97 K1500 DD/Overlander

04.08.23
Weather was nice, so I went ahead and just rewired the controller. I enlarged the hole in the firewall to 5/8" with a step bit, installed a grommet, and fed the three lines though from the engine side. The lines were attached to the controller with butt connectors and shrink tubing, then I wrapped everything in 1/4" braided ploy split loom and Tessa tape.

04.08.23 (cont...)

I put the ground wire in some 1/4" corrugated split-loom to better match the existing wire runs in the engine compartment. I zip-tied it to the existing line along the drivers' fender, across the radiator fan shroud, to the negative battery terminal. 11' was pretty much perfect. I'm glad I ordered two 3' sections for the other wires instead of the 2' I originally planned on. I ended up cutting ~8" from the blue one, and will most likely cut double that from the black.

I just need to add a 20-amp fuse (overabundance of caution) and bolt it to the Aux B of the distribution block. First I need to grab an extended battery bolt for the negative, or just bite the bullet and grab a BCI 34/78 battery. The current one is showing early signs of failure and adding accessories would be significantly easier.



Also attached the rear harness to the frame. Ended up finding some proper black zip ties, so I replaced the clear/white ones in the photo. Also attached the old ground to the hitch side. It was already bathed to the frame and just hanging...easier to attach it than try and get at the bolt from underneath. Besides, you can never have too many grounds.

Work ended for the evening as we had family over for a pre-Easter dinner.




Since my brothers were here, the three of us reinstalled the bed after dinner. Figured it was easier than trying to wrestle it back in place with the engine hoist. Took the casters off the cart as they'll eventually find another use in some kind of shop cart/furniture, or possibly a small welder cart. The gap on the bed is a bit better than before, but still not correct (and rather annoying).

mdnky said:

Needless to say I'll be trying to deal with him from now on, if possible.

Click to expand...

I'm hoping that this next generation of middle managers re-learns that employees really aren't interchangeable and that high performers truly are worth the money. I'd be going to this guy for all my parts needs. That's why I usually go to my local O'Reilly over the two Autozones that are nearer.

mdnky said:

Took the casters off the cart as they'll eventually find another use

Click to expand...

I keep a stash of casters, too.

mdnky said:

I may do that. If yesterday was the only issue in the past few weeks, I'd probably be a bit less bothered. However, it seems like every time I've been in one of their NKY area stores since January, there's an issue of some kind. I get the feeling that it may be a management issue at the district level, which is trickling down to the store level.

While trying to find that 5/8" hose for the vent line on the fuel tank, I visited three stores with each one saying the other "definitely had it". The last store was their local 'hub'. Every store was just disorganized, with people behind the counters whom were not very interested in being helpful, or in some cases knowledgeable. The 'hub' store looked like a tornado had recently made its way through the interior. At one of the stores, an employee was adamant that heater hose is perfectly ok to use as fuel line in a high pressure fuel injection system. Guess it's just really hard to find decent workers anymore.

I called this afternoon and their commercial accounts rep took the call (on the normal line). He actually tracked the order down quickly and apologized about the error. Seems it arrived yesterday, but was misplaced. When I got to the store, he had it sitting at his computer waiting for me. Needless to say I'll be trying to deal with him from now on, if possible.

Click to expand...

Yes my favorite person at the O'Reilly's in Stafford is on the commercial account counter. They're also one of the assistant managers.....

Time (finally) for an update. Truck has been sitting in KY for the better part of the past year, with the occasional startup and shuffle around the yard. Got busy with life/work stuff, so it fell way behind on the priority list. Just before coming up for the holidays, I finally transferred the title and registered it. Probably should have done that sooner, as roughly $120 of the cost was due to 'late fees'.


12.09.2023
LA Title TX, Tax, Registration + 'late fees' [$748.94]


12.20.2023
Did a thorough check of the fluids and ran it a bit. Noticed the oil level was a bit high and had a very slight milky appearance. Couldn't remember if it was like that last year or not, so I decided to do an immediate oil change. I'll monitor it a bit as I drive it over the next few weeks to see if that issue returns. The coolant reservoir was low as well, so there is definitely a coolant leak somewhere and that problematic plastic lower intake gasket is definitely on the suspect list. I added a bit of UV dye [$9.52] to the coolant system, as the previous owner had already (unfortunately) switched the truck to the standard green antifreeze. He also claimed to have replaces the hoses, thermostat, radiator, and flushed the system. Now I'm wondering if that was actually needed, or he was just throwing parts at a leak he couldn't find. Might need to clean the engine a bit to make sure anything I find is new and not remnants of a previous problem.




12.21.2023
Picked up a 5qt bottle of the cheapest oil I could find at Wallyword. SuperTech Synthetic HiMileage 5W30 [$20.12]. No sense wasting a bunch of money on what will essentially be a 'flush' oil. Only 71K, but having the extra additives might be beneficial to those elderly seals. Originally picked up a SuperTech ST3387 oil filter [$4.07] there as well, as they were out of the AC Delco PF52. However once I started to take the old one off, I noticed a significant difference in the size. Decided the smaller (shorter) WallyWorld oil filter wasn't something I want to use, so I picked up a Carquest Red oil filter (either a rebranded Wixx or Purolator) R85036 [$5.82] from Advance Auto.



Whomever installed the previous filter was a bit happy with the tightening. Barely managed to get it off, after about half an hour of trying and a trip to the big orange box store for a new strap wrench. Collapsed the old NAPA gold filter while removing it. [[SIDENOTE: the GM engineers who thought up that filter placement/setup should be launched into space on a rocket without any heat and only fruitcakes and prune juice for supplies...]]

That'll do it until next year.



RUNNING TOTAL: $5487.79

1.02.2024
Took it out for a few quick/short trips and added about $20 worth of fresh gas to the tank. Seems to be running ok, however that exhaust leak is an issue that needs addressed. Still need to figure out the ABS issue as well. Definitely need to get the front wheels off, though I'm worried what I'll find when I do.




01.03.2023
Time to tackle that annoying exhaust leak (broken studs at cat/muffler flange from removing the muffler last year). Took it up to the local family owned/run exhaust shop in nearby Florence, KY. Interesting waiting room...definitely don't have to worry about their TV being stolen.



Ended up leaving it there overnight and picking it up the next morning, as I had some other commitments to handle. They decided the flange was too rusted and warped to effectively repair, so they suggested eliminating it [$111.00]. Definitely quieted it up a bit.



Checked the coolant before leaving the muffler shop and the reservoir was low. Topped it off before heading home and it was fine when I got back, however after it cooled down (next morning) it was low again. The trip each way is roughly 8 miles in city-like traffic.


1.05.2023
I was going to take it on a quick trip to the store, but the battery didn't like the arctic weather we've been experiencing. Can't say I blame it one bit. It's on the charger now, but I have a feeling it might be time to just replace it.

Some new toys (tools) arrived over the past few days...on second thought, I might have been playing with one and run the battery down a bit as well yesterday. {oops}



RUNNING TOTAL: $5598.79

1.10.2024
Battery was definitely DOA, but just within the warranty period (2/22 sticker). So I made the 30 mile trip to the closest NAPA...during rush hour. JOY! The store let me swap the BCI.78 to a BCI.34/78 [$0.00], so I'll leave the stock connections on the side posts and use the top ones for any accessories. Probably should have swapped to a regular top post battery (BCI.34), but it's too darn cold and wet out to deal with swapping the terminal ends.

RUNNING TOTAL: $5598.79

This is an awesome build thread.

Following.
My 97 frame needs some attention as well.. I picked it up Sept of this year for $3k.
As for your frame, look into this stuff.


My buddy & brother in law have used it, swear by it. BIL just coated his old Ford tractor in the primer, never even sealed it, and it hasn't rusted in 20 years. If it's good enough for bridges, I think car frames will get some benefit.

How about this, for a solution to your frame problem ?