Re: 71' Blazer Rust bucket build
 

Well my transmission help never did show back up and I got tired of waiting so i finally found a book with good detailed drawings and assembly order. Transmission is all together with new bearings, seals and gaskets as well as cleaned primed and painted. Got the flywheel, clutch, pressure plate, throwout bushing, motor mounts, fuel pump, water pump, oil pressure lineand heater hose fittings transferred. Bought some POR 15 engine orange paint to brush on as well. Don't care for the black Got all the engine pulleys and power steering cleaned up and painted.

Took the gas tank back out to install the factory spacers that I forgot to put in the 1st time. Saw them laying on the table and was like :jdp: got it all back together correctly now though.

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Re: 71' Blazer Rust bucket build
 

Now that i have my books I feel like I can go ahead and get the dana 20 back together.
In the next day or so I am going to get the engine & transmission set in place. Thursday Mama and myself are headed up to spring Carlisle and hope to find a front floor panel while up there. This one is not terrible and I have patches here for it, but after putting the new one in my panel truck, it seems to be the easiest way to go. If I can't find one I will just go ahead and repair this one.

Re: 71' Blazer Rust bucket build
 

This book is pretty detailed for putting stuff back together.

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Re: 71' Blazer Rust bucket build
 

Had a few minutes to work on it this morning. Starting to get it reassembled as much as possible while the body is off.

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Re: 71' Blazer Rust bucket build
 

Feels like i am jumping all over the place (I am :lol:) but it keeps me motivated to get this thing done. Thursday I took the wife with me to Spring Carlisle and sourced a new front floor pan. Only saved about $50 vs having one shipped but it put it in my hands right away. I am glad I took a 4 wheel wagon with me to get it back to the truck :lol: I am getting real close to wanting to get the body back on the frame so I figured before that happened I should pull the front clip off of the tub so I could do a couple metal repairs to the passenger side cowl area. I cut out the rust, Made patches, sprayed rust encapsulator down into the cowl innards with the supplied hose & nozzle that I got from Eastwood. Welded in new patches and started to grind it all smooth. Will finish that up today hopefully. Right while all that is accessible I am going to drill the spot welds out from the front floor seam and remove the passenger torque box (nothing left of the driver side) I will run some temporary screws in to keep it together until I get to the floor replacement. I need to search some threads to see if others have done the floor pan on or off the frame or if it makes a difference.

Re: 71' Blazer Rust bucket build
 

just some more random shots of the metal repairs

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Re: 71' Blazer Rust bucket build
 

I also mentioned earlier that i bought new Dorman 2.5" ramhorn manifolds. I bought some 2000 degree paint for them and decided to go ahead and get that done. I have an old oven here I use for small powder coating projects and figured I would bake these per the can directions. Holy hell the smoke on the 2nd and 3rd baking would kill ya if you don't have good ventilation. In the end they came out looking nice, guess time will tell if it actually was worth doing.
I also got in touch with my paint supplier to see if they can still cross reference my old Martin Senour paint code over to Nason single stage urethane so i can do some lower and cowl touch up. If that is a bust I will contact my sign paint supplier to see if they can. My sign paint is already a satin finish so that would help with matching up this old original paint.

Plan for today is finish up the front metal work, get the heater core box refinished with all new gaskets. The existing heater core looks to be in great shape and I am not a fan of the aluminum replacements so since I can't find an oem replacement at the moment I am just going to leave this one for now. The two places I know have the oem cores are both back ordered with no eta. I asked Wes at Classic Heartbeat to let me know when he gets them back in stock.

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Re: 71' Blazer Rust bucket build
 

Well I got some of what I set out to do and opened another can of worms as well.
I got the metal patches on the cowl ready for epoxy.
I got the heater box pulled apart, cleaned up, metal parts bead blasted & painted and have it ready to put back together once the paint cures. Got all new gaskets for it as well. Only hiccup is the fan blade is toast from leaves and dirt in the housing with it. I have a large pile of fan motors and not one had a real nice fan blade so I went ahead and ordered a new one along with a bunch of other stuff I wanted or needed.

The can of worms comes in the form of fender rust. It could not be seen until I pulled the front clip off the tub but the upper inner brackets that bolt to the cowl were completely rusted out. I had another set of fenders here that the outside of them were toast ,but the part I needed was in great shape. Soooo, I pulled them out, got to marking, cutting and drilling spot welds. Put them in the blast cabinet and cleaned up the surface rust and got them in etching primer. Cutting them from the old fenders was no big deal because the rest was scrap but getting the rusted section off the good fenders took some work. Drilled an 1/8" pilot hole in all the spot welds so I could keep an eye on the weld as I ground the old bracket away. I chose to grind it away instead of total drill out because the spot welds were almost 3/8" and I did not want to lose all the good metal as well. Hacked it up in smaller pcs with the cutoff wheel and it worked out pretty well. I got lucky on the 1st one and did not even have to trim anything. It fell right in place the 1st time. I will do the passenger side tomorrow. Gonna go work on the garden foe a bit before it gets dark.

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Re: 71' Blazer Rust bucket build
 

More pics of the fender repairs

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Re: 71' Blazer Rust bucket build
 

Do you have more pictures of the floor fix?

Re: 71' Blazer Rust bucket build
 

If you are talking about the orange rear floor, no, It is still in same condition as where I left off. I need to finish that up as well at some point. I guess it all depends on how deep I get into the front floor replacement this spring.

Re: 71' Blazer Rust bucket build
 

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Finished up the passenger side fender repair this morning.


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I still have to reassemble the transfer case. No clue why I am still putting it off now that I have the assembly manual that goes into pretty good detail. It is supposed to hit 80* here today and then in the 60's for the rest of the week. May spend some time out in the garden getting it ready instead of spending a lot of time on the truck today. Gotta get my fencing back in place to keep the varmits out. Time is getting short now to get everything planted.

I also realized that the new starter I have sitting here on the shelf that I thought was going to save me a few bucks is the wrong one. I was thinking it was a manual transmission starter and it is for an automatic. Oh well, it will still be here for another project.



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Re: 71' Blazer Rust bucket build
 

Glad I am not painting the entire truck. Has been a couple years since I bought any from the automotive store since I have a mixing station for my sign paints. My distributor for sign paints is back ordered by 6 months on a lot of my needed mixers so that was not even an option for me. 1 gallon of single stage urethane and quart of activator was $550.
Last time I bought any it was 1/2 that.

Re: 71' Blazer Rust bucket build
 

Any idea how hard it is to find one of these little bastards when you pull the shift shaft cover off before putting the cap back on to contain it. It is the spring loaded detent ball that I had just installed (2 of them) and realized as I was sliding the cover up to meet the case that my dumb ass forgot the gasket. Instead of walking away for a few minutes to collect myself, I snatched the shaft cover to pull it off and out of the corner of my eye watched this one shoot up in the air, bounce once then disappear into the abyss I call my shop floor. Knowing I would likely never find a replacement, the search was on. After removing everything in the immediate area very carefully and scanning the floor with my 18" wide magnet I came up empty handed. Lets start moving tables, nope not under there either. After 2 hours searching I found that this little bastard will roll a long ways. It was 25' away from where I was working laying right out in the open. Almost twisted my ankle when I stepped on it going to the office. Gonna sit here for a few and take a break before going back to try it again.

It took me an hour this morning to figure out how all that went together again only to have to pop it back apart for the gasket. Hoping 2nd time goes easier.

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Re: 71' Blazer Rust bucket build
 

I learned a new word today....perseverance... But I will be glad when the mechanical side of this thing is over with. I only ended up pulling this thing back apart what seemed like a million times before I got the shift rails to go back together correctly then 3 more times to get one set of gears back in correctly then 4 times to get the thrust washers to stay in place while I set the center gear set and middle shaft back in place. I used up all my cuss words yesterday so today was nice and calm. waiting on some primer to dry for the metal tag and locking clip for the center shaft so I can get it buttoned up and hopefully hanging back on the transmission.

EDIT: One thing is for sure. IF you have never done one of these (heck even if you have) take PLENTY of pictures before and during the breakdown. If I had not done that, even with the books I just bought, I don't think I ever would have gotten it back together. Thankfully I took plenty of pics before I removed something and right after I removed it for every step. Saved them all to the computer and ended up printing a lot of them out to lay on the table during assembly. Also don't leave it torn apart for weeks before trying to get it back together. Make sure you have everything ready to go.
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Re: 71' Blazer Rust bucket build
 

And finally back in the hole. I was able to source new urethane mounts for the dana as well.


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Re: 71' Blazer Rust bucket build
 

Took yesterday off to work in the garden getting it ready for planting but jumped back on the Blazer this afternoon. Jacked the rear up and put on stands so I could get the rear brakes changed out. Bought everything new including E brake cables. Bought AC Delco hardware kit and what a disappointment it was. Made in China crap that is ...almost..... exact but not quite. the tubular sleeve that goes in the adjuster arm and is held in place with the long pin was just a hair undersized and did not fit snug in the hole. Made reassembly almost impossible by myself but I finally got it. Reminded me of shooting pool with a wet rope. Passenger rear is done including new wheel studs, Drivers rear is pulled apart, small pcs blasted primed & painted waiting to go back on in the morning. Should be able to get that as well as the fronts done tomorrow. Also installing new pinion seals on both axles. Once i change them I can get the driveshafts back in. They have all new joints and I bought all new hardware for them. Also mixed up some red primer to go under the olive on the cowl to match factory layout, although I don't have much hope of it matching too well as faded as everything is. If I don't like it I will end up cleaning up the entire firewall and painting the whole thing.

Re: 71' Blazer Rust bucket build
 

Had to take a break from the mechanicals while waiting on a few parts so spent yesterday on rear floor metal work. Got all but 2 spots welded up, may work on it a little more later today.

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Re: 71' Blazer Rust bucket build
 

got the drivers side wheel opening mostly done. Got the long panel that I made a while back welded in and ground down. Still have to make the front section and get it welded in. Once all that is done I will remove all the braces from underneath, sandblast and epoxy prime it all and make sure there are no bad spots in those areas. Once that is done will put all the bracing back in and it will be ready for when the heavy work starts on the floor replacements.

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Re: 71' Blazer Rust bucket build
 

Also got all the brake and fuel lines ran and hooked up except for the 2 that come up to the master cylinder. Figured I would wait on them until I reunite the body and chassis. Plugged the openings so nothing gets inside while still apart.

When I removed all the old lines I took lots of pictures and I pulled the lines out complete and still in the frame clips so that it would make it a lot easier matching up the new lines as well as how they laid out on the frame and in the clips. I had plenty of extra clips here so was able to clean and paint them while leaving the originals for examples. I think it all turned out pretty well.


I am still not liking the rear brake hose. It is way longer than the original and had to drill it out for the mounting bolt. Gonna continue to search for the correct one.


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Re: 71' Blazer Rust bucket build
 

Looking good, coming along great. Nice to see you repairing stuff instead of bolting on aftermarket. A little more tedious for sure, but way more fulfilling when you can say Yep I did that ... and that, and that and that lol.

Ive never owned a 69-72 Blazer. At the end of this month Ill be going in to full retirement mode, so at the prices even the junkiest Blazers are going for they are out my budget probably forever.

Re: 71' Blazer Rust bucket build
 

Nice work on the lines, l like the way you painted the clips factory color, it's all about the detail in restorations.
I wasn't able to find that rear junction in OEM, went with a SS aftermarket, but can't remember where, my camera is down at the moment, but when it's working I'll take a picture. The length looks right for travel, BTW mine bolted right up
Keep going every thing looks great, are you using SS hardware?
Thanks for showing the rear-end vent wasn't sure where that bolted to.

Re: 71' Blazer Rust bucket build
 

Mark
with the price these things are selling for it would have been money ahead to just replace with aftermarket. Since I have no intention of selling an I already had the rear floor I figured I might as well use it. I did buy the new front pan though just so i did not have to mess with all the front support repairs. I am glad I bought both of my Blazers before the prices skyrocketed. I could sell the extreme bend hooks off the front of one for more than I paid for the whole rig.


Jim,
I definitely won't be 100% correct on the restore but trying to keep as close to original as possible. The rear hose that is on it now is almost twice as long as the original. I am using stainless hardware on everything I can. Most all of the bracketry got the black phosphate grade 8 hardware


Richard

Re: 71' Blazer Rust bucket build
 

Got the front hubs, backing plates and inner fender wells blasted, epoxy primed and in chassis satin black yesterday while it was nice out. Got the new rotors and hubs together with all new studs pressed in today and got the drivers side most of the way back together. Having an issue getting the lockout to work correctly. It is like the spring does not want to keep tension for some reason. Took it back off for tonight. Going to try the passenger side in the morning before I go back to this one to see if it does right or if I am doing something wrong. FedEx has delivered my pinion nuts to someone else so not sure if I am going to go ahead and put the old one back on the 12 bolt or not. I decided against doing anything to the dana since it was not leaking.

Still waiting on the correct fuel line for fuel pump to carb, I ordered the wrong one the 1st time.

I also have a pile of 2.5" stainless pipe and fittings sitting here to get the exhaust going I want to get it at least to the rear axle before getting the body back on the chassis. I know how I want my exit pipes to be but need the body back on to see if feasible to do it. I do know they will not be going straight out the back. That is how the other Blazer I have is and the fumes would kill you driving down the road in it. I like the look of the old Nova's and Chevelle's where it exits behind the rear wheel but is tucked and pointing down kinda like this.


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Re: 71' Blazer Rust bucket build
 

Finished up the front axle this morning. Brakes, hubs and tie rod ends all on. Just need to get fluid in the brake lines after body is back on. Picture of the part number for the rear seal as well.

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Re: 71' Blazer Rust bucket build
 

This afternoon had some time to work on the bed floor again and just about have it all patched. got some old roll bar holes to fill and one more rust spot about the size of a quarter to cut out, then I can flip it over and dress the bottom side. Once that is done, remove the cross sills so I can blast them and make sure no more rot. Get some epoxy on it all and put sills back on.

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Re: 71' Blazer Rust bucket build
 

My FedEx package was in my mailbox this evening when I went down so I guess whoever it was delivered to yesterday was nice enough to drop it by. I was nice enough to let FedEx know that i had it instead of letting them chase a ghost.

Re: 71' Blazer Rust bucket build
 

Looks like I may have cost myself some money and more time not knowing what I was getting into on the 12 bolt rear. Having never worked on one I should have read up or asked questions before jumping in on it. Had no idea changing front pinion seal would create issues (physical change was easy) just did not know about it changing the backlash and stuff that i know nothing about. What made me even question it was when I tightened up the nut after putting the yoke back on and nothing would turn. Looks like I may have ruined the crush sleeve which means it all has to come apart to fix it right. I am my own worst enemy sometimes :lol: Better to get it back right now vs tearing it up once out on the road. I will find someone local to come over and take care of it. :waah:

Re: 71' Blazer Rust bucket build
 

Still no progress with the rear pinion. The guy I have coming over, I just found out that his step daughter was killed in an auto accident so I imagine he will be a bit dealing with that. Not even going to bother him for a while. Even being a stepchild I can't even imagine.

With that in limbo I decided to get to work on the floor rust which has turned into doing all the rust since it is all tied together. No need to do it twice. I pulled the new pan out of the box to check it over and it looks pretty decent. Spent pretty much all day today getting the old floor pan out after I got the cowl area supported as best I could while still giving me access without having to climb inside. With the whole body just sitting on 4 jack stands on top of the table I did not want to be inside it shaking it all around. :lol:

Now I need to get the front lip cleaned up and do a little hammer dolly work where I sheared some of the spot welds. I was surprised that all the bolts holding the rear floor to the step up came off with no issues. Even the rusted out rocker box end plates and reinforcement plates unbolted. I did have to make a cut on the inside B pillar on both sides to gain access to the 2 top mounting bolts for the rocker reinforcement plates. Either way there is no hope of keeping the inside all in original paint since none of the floor will be original :lol:

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Re: 71' Blazer Rust bucket build
 

I did not really need the stepup pc but it was the only floor they had at Carlisle. I am going to disassemble the old floor and will likely sell bits and pcs of it after I make sure my other Blazer does not need any. The Small triangular rear cab supports are included with this new floor as well so I may end up letting the new ones I bought back in 2016 :lol: go if the other blazer is still good. I still have to figure out where I want to cut the B pillar inner patch as well. My light went dead so waiting on it to charge up so I can see up in there better. Trying to keep the lower front quarter patch seam behind the lower molding on both sides

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Re: 71' Blazer Rust bucket build
 

Note to self....if another front floor pan is needed for the other project, enlist help to put it in. The panel truck floor went it like a breeze without the rear step up. This one with the step was a pain in the ass but I finally got it in with the help of some loosely applied clamps.

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Re: 71' Blazer Rust bucket build
 

Looking good!
Who manufactured that floor, looks like a great stamping

Re: 71' Blazer Rust bucket build
 

I got it from CPI at spring Carlisle. It is a Dynacorn unit and seems to fit pretty good. Was a bear getting the front potion in by myself but finally got it. Just hoping I don't have to take it out too many times if at all.


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Re: 71' Blazer Rust bucket build
 

Thanks!

Re: 71' Blazer Rust bucket build
 

Thanks for sharing

Re: 71' Blazer Rust bucket build
 

Got a few minutes today to work on it so I tackled the minor rust on the radiator support. I bought a repair section a while back but it did not fit so great so i made my own. My bad spot was not real bad so I did not need that big of a pc anyway. Took 2 attempts but came out pretty nice. Still have to clean up inside the support and spray some encapsulator in there while it is more accessible before I weld the new patch in.


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Re: 71' Blazer Rust bucket build
 

I also have to cut out the inside front cup plates from both front fenders and replace with new metal. That should go pretty easy as well. Pretty much flat metal cut on a radius.


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Re: 71' Blazer Rust bucket build
 

I have had a hydraulic iron worker for years and years. It was the smallest one they make and is 110 volt. 45 ton model that has served me well over the years. I got this one because it was small enough I can actually load it up on the truck and take to jobsite and be able to run off generator if need be. I did not buy a lot of accessories with it when I purchased it. It came with the combo cutter for cutting angle iron, flat bar and round rod then I added a rectangular notcher for the opposite side of the punch for being able to notch angle iron when building my sign frames. I also bought a punch attachment to go with it but only ever had a 1/4" punch and die that employees trashed in no time. Over the last year though I had to buy some replacement parts for the punch end due to abuse so i got looking into the different attachments that are offered for this thing. The punches have actually come way down in price so i ended up buying a pretty complete set from 1/4" all the way to 3/4". Instead of buying actual sizes I ordered them all 1/32" bigger to allow for easier bolting. I also ordered some oval punches that are perfect for a lot of the Blazer/ burb related brackets. I messed up one of them and had to get another which is supposed to ship next week. On a whim I also ordered a 1/2" corner rounding attachment and a 6" press brake that goes in the notching station. I did not have high hopes but I put it on this morning and am impressed with it. Will be great for fabbing up brackets. 1st test was to bend a small lip on the inner fender panels that I need to replace and it worked perfect.

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Re: 71' Blazer Rust bucket build
 

Just tried out the corner rounder. Grinder will do the same thing but if I have a lot of stuff to do I will take the couple minutes to set it up. Luckily all the attachments change out pretty quick.

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Re: 71' Blazer Rust bucket build
 

Thats a very cool tool. I wonder if you could use some of those fittings on an "armstrong" hyd. press? Obviously you couldn't do the real heavy stuff but small pieces like you show maybe?