's your new heater working? I made a waste oil burning unit for my shop this winter. Had it working a few weekends now. It sure has been a welcome addition to my shop this year.

Re: 86 Silverado K20 12V CUMMINS Build
 

Tired yes. Winter just seams to take a lot more out of you. The heater in the garage works very good. Better then I expected. The built in thermostat regulates the draft to the firebox very good. It holds a good bit of wood too so it will go several hours before dieing out.

Re: 86 Silverado K20 12V CUMMINS Build
 

Did u ever get a transfercase ? You were looking for a divorced gm 205 ? I know sumone that has a trailer of treasure that he has been holding out on me. I could get in there and go scouting if ur still looking.

Re: 86 Silverado K20 12V CUMMINS Build
 

I backed off looking in this last year or so but anything I could find was just too far to even consider the drive or shipping. If you can find one of those that would be awesome :metal:

Re: 86 Silverado K20 12V CUMMINS Build
 

Well winter finally let up and I found some time to work on the project. The other day I pulled the cover off the frame and rolled it outside to clean up the garage some. I decided to hook up the battery and see what it would do. A couple cranks and the Cummins fired right up! No grids, no smoke, no problem. Hearing that engine idle smooth was music to my ears!
I also got the cab completely welded, sanded and prepped for the next step-paint. I again used por15 but only on the "rusty" areas and the "new" metal and mig welds. Time will tell on that call. Got the first coat of filler on the cab corners and rockers.

http://i1284.photobucket.com/albums/...pshtf4ytyk.jpg

I used short strand fibreglass over the welded seams for sealing and strength. I will go over that with a lightweight filler next to level it out.
I also got the entire bottom side of the cab floor and firewall sprayed with undercoat/sound deadner. Then sprayed a gloss black topcoat.

http://i1284.photobucket.com/albums/...pspaurf1sd.jpg

http://i1284.photobucket.com/albums/...psoaz198wq.jpg

I think it turned out pretty good. Hopefully I will get more to update soon!

Re: 86 Silverado K20 12V CUMMINS Build
 

Nice work! That's a good feeling that winter is nearly out of here. :lol: Hearing the engine fire up is always a good motivational tool too! :)