1997 Restoration

[Delancy]

I think you deserve a new, 0 mile odometer after this degree of work, which I have one somewhere if interested.

And new carpet!

 

[truthdetector]

I think you deserve a new, 0 mile odometer after this degree of work, which I have one somewhere if interested.

And new carpet!

Ha, thanks.

I was able to get a new front OEM carpet that is stored away until after the paint job. Haven't been able to find the rear wheel-well carpets or the rear main carpet, so I'll just have to clean those up.

I don't mind keeping the original number of miles on the odometer. Looking forward to seeing the number start with a 3 years from now.

 

[Delancy]

Ha, thanks.

I was able to get a new front OEM carpet that is stored away until after the paint job. Haven't been able to find the rear wheel-well carpets or the rear main carpet, so I'll just have to clean those up.

I don't mind keeping the original number of miles on the odometer. Looking forward to seeing the number start with a 3 years from now.

Kinda the same way on miles….. your project is an unrealized dream of mine, and my hats off to you.

 

[NKP Garage]

Ooof, that frame is in bad shape. Good thing you found it and are replacing it.

 

[truthdetector]

Interesting that the new frames come pre-corroded at the top where the seam is welded. Must be NOS.

Maybe I should hit them with self-etching primer to slow down the corrosion?

 

[truthdetector]

Waiting on parts to finish the rear windows. Today, I taped them up so I could take her out for a drink.

Also, whenever I would run the engine since rebuild, I would open the gas cap and it would release a lot of pressure, so I installed a new 105-series charcoal canister and that problem is now solved.

 

[Saddletramp]

Very interesting read.
@ARJMN should read

 

[truthdetector]

Installed the rear quarter windows and got other odds and ends done and have been driving it around on short trips to put the initial miles on it.

Got the A/C charged and it is holding pressure. The compressor kicked right in at the shop, but didn’t turn on the next day. There is pressure in the system still and there is voltage at the wire, so I think I need to adjust the shims in the clutch assembly.

Got an alignment done too:

 

[truthdetector]

Installed a new head unit, reverse cam, and dash cam. All Kenwood.

Used the same pathway that the license plate bulb wires take.

A zip tie to fish the wire through from underneath:

Made a second hole next to where the wire comes in from the license plate bulbs and used the grommet that came with the reverse cam:

End result is a disconnection point inside the hatch just like for the bulbs to make it easy to remove the bulb assembly or the entire hatch.

Finished product:

 

[truthdetector]

Previously tried to install a new antenna mast into the existing power antenna body, but couldn't get it to retract all the way. Not only that, but I couldn't get the new nut on the top to secure the unit to the fender. Turns out that some of the threads came off the top when the nut was removed a couple of years ago when I started this project.

So I said screw it and bought the manual antenna mast (86300-60030) since I hardly use the radio anyway.

Was able to pull the old antenna wire out into the fender with a pull-string tied to it. Then used the string to pull the new wire in along the same pathway.

Took some contorting, a couple of scrapes and cuts, and some patience, but it is now hooked up and I now have an antenna that is not flopping around along with some great reception for the radio I never use.

Since the power antenna assembly is shot, someday I'll tear it apart and see what junk is inside of where the plastic whip is supposed to go.

If someone wants a new power antenna mast with the toothed plastic whip for a 1997, hit me up.

 

[truthdetector]

First oil analysis...

 

[truthdetector]

Second oil analysis came in.

 

[truthdetector]

Long time since I posted, but I wasn't doing much with the rig other than driving it. The engine rebuild now has > 4,600 miles on it with no apparent issues.

Here is the most recent Blackstone report.

 

[truthdetector]

Next up ... @kelly saad

 

[Hurleyburly]

Any paint/body updates?

Those oil samples are incredible. I'm an A&P/commercial pilot by trade and those numbers are incredible. Just read through your entire thread and your attention to detail is spectacular. I have a '91 that I've owned/daily driven about 8 years (with the tractor 3-FE) that in the next year or so I will begin swapping now that I have a vehicle I can use for a daily (I will be going LS, since the 3-FE is becoming harder and harder to source parts for and after a couple wheeling/long trips of dealing with random parts failing/needing replacement that were difficult to source, and I'd like to be able to merge on the highway without fear of getting rear ended here in Atlanta) and figure while I'm at it- I'm going to pull the body off and go the whole nine yards. In for a penny, in for a pound.

Very curious to see your end result with paint from Kelly. Mine is mostly rust free, been a GA/AZ truck almost all of its life but it was originally (first 2 years) a NY truck. After reading your thread and seeing the frame treatment (I was originally going to POR-15 mine), I'm leaning more towards the SW 646 Macropoxy - seems a little more robust. Curious to hear your longer term thoughts/any difficulties in application/what you ended up treating inside the frame with (did you end up doing to Eastwood rust converter?). I intend to keep the truck for the rest of my life so I might as well do it right.

Curious (feel free to DM me) if you had a ballpark cost associated with your entire project to date. I know these things quickly spiral when you get into the weeds and I'm setting aside a chunk of change strictly for mine, and doing most of the work myself- but the paint I will be outsourcing.

Regardless- excellent job, one of the finest restorations I've seen on an 80 by an owner! Great work!!

 

[truthdetector]

Thanks for the kind words, @Hurleyburly.

Have fun with that LS swap! I originally considered that, but ultimately decided to just rebuild the 1FZ and keep the truck stock. Would definitely be tough to do with a 3FE.

I am also looking forward to the results of the body and paint work. My truck's body was not rust-free and required some significant body work. Kelly knows where to find the rust, even if you can't see it. I'd say there was 2-3 times more rust than was visible from the outside and the only way to properly fix it is to remove panels and re-weld them back on. That process is nearing completion and my truck should be getting paint in the coming weeks.

Application of the Macropoxy was kind of a pain, mostly because of doing it in batches is since you have limited time to apply it once it is mixed. I wasn't concerned with a smooth finish so I brushed it on, which left brush marks, but that doesn't bother me. For the inside of the frame I did end up using Eastwood products (rust converter, chassis paint, etc.). I'm sure it's not perfect, but I don't necessarily plan to be doing much driving on salt covered roads. I've also sprayed fluid-film inside the frame using the DIY want, but probably should consider having a pro do it with better equipment.

As far as "doing it right", I'm glad I spent the time and effort using a needle-scaler, wire wheels, etc. to really get down to solid metal before applying the epoxy. I was surprised by how much of the OEM frame coating looked fine yet was easily removed with the needle scaler. I'm confident that my frame surface was well prepped and now time will tell how durable the Macropoxy will be in the long term.

The overall cost is a lot. The project intent has always to be for my enjoyment like a hobby and not with any delusions that I could ever sell it for the amount of money that I have into it, let alone time.

The pursuit of parts is fun. Replacing old stuff with new OEM is really satisfying, and it all adds up. But I gradually obtained parts over the course of several years, so I wasn't spending the money all at once.

The biggest categories of parts purchases in my project have been body and engine, but the other categories add up too like brakes, suspension, exhaust, axles, air conditioning, and interior. I have purchased more than 2,700 new OEM parts (granted, many of which are fasteners). I'm actually glad the truck has been away getting the body and paint so I've had time to recover from my parts-ordering addiction.

 

[Dparo]

Nice work. I'd like to do this with mine to an extent, just piecing together the door seals and window weather strips adds up fast. I'd replace every piece of interior plastic if I could still obtain them.

 

[Hurleyburly]

Thanks for the kind words, @Hurleyburly.

Have fun with that LS swap! I originally considered that, but ultimately decided to just rebuild the 1FZ and keep the truck stock. Would definitely be tough to do with a 3FE.

I am also looking forward to the results of the body and paint work. My truck's body was not rust-free and required some significant body work. Kelly knows where to find the rust, even if you can't see it. I'd say there was 2-3 times more rust than was visible from the outside and the only way to properly fix it is to remove panels and re-weld them back on. That process is nearing completion and my truck should be getting paint in the coming weeks.

Application of the Macropoxy was kind of a pain, mostly because of doing it in batches is since you have limited time to apply it once it is mixed. I wasn't concerned with a smooth finish so I brushed it on, which left brush marks, but that doesn't bother me. For the inside of the frame I did end up using Eastwood products (rust converter, chassis paint, etc.). I'm sure it's not perfect, but I don't necessarily plan to be doing much driving on salt covered roads. I've also sprayed fluid-film inside the frame using the DIY want, but probably should consider having a pro do it with better equipment.

As far as "doing it right", I'm glad I spent the time and effort using a needle-scaler, wire wheels, etc. to really get down to solid metal before applying the epoxy. I was surprised by how much of the OEM frame coating looked fine yet was easily removed with the needle scaler. I'm confident that my frame surface was well prepped and now time will tell how durable the Macropoxy will be in the long term.

The overall cost is a lot. The project intent has always to be for my enjoyment like a hobby and not with any delusions that I could ever sell it for the amount of money that I have into it, let alone time.

The pursuit of parts is fun. Replacing old stuff with new OEM is really satisfying, and it all adds up. But I gradually obtained parts over the course of several years, so I wasn't spending the money all at once.

The biggest categories of parts purchases in my project have been body and engine, but the other categories add up too like brakes, suspension, exhaust, axles, air conditioning, and interior. I have purchased more than 2,700 new OEM parts (granted, many of which are fasteners). I'm actually glad the truck has been away getting the body and paint so I've had time to recover from my parts-ordering addiction.

Absolutely! Great work deserves recognition!

I fully believe that- I have no doubt when I start peeling back the curtain I'll have a few surprises with rust- it is a 33 year old Toyota that's been through the ringer. Sounds like he's continuing in the same vein as you- taking it down to the studs and doing it right! Gonna be a beaut!

That's what I wanted to know about the Macropoxy- I'm (intimately) familiar with two part epoxies and they definitely can be a PITA to mix and apply efficiently without waste. When I get to that point I'll probably take the same approach and brush it on a section at a time in small batches. I'm not equipped to spray something like that, and I think rolling might be tougher to get any product into nooks/crannies/all the odd shapes that make up a frame. I will also be hitting it with a needle scaler/wire wheel/etc to knock down the dirt/33 year old factory frame coating. Gonna be a mess ha. I appreciate the insight!

And I 100% understand the enjoyment aspect. I have no delusions of selling mine/attempting to profit off of it. I have too much emotion, memories, time, blood, sweat and... (cough) no, no tears. But strong men also cry. .

I have a whole list going for parts that I'll be amassing over the next year or so to try and soften the blow, but I am excited to start replacing the crusty with the supple, the faded with the new, etc... So I get it. Definitely a project of passion- who would knowingly subject themselves to such torture? Ha!

Anyways- thanks for the reply and I'll keep an eye out for those post paint pics!

 

[DaveN]

Bravo! Really nice documenting the tear down and rebuilding it back. Beautiful!! Kudos to you and your buddy who let you use his nice garage.
This type of build will cost an upward of $100k ( I checked with someone in this forum who does this type).
Again, great job!

 

[truthdetector]

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