Project 1966 K20 adventure rig

[72cs20]

Originally Posted by Captainfab

Is that relay update for the winch a kit or did you assemble it yourself?

It came as a kit from winchserviceparts.com. I bought it at least 5 years ago and there are some deficiencies.

My kit did not come with the nuts for the large posts on the relays. It did come with the small nuts for the new 5 wire remote plug pigtail.

The cable that goes from the relay pack to the F2 post on the motor was too short. I had to re-use the old one.

The new relay pack mounting plate is different. The new one does not allow the positive battery lead to enter the relay pack from the back, like the old plate does. Now the positive lead has to come in over the top of the motor. So now there is about a foot difference in length between the negative and positive cables at the battery end.

Does not come with new boots for the three post connections on the top of the motor. The boots on this winch are in great shape, so I was able to re-use them.

Hope this was helpful.

[Captainfab]

Thanks for the info

[350TacoZilla]

The bed looks good man, the headboard can be updated at a later date for sure. So where is first trip to again? Alaska? lol

[72cs20]

Originally Posted by 350TacoZilla

The bed looks good man, the headboard can be updated at a later date for sure. So where is first trip to again? Alaska? lol

Thanks.

A 6 to 8 week road trip through western Canada and Alaska is the ultimate goal. But prices for used pop up campers are crazy high. Even 20 year old units needing work are 9k and up. No thanks! So I'm seriously thinking about building my own unit. Something comfortable to sleep two. Made out of wood, 12vdc power and lpg heat. Nothing too fancy.

But in the meantime I'm putting the truck to work. Got a little side job doing some erosion control terrace work. Went to the lumber yard to pick up the material.

Also filled up the fuel tank and got a calculation of 10.5 mpg for the last tankful. 400 miles now on the new engine so hopefully the mpg's will get a little better as it breaks in.

[72cs20]

Not much progress on the to-do-list the last week or two. But I started looking at what to do about the front leaf springs. With the weight of the front bumper and winch, the front end is sagging a bit

The old front springs had an extra leaf to compensate for the very heavy pto winch present when I took ownership. I wasn't sure I would need to do anything to the new springs with the electric winch, but it looks like they'll need some help.

Then I got to thinking maybe I'll do something to level out the stance a little more as well. I got out the jack and jack stands and played around with some various heights. I think I've settled on a 4 inch lift on the front. And this will still leave a slight rake to compensate for load.

The first pic is stock and is 22 inches to the bottom of the winch fairlead. The other two pics are 26 inches to bottom of fairlead.

I'm going to start calling around to see if I can get stock type springs made with to provide the extra height I'm looking for.

Any thoughts?

[350TacoZilla]

I cant remember here, was there a reason you didn't want to go to the 73+ style for off the shelf options? I have no issues with calling a local place for a custom pack but usually cheaper to go with off the shelf and makes it easier down the rd (or on the rd) for replacements.

[72cs20]

Originally Posted by 350TacoZilla

I cant remember here, was there a reason you didn't want to go to the 73+ style for off the shelf options? I have no issues with calling a local place for a custom pack but usually cheaper to go with off the shelf and makes it easier down the rd (or on the rd) for replacements.

One reason is that the suspension on these trucks work very well when in good condition. I knew I was going to completely go through everything, so it was easier to keep it stock. The stock type springs are still readily available.

I did look at updating to the 73+ front springs, but it looks like there would need to be modifications made to the bell housing crossmember. Or it would need to be removed. And the brake plumbing for the right front wheel runs along that crossmember. And honestly, at this point in the project, I'm not too motivated to make any big changes.

It's a good question though. I've always considered this an evolving project. The future may see an engine/transmission change and an opportunity to re-visit the front suspension.

So I did call around locally about spring work. Using my springs, it would cost about one thousand bucks. That's for re-arching and adding leaves. I said no thanks.

Fortunately, I kept the old front springs. I dis-assembled them and picked the secondary main leaf and the added leaf that installed years ago. The secondary main leaf has a military wrap at the front which I cut off. I cleaned and painted them. Then I removed the springs from the truck and dis-assembled them. Then I inserted the leaves from the old springs into the new and now had my own custom spring pack! They came out well. In the pics you can see the difference between the stock pack and the modified one

Now the front springs have a slight positive arch and provided 2 1/2 inches of lift. I think it looks just right.

[350TacoZilla]

Looks good man and doing it yourself is pretty satisfying I bet. I can't believe local shop wanted that much, cheaper to buy all new at that point! Makes you wonder how they stay in business if that's their rates just for a re-arch and add a leaf (or two). I have often made Frankenstein packs for my trucks to try and tune the ride vs hauling ability but have also had local place re-arch my springs for I think $100-150 but that was 10 years ago by now lol.

[72cs20]

Originally Posted by 350TacoZilla

Looks good man and doing it yourself is pretty satisfying I bet. I can't believe local shop wanted that much, cheaper to buy all new at that point! Makes you wonder how they stay in business if that's their rates just for a re-arch and add a leaf (or two). I have often made Frankenstein packs for my trucks to try and tune the ride vs hauling ability but have also had local place re-arch my springs for I think $100-150 but that was 10 years ago by now lol.

Quite satisfying indeed! Nice to re-use old parts and a few hours of time. I did need to install new longer travel shocks. The ride is firm and solid but not jarring. This old truck rides way better than my 2017 F-250.

Still working on and making adjustments to the little things. I made up a set of new spark plug wires to replace the old cobbled together set. Smoother running engine now.

The parts house engine fan clutch decided to fail in the locked mode. Amazing how loud it is in the cab with a locked fan clutch. It got replaced with a severe service Hayden unit.

Made an adjustment to the accelerator linkage at the throttle body throttle lever. Drilled a new hole a little higher on the throttle lever for a more smooth transition off idle. Much improved drivability.

And I finally dealt with the lack of brake adjustment slots on the brake backing plate of this 14 bolt axle. Drilled and slotted new holes and installed plugs. And I discovered that I had put an left side brake shoe adjuster in the right side. Sheesh!

Just another week of working through the to-do list to ensure a good driving classic. Not real exciting and thanks for reading and following along.

[72cs20]

The holidays and wet weather are gone so back to working on the truck.

I figured it was about time to get rid of that blue tape and patch the old gas filler neck hole. Done!

To enhance the usefulness of the bed, I attached some stake pockets and made side boards. Been doing a lot of hauling and test drives to accumulate miles. 662 miles now showing and no catastrophes yet.

In an effort to decrease the gear whine from the overdrive I drained the GL-5 75-90 oil and re-filled with Red-Line GL-4 MT-90. Noticeably less whine in 4th gear overdrive on the highway. It could still be very annoying on long trips however. We'll see how it goes.

With the bed deck, side boards and tie down gear in the drivers side storage box, the weight is now up to 5860 lbs.

[350TacoZilla]

As long as its not a mechanical fault causing noise what about another layer of sound deadening on underside of trans tunnel area or small shield around the OD unit itself with a layer on it?

[72cs20]

I have read that by design the straight cut gears make noise. Some say it isn't bad, some say it is. I'm not done working on making it easier to live with.

As you said, adding more insulating material or maybe a heavier weight oil could help. I like this thing. it's fun to use and I want to find a happy medium.

And by the way, Advanced Adapters told me over the phone that the reason they discontinued it was because of the noise complaints.

[72cs20]

There is now a bit over 1100 miles on the odometer and the testing phase is going well. In order to flesh any issues I drive the truck whenever possible and so far only the rear driveshaft has needed immediate attention. A vibration between 50 and 60 mph. It took a few tries but the driveshaft shop finally got it balanced properly.

On the to-do-list was to fix the overdrive unit leak. I decided to take the whole trans and t-case as one unit and back it out far enough to apply the necessary amount of sealant. A solid quarter inch bead around the tranny front bearing retainer and shove it back into the back of the od unit and it's good! No more drips. Unfortunately I got so busy with this I didn't take any pics.

Fixing the od leak required removing the seats and flooring. A good time to install the rear of cab covering before the seats go back in.

And after the flooring went back down, install the permanent shifter boots.

The front axle needed a new pinion seal. I removed the yoke only to find it in bad shape. Ordered a new one. The pinion shaft itself has a lot of play in it so it looks like the front diff will need some attention.

[GottaK20]

Hey man, this is one of my favorite builds on here, any updates?

[72cs20]

Originally Posted by GottaK20

Hey man, this is one of my favorite builds on here, any updates?

Wow! Time has flown by this year. Thanks for the reminder. Work on the truck continues. I'll get an update posted this week.

[350TacoZilla]

Oh yeah straight cut gears whine for sure. Muncie M20 & M21 are way quieter in car than M22 for that reason though straight cut gears are also stronger if all other things are equal.

I meant mechanical fault more like its not eating a bearing or something, the turn the radio up more till the problem goes away solution that ends up costing you 10x more to fix later.

[cwcarpenter98]

Welcome back! I like the new wheel and tire setup. It fits the look of the truck much better in my opinion

[72cs20]

Originally Posted by cwcarpenter98

Welcome back! I like the new wheel and tire setup. It fits the look of the truck much better in my opinion

Thank you! And I concur!

[straight6chevyguy]

Looking good!

[joesscamaro]

Great choice on the tires & wheels!

[72cs20]

Thank you fella's.

[350TacoZilla]

Definitely suits the truck! I like the old 9.00-16 tires but those are near hens teeth now so I have also started using 255\85R16 or 255\80R17's when I can find them. Currently both my wifes 1500 ram and my dad's ram 2500 are running the 255\80R17 mastercraft CXT's and they have been a good tire for us but kinda ridiculous that they cost more than a larger tire of same brand\model.
I really wish there was a redneck millionaire out there that would invest in a company to start remaking the old size's and tread patterns again, maybe even be a decent person that doesn't price gouge lol you know while I'm dreaming.