'94 buildup

[hunt-n-fish]

Cut out some of the rust ... now it's visible how the rotting formed. Thanks stupid hole in the fender.

Time to bring out the duct tape.

It looks as tho you are putting alot of time, effort and a few $$ into your ride. Please take the time to fix it properly now while you have it apart. Clean up the rust( wire brush is okay, a sandblaster is way better ), weld in patches and paint or coat with a rubberized undercoating. Duct tape won't do shit but age and fall apart and let more water in.

 

[Boggin]

alright i vote zorro as the new host for powerblock on spike

X2

 

[Zorro]

Alright, I fixed the rust hole. Quick and professional. Next.

Then I realized I was being a bit mean. This truck has a lot of good memories, and it's served me right. I couldn't do a cheap arse fix like that. I mean ... I can spoil, my truck if I want to, right?
So I did. Chip Foose just called, said he wanted me to teach him how to do such an awesome job. I declined, I'm just too cool for Chip.

(for those worried, I will actually clean the rust with acid, cut and shape a plate, JB Weld it in place, paint with a thick rubber paint kinda coating, fill with expanding foam to avoid standing water, and do the same for the hole inside (plate/JB weld/rubber coating) )

I was also able to steal the brake pedal. That was a battle of epic proportions, our grandkids will read about it in history books. They will know everything about the stripped top bolt holding the parking brake assembly that prevents its removal, the dirt in the face. Hopefully the editors will skip much of the swearing.

Unlike mjones' situation my pedal bracket is actually identical to the one found in the manual Exploder, not a light duty version. This means I will do everything in my power to not remove it, and just take out the auto brake pedal (done) and slide the clutch and manual brake pedals in (far from done).
You can see just the bottom of the pedal bracket in this shot.

 

[mjonesjr]

Nice to see that your brake pedal bracket is the strong version.

looks good!

 

[Combs Customs]

Do yourself a favor to get that clutch pedal in. Unbolt the parking brake (3 10mm bolts) and fold it back behind where the brake pedal would be. Then, under hood, undo the 10mm bolt holding the wire harness together thru the firewall. Then, putting the clutch pedal in becomes a cake job.

 

[Zorro]

I had already read that (maybe you suggested doing it), and I'm going for it, sounds like a piece of cake.

Except the top bolt (the least accessible one) of the parking brake is stripped. Actually, it's not stripped. It came out 2/3rds of the way ... and the nut on the other side somehow came loose. So now I have a loose bolt with an unaccessible nut stuck on the other end that refuses to let go of my parking brake.
I'm trying to cut it using a wireless Dremel now. I just have no other way to take the mofo out.

Good call on the 10mm bolt for the wiring, I was wondering how it was held.

Edit - got the top handbrake bolt off. Dremel FTW. But now ... the connector bolt is stripped! I'm losing my mind here. I remember why I went to college.

edit again - removing the handbrake and trying to work in such tight quarters is a very poor idea. Just doesn't work for me. *uck this. Pedal bracket is coming out. I haven't been this enraged in ages.

 

[Zorro]

Victory. This is by far the most nerve racking job I have done in a while. There were times I felt like crying. Every single aspect of the things I'm about to describe was off the charts of PITAness.

I took the handbrake thing completely out. Yes, I fought with the broken nut, yes I fought with the stupid clip that hold the cable and I fought with the spring to take the end of the cable.

Then removed the big connector. Went well, actually.

Still not enough room to maneuver ... had to unplug every connector in the corner and move wiring away as much as I could.

One bushing on the brake pedal broke as I was finishing. Started over.

And here it is. Electricals are re-connected, handbrake will go back on (albeit with 2 bolts instead of 3) tomorrow.

Interestingly enough, the connector for the clutch sensor is already there. Sweet.

3 pedals. If that ain't FTW, I don't know what is. But again, I can not describe how infuriating this job was. It almost made me keep the auto transmission. Almost.

(obviously I got rid of the silly "racing" bolt on pedals)

And getting ready for the clutch master ...

 

[ZMan]

(for those worried, I will actually clean the rust with acid, cut and shape a plate, JB Weld it in place, paint with a thick rubber paint kinda coating, fill with expanding foam to avoid standing water, and do the same for the hole inside (plate/JB weld/rubber coating)

don't bother with the expanding foam, that will hold water in.

 

[Zorro]

Oh noes!!!!! Time to go shopping for a new 12mm wrench.

 

[mhughes165]

damn man, from the looks fo the truck ur in the rust belt lol

 

[Zorro]

damn man, from the looks fo the truck ur in the rust belt lol

Even worse ... Canada!

My DD is 2 years old ... and there is rust everywhere on the underbody.

Trust me, my next car(s) will come from the Texas or Arizona!

 

[mhughes165]

looks like ur master is leakin at the back from the pics, i would check that out while u got the truck apart

 

[Boggin]

Haha Look At This Guys Muscles, Tearin Wrenches Apart :thumby:

Nice Build..

 

[Zorro]

Woot! Lookey what the man in brown brought to my doorstep! Perfectly on schedule!

 

[BlackBII]

looks like ur master is leakin at the back from the pics, i would check that out while u got the truck apart

I was gonna say the same thing, and damn that thing has cancer!

And for the wrench, shoulda got a Craftsman

But if you take a look at my muscles, I've even snapped one of those before.....