41DegreesSouth Build Thread

[ryanroo]

Originally Posted by Billhilly

This, intrigues me....

i was using a router to machine aluminum in my garage last night. still chilly enough to have the heat on in the garage, had to keep the doors closed. i was sad i couldnt share the sweet song of 25,000rpm carbide spinning in 6061 with the whole cul-de-sac!

its my guess that they are all wondering when i'll move... HA

[Billhilly]

Originally Posted by ryanroo

i was using a router to machine aluminum in my garage last night. still chilly enough to have the heat on in the garage, had to keep the doors closed. i was sad i couldnt share the sweet song of 25,000rpm carbide spinning in 6061 with the whole cul-de-sac!

Ahhh, starts to make a bit of sense now! I'm pretty lucky around here. Only one neighbour across the road I have to worry about.

[Billhilly]

Another paint day today. Replaced the bodgy patch on the antenna hole, got the front guards prepped, and then etch primed, and primed everything, then top coated the underside of the cowl and the inside of the guards. Tomorrow should be top coat on those three bits and the tailgate. Underside of hood is done, top will be done as a seperate run apparently.

[1985-GMC]

Nice progress!

[Palf70Step]

[Billhilly]

Thanks guys! Trying to keep at it! Working towards getting the doors finished and off for sand blasting. Installed the door motors. Just welded a small tab to the existing lever and bent up the connecting rod. With the motor bolted straight to the back edge of the door with a couple of 1/8" bolts, the pull is pretty much vertical out of the motor. Pretty clean and simple. Drilled door and A pillar for wiring. Only panel work required is where the original camper mirrors were bolted on. When the bolts were done up it pulled the panel quite a bit. Need to get the doors off, then cab dismantled and lifted off next.

[1985-GMC]

Very nice! I've never wanted it before but recently I've been contemplating putting power door locks in my trucks. It does come in pretty handy.

[ryanroo]

I agree. Never cared much for power doors, but I'm really considering windows and locks. More locks than windows. Looking good billhilly! Still digging that color!

[Billhilly]

Originally Posted by 1985-GMC

Very nice! I've never wanted it before but recently I've been contemplating putting power door locks in my trucks. It does come in pretty handy.

Thanks, yeah, it's part of a bigger plan (see below).

Originally Posted by ryanroo

I agree. Never cared much for power doors, but I'm really considering windows and locks. More locks than windows. Looking good billhilly! Still digging that color!

I'm now waiting to see all the painted pieces actually bolted together back on the truck. Still kind of hard to visualize the finished product. But thanks again!
I wasn't that stressed about power door locks, but when they failed on my DD I could see what a pain it was without them. Also, I'm going to make a half height topper (?)(or cap?) over the bed for my work tools, so in theory I will be able to put motors on the door latches on that and lock up the whole deal with one click. That was more of the driving force. Easiest to do it now, and just another item to slow down/complicate the build!
So the hood was finally done nearly ten days ago. Cowl is all bogged and ready for one last prime/paint. Work/life has over taken the last two weeks so hopefully this week will open up a little for me. We shall see!
Ryan, a couple of pic's below show the 'panels' I attached to the stock battery box's to give me more 'wiring' space. On the left hand one, beside the mega fuses is where I was going to mount all my relay's and figured something like your flush mount one's would make for an much tidier finish.
Rubbish photo's sorry, the upper box on the right hand side is an external regulator. I have a 150 amp Zena Welder there in place of the alternator. It can switch between being an alternator, and welder. The bottom box is the welding controller. Cause it's going to be my work truck I figured you never know when someone might need a small welding job done away from mains power. (I also got it for half price!). I also picked up a second hand Redi Line generator for real cheap. I'm going to mount it in the front corner of the bed for mains power for a small angle grinder/drill.

[ryanroo]

I totally dig the idea of a welder. i had that idea a few times, but in the end i decided it wasnt a necessary add on for my truck. i am dealing with confined space as it is anyhow and the reality of it is that i will probably just drive my truck and pull trailers once in a while. it wont ever be for serious work... haha i am already planning the 'for everyday use' build on my yellow truck so i dont have to drive the spiffy one everywhere if i dont want.

those relay holders are this

https://www.alliedelec.com/te-connec...1002/70199126/

they work with the normal 4 or 5 pin Bosch/Tyco relays. they do require a certain double crimp terminal to lock into the holder. they are linked in the lower part of that web page. they interlock so they can be mounted in a gang like i did, or they can be mounted individually.

[1985-GMC]

Now that'll be cool! I've never seen one of those.

[Dieselwrencher]

Great build you have going on here! It's turning out super nice! I really like the sway bars you went with. I might think of adding them to mine at some point. Don't feel bad about your build taking so long to complete. Mine has been a real long time too. I was reading through your build and it was going through my head all the little stuff I have and need to put on my truck. Gee whiz. Good luck getting it painted and together soon!

[Billhilly]

Originally Posted by ryanroo

I totally dig the idea of a welder. i had that idea a few times, but in the end i decided it wasnt a necessary add on for my truck. i am dealing with confined space as it is anyhow and the reality of it is that i will probably just drive my truck and pull trailers once in a while. it wont ever be for serious work... haha i am already planning the 'for everyday use' build on my yellow truck so i dont have to drive the spiffy one everywhere if i dont want.

those relay holders are this

https://www.alliedelec.com/te-connec...1002/70199126/

they work with the normal 4 or 5 pin Bosch/Tyco relays. they do require a certain double crimp terminal to lock into the holder. they are linked in the lower part of that web page. they interlock so they can be mounted in a gang like i did, or they can be mounted individually.

Yeah the welder thing was outa my price range, but a guy down here had bought some Zena stuff in and it didn't sell, so half price to me! Thanks for the link, I found some Hella ones local. They will be here this week. Didn't know how I was going to handle the relays so was timely seeing your deal.

Originally Posted by 1985-GMC

Now that'll be cool! I've never seen one of those.

Don't know how much it will get used, but I needed a new alternator anyway. And it continues to over complicate things!

Originally Posted by Dieselwrencher

Great build you have going on here! It's turning out super nice! I really like the sway bars you went with. I might think of adding them to mine at some point. Don't feel bad about your build taking so long to complete. Mine has been a real long time too. I was reading through your build and it was going through my head all the little stuff I have and need to put on my truck. Gee whiz. Good luck getting it painted and together soon!

Hey Ryan, Thanks! Yeah the time frame is starting to get embarrassing now! In my defense I took a bunch of time off in '07 and rebuilt my (120 year old)($$!!) house so it was more comfortable for my daughters (they've now left!) and was sick for a year starting 2012 so I've certainly managed to drag it out!
Oh, after working through the other Ryan's build thread, I am in the process of getting through your's! Looks very cool. You guys certainly lift the game. Plenty for me to think about!
Got a few nights in this week sorting through everything I had, and everything I need to order.... Lead time down here is a little longer than you guys have to deal with! Got the doors off last night and some basic panel work done. PO musta had something heavy (long?) under the seat and kept slamming the door on it... or was it the seat belt end? Who knows but he put a good little dent in there! Scraped the under seal out from the inside of the doors so I can treat the surface rust, and have just finished paint stripping the outer skin. Good (basically) rust free doors. Will sand blast the rest of the paint off.
Day's passing me by. Better get back at it...

[Dieselwrencher]

Nice work repairing the dents. My doors had weird located large dents in the doors. It really makes ya wonder how much stuff people used to cram in these things and slam the doors til they shut.

[Billhilly]

Must have taken some slamming huh! I've made it through most of your build thread. I see you spent the time and re installed the front fender seals. I've got new seals down here and was wondering if it was worth the agony of putting them back on. What exactly do they do? They stop spray coming through? And they were not on the base models, only on the higher spec trucks? Just another job to do but would appreciate your thoughts.

[Dieselwrencher]

If I remember correctly they were only installed on air trucks. They're supposed to deflect warm air from the engine compartment from getting in to the door jamb. My cab had the holes and I had the brackets so I figured I better put them back on other wise I would have regretted it later. Plus it might slow the dust down from getting in the door jamb too.

[Billhilly]

Really need to bring this up to date.....
With the doors done I moved back to the cab. With all the main rust repair done, I thought I'd get everything sorted in a couple of weeks, not! The cab had had a camper on and there was rust around the rear window, and a row of dome holes around the inside. I thought it was just surface rust but was proved wrong when I wire brushed it off. I managed to fill all the holes with the welder. The sunburnt roof ended up being much more pitted than I though as well. I wire brushed it, then paint stripped it twice. Then some DA action, followed by a couple of hours of hand wire brushing and phosphoric acid.

[Billhilly]

I wanted to carry a two stage hydraulic jack and tools in the cab so spent way to long making up holders for everything. I am also going to install three lap/shoulder belts so added am additional belt point for the middle shoulder belt. We have pretty strict rules for this sort of thing but managed to keep everyone happy. You can see where I mounted it below the rear window with a series of spot welds.

[Billhilly]

Again, to keep progress slow I thought I'd add my po' boy cowl hood deal. Well, instead of a cowl hood, I've got... cowl air. Anything to lower under hood temps, and propane loves the cold too. I will wait and see how everything lines up, as to whether I run some enclosure around the air cleaner or not. It'll be interesting to see how much flow I get. I didn't like how it looked once trimmed down so added the lip, and if I add a boot it gives something to bolt to.

[Billhilly]

The trip to the sand blaster was delayed a few days so the next/last big cab job was RHD wiper linkages. Easy huh!? Just follow the drawings in the assembly manual, how tough could it be? Weeell, The more astute of you may be able to spot a few 'inaccuracies' with the drawings, but I blundered right in and had to learn from my mistakes. Might come as a shock, but not for the first time! Anywho, My long suffering lathe guy had turned up a couple of critical pieces so the rest was just slice and dice. Ha! Ended up being one of those jobs where half millimeters and offset were critical, and clearance to the cowl was almost non existent. I may be out by a couple of degrees of sweep, but please don't judge me to harshly! I've never seen pictures of this, so I give you my interpretation of RHD wipers!

[1985-GMC]

Looking really good! That's a ton of work

[swamp rat]

That right hand drive has me pretty jealous, thanks for the update!

[Billhilly]

Originally Posted by 1985-GMC

Looking really good! That's a ton of work

Thanks! I couldn't believe that a cab that was basically 'ready for paint' could soak up so much time. The 'to do' list ended up running onto the second A4 page!

Originally Posted by swamp rat

That right hand drive has me pretty jealous, thanks for the update!

I don't think I will be doing another one anytime soon! My one bit of advice to anyone considering buying one of these trucks is to save yourself some money and spend more on a rust free (and potentially original paint) truck!

[sharpmark]

great photos thanks.
doing one of these up isn't for the faint-hearted especially over here!!!
well worth it in the end - I love driving mine

[Billhilly]

Originally Posted by sharpmark

great photos thanks.
doing one of these up isn't for the faint-hearted especially over here!!!
well worth it in the end - I love driving mine

Thanks Mark. Yeah, not being able to drop down to the wreaking yard and get spare parts is a bit of a drag!
I continue to underestimate the time required on this job! Anyway after three days of professional help the cab and doors are now ready for primer.
Then block sanding, seam and drip rail sealing and final paint!! It will get primed in the booth tomorrow and we'll bring the bits home for the final coat.
One step closer right.