Slick 60's

I am finnaly back to work on the crew cab. I had some engine problems and got so fed up with the whole thing that I had to take a break. When I installed the new fuel pickup I put it too close to the bottom of the tank. When I did the conversion I never cleaned the tank I just siphoned out all the gas and refilled with diesel. Well there was a bunch of junk in the bottom of the tank and it got sucked up into the fuel filter. If it was a new filter it would probably have survived, but it was the one that came on the donor vehicle. The junk got past the filter and took out the fuel injection pump.

After taking a hiatus for a while I got the pumped changed out. Now it is running good.

I cleaned up the roof and floors so I could paint them. Here is what they looked like before.




After cleaning.



Now they are painted with POR15.




I did the same thing with the step wells.





I got the step wells painted with POR15 then top coated with truck bed liner material. I did not get a picture of that.

The floor got done as well. No rust holes in the floor pans.





I also got the air cleaner recessed into the inner fender. I need to come up with a 4 inch radius 4 inch exhaust elbow in order to connect the air cleaner to the turbo.








When I cleaned the roof off I discovered some nasty rust above the drip rail above three of the doors. I am trying to determine the best way to repair it. I need to get it sealed up so the inside will stay dry.





Well that's all for now. Once the roof is patched I plan on putting sound deadner and insulation up there. The same goes for the floor.

Nice to see you back. love your truck and the progress.

Cool!
How did you go about marking the fender for the cut?

I had the piece that went into the fender. I had it bent up at a local sheet metal shop. I took careful measurments and used a level in two directions to make sure it was square. I hung the level off the top of the inner fender into the engine compartment. From the level I measured down how far I wanted to go. I needed to get the air filter outlet inline with the turbo inlet. When I had the straight portion marked out I used a template I made from the piece that was going to be inset. I traced around the closed end. That gave me the correct shape that needed to be cut. I traced the template onto the fender. I had to take the curve of the fender into account so I made it a little small. Once it was cut I trimmed the opening until the fabbed piece fit.

The 6BT 5.9 weighs about 1100 lbs.[/img]