Re: Project: Montezuma
 

Back corner

Re: Project: Montezuma
 

Pass A pillar replaced and floor removed

Re: Project: Montezuma
 

Passenger lower firewall repair

Re: Project: Montezuma
 

Nice work, and nice work space too. :chevy:

Re: Project: Montezuma
 

-
Thanks for sending me the link Matt! Truck is looking good. You have done a lot of work to it so far. I will try to follow along to see how you are progressing on it.

LockDoc

Re: Project: Montezuma
 

Damn fine work

Re: Project: Montezuma
 

Need to get bigger wheels to allow clearance to install calipers. For now it will roll on orig 15" steelies.

Then I can figure out brake lines...

$175 from POL on tie rods and ball joints, $100 on KBS paint kit, $300 at napa on hubs/rotors/calipers, $70 at advanced auto on bearings seals and dust covers. All I needed was spindles from a square body which I got for free. Maybe 45 bucks on grease and some other random stuff I bought. So $700 total and that was buying the highest quality bearings/tie rods/ball joints I could get. To buy the same kit online would have been $1200 for 8 lugs and I wasn't too confident in the quality.

Im putting together some info on 8 lug swap here: http://67-72chevytrucks.com/vboard/s...d.php?t=804757
I will give a parts list there when finished.

Re: Project: Montezuma
 

Drivers side lower firewall repaired. Part 1

Re: Project: Montezuma
 

Drivers side lower firewall repaired. Part 2

Re: Project: Montezuma
 

Rear - Lower cab wall repairs

Chased rust in a few spots. Pretty thin in places around the factory welds.

Re: Project: Montezuma
 

Sealed up the seam on the firewall and rear of the cab where the floor will be welded up against. Going to topcoat the epoxy sealer with eastwood rust encapsulator product for added measure.

READY FOR THE FLOOR PAN!!

Re: Project: Montezuma
 

Job well done on ALL the work, AND the parts selection. An old set of rusty rotors that can take a little machining is a very good thing!!!

Was really glad to see your drum stuff go away!!!

Re: Project: Montezuma
 

Thank you, definitely been learning as I go. A lot of head scratching.

Really excited to put in floor pan and hopefully it goes smoothly.

Re: Project: Montezuma
 

Floor pan install

I cut 1" off both the front corners of the pan to make it easier to fit into place.
I cut off the lower firewall brace at an angle to make it easier for the pan to fit up into place.
I cut notches out on both sides of the front to fit around the humps over the firewall supports that connect to the floor.
I made a pie slice along the front drivers side edge to bend in the floor pan lip to fit past the pillar

Re: Project: Montezuma
 

I fit the front edge up into place ( with the help of two people) and trimmed where needed (as mentioned above). I didnt take pictures but I had to trim the front pan lip where it sits in the firewall lip, the 4" or so where the 'hump' comes up, that lip on the pan was too deep and caused the pan not to sit flush.

Once the middle of the front of the pan looked good, I clamped it, then raised the rear of the floor pan up to my old 'white line' I marked on the original floor.

I then took self tapping metal screws and started on the front, working my way on the inner halves of the floor pan. The outer portions needed to be bent down and really did not want to snug up to the firewall. Lots of screwing, pulling to get the whole pan to move forward. its close and my old measurements line up. It took about 2.5 hours for me to get it in there. I also had to take out the kick panel replacement because it was too tight to fit in floor. I will have to trim it and then weld it in once the floor and all is done.

The pillars are reproduction, and the rear holes in the floor do not appear to be forward enough to be bolted in to the floor. The forward holes look good. So I will probably just bolt the front two holes and weld in the back two. Not real happy with that but I didnt have much to work off of. I was pretty careful when replacing those, making sure all the angles and measurements were right. Im not sure why its like that, I gues its just the difference in repro parts. Not too comfortable with it though (inputs welcome).

Now im going to put the doors on and start test fitting with corners/rockers.

Next (i think) I will do the cab corners and then outer rockers. Leaving everything in with those metal screws till I get it all straight.

Re: Project: Montezuma
 

Holes not quite where I want them, but again my old measurements between the floor and bracing are basically dead on. A little confused. Not sure to keep going or what. Thats why I think ill see what doors/rockers/corners look like mocked up?

Re: Project: Montezuma
 

Exciting progress indeed

It blows my mind how people learn to weld and fabricate because it’s something I can not personally achieve

Re: Project: Montezuma
 

So the metal screws are great for smaller patches. For the big heavy pan that needs pulling into place, I should have started with the clamps, then used bolt/nuts to suck it up into place in the corners, especially. That did the trick.

Also had the rear of the floor pan (DS) a little high so my door didnt want to shut. Looked at the line I drew on the back of the cab and it showed the same. Adjusted it and now we are good there. Doors shut pretty good and line up.

Now ive got the task of rear pillars, corners and outer rockers. My outer rocker is giving me issues.... TBD

PICS of the floor sucked a bit more up into place. The PS pilar not quite lining up I think is a mix between inaccuracies with reproduction pieces and me not having a floor pan in place to know I needed another splice to give me more flange area to bolt to.

Re: Project: Montezuma
 

Rocker fiasco (possibly?) Looks to be meeting the inner rocker too low and gunna need quite a bit of pie cuts where it meets the cab

Re: Project: Montezuma
 

Looking good. Hope you get you rocker problem dealt with.

Re: Project: Montezuma
 

Checking the situation...

Inner rocker is not in the right place on the high-hump complete repro floor pan. The inner rocker ledge where the outer rocker sits on is slightly too high.

Pretty sure thats the tweak I need but going to get some measurements on a factory cab... Also im trying to find a set of original doors to avoid door skin and lower section repairs.

Re: Project: Montezuma
 

Cleaning up the old cab corner job. They cut off the bottom few inches of the original corner and put the replacement over the rest. Used about a gallon of rubberized sealer and filler. Removed all of the old...

Re: Project: Montezuma
 

Mocked up cab corner. You can see the back will need to be spliced and dropped to match the rear cab line (but ill deal with that after the rest is done). Also had to cut a small piece off the floor pan to get the corner to sit in where it needed to. Small cuts around the curve to get it to shape right.

Re: Project: Montezuma
 

Corner cut to fit and put in place

Re: Project: Montezuma
 

Rocker mock up and inner pillar cut to fit. Pillar will need a few splices and metal added. Cab corner is going to be cut along the door gap and moved over to match the rest of the gap distance. Rocker will need big time cutting along the outer edge and tweaked to get gap to match.