Over 25 Years Later, Finally My 71 C-10 Truck Build

[hgs_notes]

Thanks Bill. It's going better than I expected for me being a newby on body work. Small update. Finished welding the inner door panel. Still have some grinding to do, and I'll have to plug weld the inner braces back in yet. I also got the door hinges rebuilt this morning. One of the pins was reluctant to come out, but nothing excessive hammering couldn't cure. What a difference. The new pin kit has brass bushings, compared to the original plastic ones. They are smooth and tight now. I can't imagine why anyone would spend a couple hundred dollars for replacement or rebuilt hinges. The pins and bushings are about $15 and it only took me about 20 minutes to do both driver side hinges. The only tools you need are a vice, a hammer and a pin set punch.

[nuke1]

Looking really good! there is some serious progress happening here! keep it up and in no time you will be painting.

[hgs_notes]

Took it easy this weekend. I basically didn't want to be covered in metal filings and grit again, so took a break from the grinding. Instead, I went over to the storage garage and stripped out some stuff from the original cab. All that's left is the pedals, wiper motor, ignition switch and dash pad. Then it's time to get rid of it. Oh yeahm the rear slider and windshield trim also.

[hgs_notes]

I took today off from work, mostly because I caught a cold this past weekend and my head feels like a balloon, but I took care of some personal things also. I can't let an off day go without at least some progress though. My headers got delivered today, and about 20 minutes after I signed for them, they were installed. It sure is easier when there is no front clip on. No major issues. The #2 tube rubs the top of the motor mount bracket by the frame. I think I'll pull it off and clearance that spot a bit. They hang down a bit, but I don't have a really low drop. They are in about the same position as my old cheapo headers.

They are Flowtech 31500FLT headers. Ceramic coated and should work great for my tiny small block (283).
http://cgi.ebay.com/ebaymotors/ws/eB...K%3AMEWNX%3AIT




I also installed the alternator. Bought it off a board member. It fits, but has the wrong plug connector, so I'll have to find the right one or just put spade ends on and wire it that way.

[hgs_notes]

Didn't get much time today, but did manage to get the door skin off and grind down some welds. Also tacked in the inner door braces to the new inner panel. I found out the metal bracket holding the window glass was in tough shape. The channel for the rollers is bent up a bit and there is a crack on it. I'll have to decide whether to repair this one or canibalize one of the many spare doors I have laying around.

[nuke1]

Looking good bud, I too took a personal day, worked on the camaro, work was slow, so ...... anyways, great looking headers! very nice, door is looking good too, sure is coming along, just remember any questions just ask.

[hgs_notes]

Thanks James. I learn something or get better at something everytime I work on it. I tried to weld up the crack in the window guide and I think it turned out ok. I'll post a pic after the weld is ground down. Straightened the back channel piece better. Finished all of the welding for the inner panel and got most of the grinding done with that. Removed the vent window. Did some hammer and dolly work on the inner door flange to straighten it back out after removing the outer skin and spot welds. And I layed the new skin on to see how it fits. There are a couple little things to do before it will sit correctly, but I think it will be alright.

I ordered 50 sqft of fatmat. Got a kit from sounddeadener.com for $79 and it comes with a knife and roller. Pretty good deal. I have to go through my parts storage to see what window seals and felts I have, if any. I'll probably have to buy all of it.

There are still a few things to do before the new skin goes on, but I'm getting there. The other door should go a little better with the experience I have now.

I have a small sample of the paint I want and I'm hoping it is enough to do the firewall behind the engine. Then I can set the cab back down on the mounts and get a better idea of how stuff is fitting.

Does anyone know where to get those little square nuts that go in the doors for the door panel screws? I had a couple pop out and one that a screw broke off in I need to replace.

[nuke1]

It all takes time my young apprentice!!! LOL> patience is the key, let all of your troubles disappear and go to work, that is what I do, the best medicine is this stuff if you ask me.
Just to let you know,, I saw what was under your name, I drew this 4 years ago and got it put on me!

[hgs_notes]

Originally Posted by nuke1

It all takes time my young apprentice!!! LOL> patience is the key, let all of your troubles disappear and go to work, that is what I do, the best medicine is this stuff if you ask me.
Just to let you know,, I saw what was under your name, I drew this 4 years ago and got it put on me!

Patience huh? Some would call it procrastination.

Nice tat. I don't have any, just scars. Here's what my avatar was shrunk down from. I did a search on yahoo years ago for gear head and this is one of the images that came up. I loved it.

[hgs_notes]

I really wish I had more progress to report, but what are ya gonna do? Yesterday was spent with my oldest kid and wife at the U of MN campus for a open house. She'll be going there in the fall. Just got the estimated costs...ouch. I also procrastinated on ordering the sound deadener so it won't be here until tuesday. So I just finished up some things on the door to get it ready. Followed some of nuke1 metal dressing and ended up re-welding a section. I had the butt weld slightly misaligned so when it sanded flat I could see the line of the two pieces together. I added some weld on the inside which should make it stronger.

I kind of fixed the sash channel. It had a bow to it, the channel was banged up and the glass did not fit so well in it. I'll have to order a new rubber for it. Anyway, the driver door should be finished later this week.






I was thinking about using my paint sample, but now probably won't because it takes a different hardener than what I have now, and is not the same type of paint I'll be using later, so buying a bottler of the right hardener would probably be a waste. I'll set the cab back on the mounts and start fitting up the panels as I go.

I also pulled more parts off the old cab today. About all thats left is the rear window and windshield trim.

[hgs_notes]

Busy day today. I worked until about 2:30, then headed out to the garage. The fat mat came via ups today, so I layed that on the door skin. Sure is easy to do when it's open like that.


I sprayed some primer inside the door the other day. I drilled the holes for the mirror, and tack welded the brace inside the skin.



Then I cleaned up the edges where the skin meets the inner door flange, applied the panel adhesive and set the inner on the skin. Started hammering the flange over bit by bit.



Then did it some more until it was as flat as I could make it.



I used a hockey puck as my dolly. I used a vise grips to clamp a couple spots and it did dent in the bottom edge of the skin just a bit. I little filler will take care of that.

[hgs_notes]

After getting that door back together, I had to see what it all looked like. I got a few bolts out and put a couple panels on. No adjustments have been made here, just wanted to see it look more like a truck, even for just a day or two.

[lyrikz]

your doors fit awesome.

Mine suck. Trucks looking really good.

[my67chevytruck]

great progress!

[wancosc356]

Great work man! I think I might cut my doors open like you did, just to clean it all up and put some sound deadener in it.

[hgs_notes]

Originally Posted by lyrikz

your doors fit awesome.

Mine suck. Trucks looking really good.

Thanks, it looks better from the side than from the back looking forward. It's coming back off for primer anyway. I'd like to see some progress on yours.

Originally Posted by my67chevytruck

great progress!

Thanks!

Originally Posted by wancosc356

Great work man! I think I might cut my doors open like you did, just to clean it all up and put some sound deadener in it.

Thanks, but I don't think I would recommend cutting the doors open unless you had to for rust repairs anyway. This one door was a ton of work, I have no idea how many hours I have in it, plus the frustration of panels that are not stamped the same as the originals. I'm happy it turned out, but I am not looking forward to doing the other door. This was by far the hardest "body work" project I did so far.

[nuke1]

Looking really good! just beware of the nibbler bits, they get into everything, and I mean everything, check your socks before going into the house, they follow you around then the wife steps on one and all H#ll breaks loose, trust me.

[hgs_notes]

Originally Posted by nuke1

Looking really good! just beware of the nibbler bits, they get into everything, and I mean everything, check your socks before going into the house, they follow you around then the wife steps on one and all H#ll breaks loose, trust me.

They do look like sharp little nail clippings made of steel huh? And she likes to be barefoot most of the time.

[Palf70Step]

Originally Posted by nuke1

Looking really good! just beware of the nibbler bits, they get into everything, and I mean everything, check your socks before going into the house, they follow you around then the wife steps on one and all H#ll breaks loose, trust me.

Originally Posted by hgs_notes

They do look like sharp little nail clippings made of steel huh? And she likes to be barefoot most of the time.

Oj YeaH, been there done that. My wife, like most in the south, go around barefoot (in the house I am not sexiest )

It is NOT FUN hearing about it for the next several decades (yeah, I still hear about it )

[hgs_notes]

With both daughters starting softball this week, I didn't get much garage time. I finished fitting up the inner door panel on thurday, and finished welding it out today. There is a little more to do to finish it up before filler and primer, but it's very close now.

[hgs_notes]

I was able to get most of the filler work done on the inner side. Just need to scuff/sand and clean it, then the inside is ready for epoxy primer. I'll probably do the driver side inner also and spray both doors at once. Then do the outer skins and get them in primer next. I used a zinc primer for the hinge areas. That was bare metal from the factory.

[hgs_notes]

Duck, duck, gray door!

Not a lot done, but progress is progress. Between chasing after kids games, and taking a few days off with the wife, there just hasn't been a lot of spare time. I primered the hinges also. After this is mounted back up, I'll do the same to the other door.

[hgs_notes]

Yesterday I got the driver door inside primered. The transition areas for the inner door panel turned out ok with some filler blending them in. Both doors are now mounted. I'm having a little trouble with some door gaps. The top and bottom on the driver door are real tight. These are doors from my original cab and with the new door skin and inner panel the door may have ended up being a bit taller. I don't know. The passenger side one is tight also, but not as bad. The gaps on the rear edges are good.

I guess the next step is getting the outside flat and smooth and in primer.








Blended the innner dor panel in, you can see the corners are not the same bends:

[nuke1]

One more thing, movethe door down to wher the top gap is good and cut the bottom off and weld it back up, but make sure the body lines match up first!!! BTW< it sure is coming along good, sure gettintg there, keep it up.

[hgs_notes]

Originally Posted by nuke1

One more thing, move the door down to where the top gap is good and cut the bottom off and weld it back up, but make sure the body lines match up first!!! BTW< it sure is coming along good, sure getting there, keep it up.

The thing is, the body lines are pretty good now. Rookie mistake. Should have checked for fit before I glued the skin on.

I ended up having the door just a bit too tall to fit the door opening properly. If you have the rocker already replaced or set in, you need to make sure the panel is in the right position on the door. They can be moved around a bit, mine should have been slid upwards about 1/8 - 3/16" for a better fit. If the rocker work will be done later, no problem, just fit the rocker to the door when you do that. Also, avoid using any hard clamps like the vise grip style to hold the panel in place because it will dimple the panel and need some filler work later to flatten it back out. A softer spring clamp with a broader tip would be better.