Project 1966 K20 adventure rig

[72cs20]

Originally Posted by layinrocker65

Who makes those storage boxes?

https://www.zoro.com/buyers-products...commended=true

[layinrocker65]

Thank you

[72cs20]

Still progressing with this beast and finishing up the detail work.

I finally got around to installing shocks at the rear axle. They are Bilstein 5100 series units. The bushings on these shocks use 1/2 Inch bolts. To fit 1/2 inch bolts into the upper factory 3/4 inch mounting holes, I used some 3/4 inch outside diameter dom tubing with .120 wall(.510 inch inside diameter) to sleeve those upper mounting holes. The lower mounts are stout aftermarket sourced with 1/2 inch bolt holes.

To address the driveline vibration at 50+ mph, I've decided on CV joint at the transfer case end. And at the rear axle end I used a 4 degree shim to get the pinion and driveshaft on the same angle. I also had to change out the t-case rear output yoke to a CV style. Should get the driveshaft back from the shop next week.

The interior configuration is now the way it is going to stay so it was time to trim down and bend the main transmission shifter. I put some heat to it and made a bend towards the driver. Then I removed about 8 inches between the bend and the shift knob. Then I welded back together. Way more comfortable shifting position now.

[72cs20]

I had some air conditioning tasks to take care of. I never really liked the rotary knob control panel that came with the system. So I bought the newest control panel that is out now for the 64-66 trucks. It is pricey but way nicer and is also backlit.

In addition to the nice factory style ac vents there were still two ducted outputs from the ac unit that needed to be finished. I didn't want to use the whole lower duct assembly that came with the VA system. So I cut off the section I did want to use and rtv sealed off the open end with some thick cardboard. Gave it some black paint. Screwed it to the dash and ran the ducting. Great air flow now.

[72cs20]

Time to deal with the front bumper. The old pto winch mount is cool so I'm going to re-use it. I have an old Warn 8274 winch that will look good and work well on this truck.

The pto winch and its bracketry was mounted in this bumper almost permanently with a lot of thick steal. Very well done. It all had to be cut out with a grinder and cutting torch.

I then cut out enough of the middle to fit the Warn winch mount. Today was just mock up day to see how it all fits. Tacked in a few places and bolted to the truck. It fit nicely.

Then I set the winch in place to check fit. Pretty good but I think tomorrow I will move it down one inch and to the rear an inch.

[72cs20]

Winch and bumper fit up done. Moved the winch mounting plate down and back one inch. Bolted in with grade 8 1/2 inch hardware on 1/4 inch steel L-brackets. I cut the front bumper into two pieces and bolted her up. A little hammer work to the bumper and some paint and this step is off the whiteboard.

[joesscamaro]

That turned out great! Looks awesome!

[350TacoZilla]

Nice! Good work man, one step at a time. I always think of the old forestry trucks with those bumpers, just need the headlight guards added lol.

[72cs20]

Thanks for your inputs guys!

One more thing before paint is tow hooks. Again I scrounged around my stash of miscellaneous brackets and found a couple that would make good backing for anchoring tow hooks. Done!

I will be completely going through the winch soon also.

And a couple of shots after paint.

Last pic is of a brush guard that I've been test fitting. Picked up at a swap meet a couple of years ago. It had a tag on it that said 1960 F-250. It seems to fit the body lines of the Chevy well though. I haven't decided yet if I want to use it . The truck has a much cleaner look without it

[cwcarpenter98]

The winch and bumper looks great. I like the look of with and without the brush guard. That's a tough decision

[350TacoZilla]

That looks great on there. For me 100% with brush guard and maybe add small support from middle bar of guard to the rear of bumper.

[The Rocknrod]

That is a pretty cool brush guard, most people don't have them so it'd be a cool thing to have on there especially for the look your going for.

[72cs20]

Today was weigh-in day. Drove over to the local scale and weighed in at 5500 lbs. That's with me in the seat, full 31 gallon gas tank and the truck as shown in the pic below. Add another 100 lbs for the bed floor boards and headboard cover. This truck has a GVWR of 7500 lbs. That leaves 2400lbs for the build out to travelling weight. One of the goals is to keep the weight below the GVWR.

There is now 208 miles on the odometer. Braking, steering and overall handling are excellent. It's a good driver.
The driveline vibration mentioned a few posts ago is solved. Turns out the linkage for the front axle shift lever was binding up enough to not dis-engage the front output shaft. Re-adjusted that linkage and now smooth over 50mph. I also finished up my pinion/driveshaft issue with some 2 degree shims under the rear springs and a CV joint at the transfer case end of the driveshaft.

So far, overall, everything is working well. Still needs some tweaks here and there. Nothing major though.

[bsarts]

Congratulations on your accomplishment! That's a beautiful truck.

[The Rocknrod]

Nice work.

[layinrocker65]

How’s that overdrive box working? Project looks awesome.

[72cs20]

To everyone who has commented, complimented and suggested. A big thank you! It's all good for the motivation!

Will definitely be re-visiting the brush guard fit up.

About the overdrive. I'm not going to call it a resounding success but it does do what it is suppose to do. The truck will run 65mph at about 2300 rpm. This is with 4.10 gears and 31.5 tires. So that part is good.

On the downside it is noisy. I had heard these had some gear whine and now I can personally attest to this. Thankfully it isn't too bad in 4th gear, the most used.

It leaks where it mates to the main tranny. I followed the instructions very carefully and that's where I messed up. Silicone is used and I should have used more than the instructions called for. They called for a "paper thin film" but this is not adequate. A quarter inch bead would be more suitable. So now I have to disconnect the tranny and move it back far enough to clean the mating surfaces and apply a proper amount of silicone to keep it from leaking.

But, back to the details of re-assembly. Today I re-installed the radiator overflow tank and the windshield washer reservoir with all their plumbing. Just need to wire up the washer pump.

[The Rocknrod]

That radiator, who makes that one?

[72cs20]

Originally Posted by The Rocknrod

That radiator, who makes that one?

That is from Cold Case Radiators.

Thanks Joesscamaro.

[joesscamaro]

Your rig is looking awesome and congrats on putting miles on it. I'm sure it's a good feeling!

[bsarts]

If you tear it down to reseal that overdrive, don't use silicon again, use an anaerobic sealer like Locktite's gasket maker. Smear it around with your finger, not too thick.

[72cs20]

Originally Posted by bsarts

If you tear it down to reseal that overdrive, don't use silicon again, use an anaerobic sealer like Locktite's gasket maker. Smear it around with your finger, not too thick.

Thank you for for that tip. I actually did use the Locktite version for gear oil applications. Silicone is the term they use generically in the instructions. So, I either did it wrong or didn't use enough and now there is a drip. It's very slow. But because I hate leaks so much, I'll need to get this done sooner than later.

[350TacoZilla]

I'm not sure if I'm surprised the weight isn't more or isn't less lol. 5500lb sounds heavy vs what these trucks in 2wd form normally weigh but almost seems like it should weigh more with the bigger 3\4t 4x4 running gear, sm465,OD and transfercase. Either way I'm happy your getting close to just being able to jump in it and go here soon.

[72cs20]

Originally Posted by 350TacoZilla

I'm not sure if I'm surprised the weight isn't more or isn't less lol. 5500lb sounds heavy vs what these trucks in 2wd form normally weigh but almost seems like it should weigh more with the bigger 3\4t 4x4 running gear, sm465,OD and transfercase. Either way I'm happy your getting close to just being able to jump in it and go here soon.

I was hoping it would come in around 5k. But now 5500 seems about right since everything I put back into this truck is bigger and heavier than stock. And now the truck is at the point where I'm confident I can hop in and use it for everyday transportation. It isn't finished, but certainly functional and useable.

This last week I got a few more things crossed off the whiteboard. Dressed up some wiring behind the dash, dove into the winch and made a more permanent attachment for the mud flaps.

I bought the winch inoperable years ago but these 8274's don't generally catastrophically fail. It is usually corrosion on wiring connections or one or more of the relay's go bad. So I installed a new updated relay and wiring kit and now it is a working unit. Now I just need to decide whether to use wire rope or synthetic for the winch line.

I had the mud flaps temporarily hung with eye hooks and threaded links. The flaps would fly up in the wind and the links were noisy going down the road. Now they are bolted to some welded in angle. They shouldn't fly around or make any racket while driving.

[Captainfab]

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