1973 K5 Blazer Frame Off Rebuild
This is the tale of a 9 year saga.
Final Assembly is underway!!!!
I started with 1 rusted but decently taken care
of
running '73, bought a totally rusted, not running '73, and started from
there.
The running one I had already outfitted the year
prior
with a 14bolt FF axle, 2.5 Skyjacker lift.
It came from the factory with an SM465 Manual
Transmission
coupled to a NP205 all gear transfercase.
The engine had over 200,000mi on it, and had been
rebuilt once with a top-half rebuild after that, so I retired (sold) it.
Here is my master plan:
Goal #1: Off-Road Capability.
Michigan area,
mostly
mud, sand. Some light rock crawling.
Goal #2: Street Drivable on a semi-daily
basis.
Goal #3: Make as RustProof as possible!
Goal #4: Keep as original looking as
possible.
I'm
not much for gaudyness, and I like the OEM look.
To meet the goals here's the template I came up with:
- 1973 Chevrolet Blazer
- Full Fiberglass body with 8 point roll cage to frame
- Chevy Small Block 383 Stroker. (GM Goodwrench HT 383) -
Redecided on RamJet 350 Crate Engine
- Keep the SM465 Manual Transmission and NP205 Transfer Case
- 2.5" Spring Lift
- Overall .5" Body lift.
- 35" Tires (Don't worry, with the weight savings of the Glass
body, these
will clear no problem!)
- 3.73 Gears
- Dana 44 Front, ARB'd
- 14 Bolt Full Floater Rear with Detroit
- Converted AC Compressor to Air Compressor
- Line-X Entire body, inside and out(Ok, I added this one!)
Here's what I've done thus far (23Aug2008):
Torn down both trucks.
Frame:
- Sandblasted the best frame
- Re-inforced the frame in the typicaly vunerable Chevy truck frame
areas:
Rear shock mounts, steering gear mount.
- Painted the frame with DuPont Imron.
Drivetrain & Chassis:
- Rebuilt both axles, Rear is a 14Bolt FF, front is a Dana 44
converted
to
3/4 ton. Added Detroit Locker to rear and ARB Air locker to the front.
- Had my 50gallon fuel tank "Renu"'d. (cleaned, checked, and dunked
in
some
type of expoxy to coat inside & out)
- Rebuilt the SM465 Transmission and NP205 Transfer case. All they
really
needed were new bearings and seals, and 1 shift fork.
- Purchased H2 tires/wheels. Installed with .25" wheel spacers to
clear
the
tie-rod ends and to make up for the increased backspacing of the H2
wheel.
- Installed sealed vent tubing for both axles, transmission &
transfercase
to be vented up high somewhere in the engine compartment.
- Installed all new Stainless steel brake/fuel lines.
- Installed Off-Road Design sway-bar disconnect.
- Installed RamJet 350 PFI Crate Engine
- Installed Serpentine Kit
Body:
- Installed the new US Body Source fiberglass body.
- Installed new Steel doors & Tailgate. (Doors were cut from
template
from orginal '73 doors and reinforced with the orginal '73 door
reinforcements)
- Installed US Body Source one-piece Tilt Front Clip on
fabbed
hinges.
- Fabbed & installed 6 point full roll cage to frame, including
sub-cage
for mounting front seats.
- Installed all lights/grilles/bezels.
- Installed original metal dash
The body is by far the most work. The fiberglass does not come
pre-drilled
with all the nice holes/weldnuts/reinforcments..etc, you must do that
yourself.
Heres just a sampleing of what I can remember I've done to it:
- Cut out the original dash, modify it slightly, sandblast it,
paint it
and
install it in the fiberglass.
- Fit all the steering column/pedal reinforments and components.
- Fit the wiper motor and wipers to the fiberglass.
- Fit all the HVAC boxes on the firewall.
- Reinforce the FBHP area to accept the stock door hinges. (I
ordered the
orginal reinforment NOS from a dealer that had them, and used those.)
- Fit the doors and tailgate to the fiberglass openings. Each
taking
several
days to get fit right.
- Cut out the original '73 roof rail header and fit it into the
fiberglass
header with stainless steel screws.
- Fit the orginal fiberglass top to the new body.
- Removed and reinstalled raditor mounts (formerly front radiator
support
mounts) 1" rearward to ensure radiator clearance to tilt front clip.
Cut
the raditor support (OEM goes whole width of vehicle) down to only the
raditor section and fabbed supports from the top of it to the firewall.
Final Assembly is underway!
I dissemembled
everything and took the body for Line-x, just before christmas 2004. I
got it back and started final assembly:
- Installed and bolted down entire body
- Installed roll cage
- Installed Dash
- Assembled and installed Tailgate with refurbished and/or new parts
- Assembled and installed Doors with refurbished and/or new parts
- Assembled front end pieces
- Refurbished and assembled heater box
- Created Custom Battery Tray
- Almost done wiring. I have about 3 circuits left to start, and 2
to still complete. So lots of things got installed here, Stereo,
wipers, lights, etc...
What I need to do from here:
- Finished assembly: Interior components like dash switches,
console and rear seat. Engine bay components like Washer fluid tank....
- Exhaust
- Plumb the On board Air system
Documentation
Here is my Part
number/Source list page
This is not a perfect list. It's missing some things, but eventually
it will all be there
Check out the master price
list:
This is my price document. It's not perfect, but gets the overall
picture
of things.
Keep in mind, this is just "thus far" pricing!
Check out some wiring diagrams:
Some Catia wiring models, and if you can't
read Catia models, there's a jpg for every model.
Check out the Pictures
K5 BLOG
23Aug2009:
It's Been a long while since I updated. So I procured the RamJet
350 crate engine, installed that. Installed the serpentine kit. The
wiring is complete. Installed the starter, alternator and various other
engine components.Throttle cable installed, need to do exhaust yet, and
driveshafts. I really hope to have it done by this fall, she's close!
05Sep2006:
Wiring is still underway. It's alot of work. 1 circuit at a time. Lots
of little details to work out. Relay seal numbers, bases, differnent
packard connectors. My Electrical engineering buddy accused me of
starting a packard museum, I have a whole 24 bin organizer with
different packard connectors. I think I bough the rest of the countrys
avails stock on a couple of them, like the "PC Bow" connector that
mates to the Printed Circuit on the back of the Gauge Pod. Anyhow, I've
got about half the circuits completed. Alot of them depend on others,
so I estimate by CHristmas I should have this wiring done. I've got my
bumpers coming, so I can complete the wiring in the back of course.
It's slow, but going. I've got a nice new OEM type mirror with compass,
Homelink, outside temp and maplights, that took me 3 days to wire into
the plan. Stereo is mostly wired. I've got to do the alarm functions on
it still. (Stereo sounds sweeeeet!) Slow....but sure....
02Feb2006:
The budget is completely blown away. Everything little piece I install
is brand new, GM if I can get it.
I'm in the middle of wiring. I chosen to wire from scrach as opposed to
using a stock kit, or a Painless kit, as these kits just don't allow
for the kind of extras that I have planned and don't include alot extra
harneses anyway, like the AC clutch, heater, some of the engine
sensors..etc. Anyhow, for this job I've been consulting with a good
friend of mine who's an Electrical Engineer. For the wiring task we
choose to use switchable circuit breakers in place of fuses. I've
purchased all SXL grade
automotive wire, rated to 125C. SXL wire is what's called a
crosslink wire. Also available in crosslink, is GXL and TXL, just
a little thinner wall, the OEMS use these for stuffing many wires in
the same place, like say a 50pin computer connector. Anyhow, alot of
people don't realize that there's a huge difference in qualities of
various wire. The stuff you find at the auto parts store, frankly, is
crap. It is not even GPT rated. Look at the difference here.
For that test I placed a length of SXL (the yellow) and a length of
some "Primary wire" I purchased at Napa a few years ago right in
front of my 55,000BTU reddy heater. The primary wire was in flames
within 3 seconds and the insulation gone within 5. The SXL wire I
removed after 30seconds, a little discoloration, but still flexible
and the insulation remained in tact and did not reveal any of the
wire it was protecting. Also purchased, were high quality
terminals and connectors. Butt connectors, ring terminals and such. I
choose solder ring heat shrink terminals. These have a pre-measured
amount of solder already encased in the heat schrink, place your wire
in it, put in front of a heat gun, the heat shrink tubing shrinks to
seal around the connector and the wire and the solder inside melts. A
perfect sealed connection. I purcahsed all this stuff at DelCity,
there's other places you can buy too, but DelCity had the most
reasonable prices the an individual could buy and in smaller amounts.
(ie DelCity lets you buy minimum 100' of wire, some other places were
minimum 250' ofr wire) So the wiring has commenced.
Update: 19May2005:
Well
it seems
I'm getting out of control. Every single part I put on this thing
during assembly is GM new if I can help it, otherwise it's new from a
3rd party, or if it's not offered anywhere, I take my sweet old time
and carefully and painstakingly refurbish it myself (sandblast, tap,
re-thread, clean,prime,paint etc). I starting pulling my old crap
off the shelf for installation and just coulnd't bear to bolt on rusty
old 250K mi stuff. Cost is going high because of all the new GM parts I
never really orginally planned on putting on. Back in 1998 when I
started I had little means to do such things, the plan really was put a
glass body on and a new engine. Well, during the project, I found
that after at least 250K mi (could be more, I think it may have been
350k), everything was showing signs of wear. Stupid things like clutch
cross shaft seals, armrests, turn signal cancel cam, door panel seals,
rear window tracks, even just fasteners. Well I was smart enough there,
before I started I went to Quality Farm & Fleet and bought $300
worth of grade 8 & 5 bolts/nuts/washers, every size, and a nice
organizer bin thingy. That was one of the smartest things I've done,
it's very nice having every length bolt in 8 different diameters and
thier proper washers and nuts, no more hunting, tapping, cleaning, etc.
Just pick and install. Anyway, sometimes I sit back and think I spend
way to much on stupid crap like $38 for clutch rod boots, and $8 for GM
window regulator rollers. No one part is ever that expensive, but it
adds up, quick. But the way I see it, when finished, every single
part/fastner will be brand spaking new or like new, so in theory,
everything should be perfect and operate perfectly, be sealed
perfectly, look decent, etc, etc. In theory, anyway........
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