And so it begins.

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KLF

Frame waxer
SILVER Star
Joined
Apr 5, 2003
Threads
246
Messages
10,203
Location
Southern NH
After 23 years and 240,000 miles (some hard ones), I finally decide that this was the year that the truck needs some TLC. I'm finally starting to get some rust spots here and there and the original paint is really faded and no longer salvagable. So, I didn't renew the plates and sticker last month. Took it for one last spin yesterday, then started tearing her apart. She had a long conversation with Mr Pressure Washer yesterday, I was filthy when I finished, and my driveway was a disgusting mess (still not sure how I'm gonna clean that up).

Plans are for a total frame-off, with some improvements. Finally converting the interior completely to gray, with upgrades from my parts collection (power windows, locks, etc.). Seats will get redone. New tunes. Factory sunroof from a 4Runner to be installed. Engine will get a total refresh, although it is still running fine. New suspension. Still not sure what I'm gonna do about wheels/tires. I found a really good body shop that does a lot of restore work to spray the cab and bed.

I was very pleased to pull the bedliner yesterday and find not one speck of rust under it, the inside of the bed still looks like the day it left the factory, just dirtier. The cosmoline I put on all the inside seams 8 years ago did the trick.

Ditching the bedliner if anybody wants it. Selling the 35's and Smittybuilt rear bumper soon as well.

I'm going to go insane not having a truck to drive, I may need to come borrow one from somebody.
TazSmall2.jpg
TazBack.jpg
 
Had no idea u bought that puppy new! LOT's of work.. will it be done for the Fall Gathering? Looking 4ward to the build as well.
 
Didn't buy it new, I picked it up in 2002, it started life in New Mexico which is why it has been able to stay so rust-free for so long. It didn't come to NH until about 1997, but it mostly sat in a garage with a cover over it for 5 years. I still chat with the PO occasionally, he's promised to help me pull apart the big stuff when I need a hand.

Fall Gathering? Ya sure... in 2012 maybe. I gotta work on this as time and money allow.
 
Small update: been slowly pulling pieces off, cataloging, labeling, cleaning, etc. This truck has been getting almost annual treatments of 90W sprayed underneath and anywhere not visible, and now it's paying off. When I pulled the front parts (grille, bumper, headlights, etc) it was gross and nasty. Soaked it with SuperClean, then hit it with the pressure washer, the original body and frame paint still looks new.
Clean1.jpg
Clean2.jpg
 
wow that tuk is still in great shape, look forward to seeing the rest of your build:cheers:
 
Not much update on the truck, but this arrived in my garage on Friday, it'll come in handy for fabbing up a new rear bumper, for starters.
Welder1.jpg
 
Nice! which model?
 
Millermatic 211 Autoset.

Just finished the electrical wiring a few minutes ago. Now, where's that bumper...
 
Stripped the interior on Monday. Anybody want anything? Free for the asking, or shipping. Dash pad and glove box are spoken for. Door panels are decent. But everything is butt-ugly red. It goes to the trash soon...
 
Wow. Not even a picture of the mint oem tailgate in factory primer which you stole off ebay for $25.
 
Body is stripped down to sheetmetal. Engine & tranny out. Rolling chassis, cab, & bed are hiding under a tarp, looking very sad and neglected. To be pulled off in the Spring.

Started tearing the engine apart the other day. Slow going, as I predicted.

Rear bumper is done. I pity the ricer that tailgates me.

Will try to pick out a few pics from the 100's that I've taken so far and update.
 
Update:

Engine is at the machine shop getting a few things (re-bore, decking, polish/balance, etc), parts are in the garage waiting to be installed once I get it back this week.

Cab and bed are off the frame. I built a nifty cart to put the cab on, so I can easily move it around. Got the windshield out the other day, that job sucked.

Cart1.jpg

Cab1.jpg


Frame heading to blaster soon. Overall very minor rust issues on the cab, but it's a good thing I got to them now.

Frame1.jpg


Will probably be getting new springs, the OMEs are pretty worn out.
 
I admire your ambition Ken!
That's a lot of work your doing there!
 
Update:

Sorry for not keeping this up to date. Truck is back on the road, passed NH inspection with flying colors on 10/6/14 (2 weeks ago). Photos that I took yesterday for the insurance company:

LongFront.jpg


Engine:
Engine.jpg


Interior:
Interior.jpg


And some bling on the tailgate, can you see it?
Tailgate.jpg


I've got about 750 miles on it so far, getting almost 20 mpg out of the engine, I'll run it for another month or so and do another valve adjustment and oil change.
 
Basic timeline:

July 2010: Started tearing it apart

Oct 2010: pulled engine

Nov 2010: Engine apart, block sent off to machine shop for reboring, crank balance, few other things
Spring/Summer 2011: Body stripped off frame. All parts cataloged and checked to see what needs to be replaced. Cab placed on wood dolly, bed placed on utility trailer. Frame out to sand blaster, painted, then back rollable.

Fall 2011: Begin re-assembling engine, New pistons, bearings, all new gaskets/seals. Intake, valve cover, few other parts out for powdercoating.

Spring 2012: Finished engine. Not much else done, due to large project at work.

Spring/Summer 2013: Body to paint shop. Doors replaced. Lots of parts cleaning, blasting, painting. More than I thought possible. Select hardware and brackets sent out for re-plating. Start building frame: install engine & trans, wiring upgrades, etc. Rebuild all suspension.

Fall 2013: Body back from paint, install on frame. Install enough engine parts and wiring to get it moving under own power. Engine fired right up. Parked for winter.

Summer 2014: finish assembly. LOTS of wiring added. LOTS, with provisions for more accessories. Nothing from the original ugly red interior was re-installed, everything is gray now, but I still need to get a new headliner made.

I can say without reservation that every single bolt, nut, screw, and other fastener has been removed and reinstalled on this truck during this rebuild. Lots of hardware replaced with stainless. Every seal, gasket, O-ring, etc has been replaced. Not a single leak anywhere, nothing. New Duratrac 286/75-16 tires, which I am really liking so far. Sorry missed the Fall Gathering, but I just couldn't make it.
 
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