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  1. mdnky

    97 K1500 DD/Overlander

    05.02.24 (cont...cont...cont...cont...) Took a break to eat lunch and let the paint dry, then it was time to undercoat everything with FluidFilm Black. I have it sitting here, so might as well use it. I found a use for the huge pile of empty Kroger pickup bags...they're decent for masking and...
  2. mdnky

    97 K1500 DD/Overlander

    05.02.24 (cont...cont...cont...) I cleaned the frame with a wire wheel, then reinstalled the new bracket using the body mount to locate it properly. After tacking in place, I jacked the cab up a bit more to remove the body mount, then I welded the bracket in place. Once everything...
  3. mdnky

    97 K1500 DD/Overlander

    05.02.24 (cont...cont...) Tacked the sides to the main face in a few spots, then removed it to weld it out. I definitely should have used 0.35 wire, but the 0.30 was already loaded and is getting old. So I decide it was time to use it up. I'm probably past due on replacing the contact tip...
  4. mdnky

    97 K1500 DD/Overlander

    05.02.2024 (cont...) Checked the fit of the new 'face' plate with the body mount. It looked good, but it will definitely need some support. Time to make some triangles. I took a few measurements and transferred them to the deck section, then I cut them out. Really starting to like this...
  5. mdnky

    97 K1500 DD/Overlander

    05.02.2024 First thing I needed to address this morning was the passenger's rear cab mount. I very briefly considered a trip to the UPull yard, but I quickly decided that would likely be a waste of time (parts most likely rusted, not to mention being a big PITA to remove by the yard rules...
  6. mdnky

    97 K1500 DD/Overlander

    05.01.2024 (cont...) Finished chipping as much scale from the problem area, then blew it off with a leaf blower before saturating the area with Corroseal. Once I reinforce it, I'll heavily cover this area (and the rest of the frame) with black FluidFilm. That should prevent, or significantly...
  7. mdnky

    97 K1500 DD/Overlander

    05.01.2024 Inspected the problem area on the driver side today. Used a BFH and a screwdriver to knock the scale out and see how bad it really is. This is basically what stalled the project. I need to temporarily reinforce the area, but I don't have the time needed to pull the tank...
  8. mdnky

    97 K1500 DD/Overlander

    04.30.2024 (cont...) Moving on to the frame, I wire brushed around the part of the previous repair that I cut out last week, as well as two grounding spots. Then I did a quick dirty weld to seal it up. Cleaned up the welded area and a few bare spots, then put a good coat of self-etch primer...
  9. mdnky

    97 K1500 DD/Overlander

    4.30.2024 Started the morning by wire brushing the shock mount, then cleaned it well with brake parts cleaner, mineral spirits, and alcohol. I put a heavy coat of Corroseal on it and left it to dry in the sun. At the end of the day I put a heavy coat of satin enamel on it as well.
  10. mdnky

    97 K1500 DD/Overlander

    04.28.2024 Need to get this thing movable before heading south. I thew a coat of satin black enamel where the spring hanger sits. After the paint dried a bit, I attached the spring hanger to the frame using four M10-1.5x30 (class 10.9) flange bolts and serrated flange nuts. I also added...
  11. mdnky

    97 K1500 DD/Overlander

    Thanks! I haven't used their stuff before, but I know a few Jeep guys who have. Based on what I've heard from them, and what I've seen from this piece I have, RB definitely makes a nice product. They definitely seem to be more refined than the Safe-T-Cap products I've seen. There's plenty of...
  12. mdnky

    97 K1500 DD/Overlander

    04.15.2025 (cont...cont...) I cleaned the inner side of the reinforcement with brake parts cleaner, followed by a couple passes with mineral spirits, then finally alcohol. I put four good coats of 2000° Primer just on the newly clean inside section. I left it to sit in the sun and dry...
  13. mdnky

    97 K1500 DD/Overlander

    04.15.2025 (cont...) Took a few minutes and built a simple a jack extension from some scrap wood and deck screws. This will let me lift the body just enough to clear the frame reinforcement, while not being in the way. Ended up cutting and punching the rivets out on the gas tank crossmember...
  14. mdnky

    97 K1500 DD/Overlander

    04.15.2024 Started the afternoon by throwing a heavy coat of satin black enamel on the spring hanger, then left it in the sun to 'bake'. The next step was to get rid of the rivet remains still stuck in the frame from the hanger removal. They didn't want to come out yesterday with the air...
  15. mdnky

    Lower Control Arm Bolt Source??!!?

    What truck? On a K1500, it should be a M16x2.00-137 [GM 15989896] {forward} and a M16x2.00-114 [GM 15989896] {rearward}, both class 10.9.
  16. mdnky

    97 5.7 sierra, poor acceleration, +15-20 fuel trims.

    Have you checked the catalytic converter to make sure it isn't plugged?
  17. mdnky

    97 K1500 DD/Overlander

    Yeah, they actually had a bunch trucks with them, but more than half were missing lids. Figured either someone took them, or possibly they got lost when someone checked what was inside. Tons of plastic parts like that all over the ground (fuse covers, shrouds, etc.) in every aisle. The first...
  18. mdnky

    97 K1500 DD/Overlander

    04.14.2024 Hit the local u-pull type junkyard. They had a decent selection of GMT400s and 800s. Also had a really nice baby blue '76 with an almost perfect body (no rust in usual areas, good paint, good frame) minus a crunched RF fender. Sadly, someone had done some selective surgery to the cab...
  19. mdnky

    97 K1500 DD/Overlander

    Have plenty of them, just not the best option in this situation. The steel in that area is already too thin, so I'd rather not eat away any more than absolutely necessary. The wire wheel is fine for the rust/paint, just takes a bit more time and doesn't remove the good steel. The only parts...
  20. mdnky

    97 K1500 DD/Overlander

    04.13.2024 (cont...cont...cont...cont...) Finished out the day by clamping the spring hanger to the frame and cleaning it with the grinder using a wire cup and wire wheel. I haven't treated it with Corroseal and paint yet, as I'm going the junkyard tomorrow and the ever-so-small change that...
  21. mdnky

    97 K1500 DD/Overlander

    04.13.2024 (cont...cont...cont...) Did a quick test fit on the reinforcement section. Had to remove the middle cab mount, so I could get enough slack to jack up the body a bit for the reinforcement to clear the rear cab edge. The initial try with the 15mm socket and the breaker bar was not...
  22. mdnky

    97 K1500 DD/Overlander

    04.13.2024 (cont...cont...) Well...now that the bracket was off, that meant it was time to do the fun (NOT) part of this project. Cleaning up this mess... I used the plasma cutter on a lower setting (30A/55PSI) to trim a few of the bigger remnants. Not wanting to accidentally cut the...
  23. mdnky

    97 K1500 DD/Overlander

    04.13.2024 (cont...) Put the jack under the rear diff, then jacked it up ever so slightly to take tension off the springs. Then I used the grinder with a wheel-O-death to cut the head off the rivets. I cleaned up the cut surfaces with the band file sander (36grit). Then I used the RBFH (aka...
  24. mdnky

    97 K1500 DD/Overlander

    04.13.2024 Great weather today... I hooked up the plasma cutter to the 50A/240V outlet in the kitchen island, usually used by the cooktop. Did this via two 40' 8GA extension cables and a NEMA 10-50P to 6-50R adapter. Running the machine on a proper circuit...definitely worth it. Doing so also...
  25. mdnky

    97 K1500 DD/Overlander

    04.06.2024 Hammered a 13mm impact socket onto the cab mount bolt, then gave it a turn with the breaker bar. As expected, it barely budged a fraction of an inch before snapping off. JOY! The mount is in pretty shape, so looks like I'll be rebuilding it. 04.07.2024 Right at the end of the...

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