This is where you should cut on the side. And the top cut can be done now, doesnt hurt. And the pinch weld across the top of the firewall, where it begins to arch up from the side of the truck towards the middle, right where that arch begins, thats where you cut down....

 

Love the drawing, I know you always have cut out the inner fender well but what holds it together when you put it together? Just the dense bolted from the cab side and one on the core support side?

 

Exactly. You could fit some flat bar there. But with this much structure cut out..a frontal collision will total it anyway.

 

Well it's been about 2 months since I've updated on here. Work has been crazy and doing more side building than spending on my own mini. Hoping to get some time in here pretty soon. With a crazy work schedule and adoption classes going at the same time I barely have had time to sleep. But here's what I've gotten so far.

I too have spent many hours cutting re configuring the air box to keep stock ac and heat. With the help of mike it has become a possibility.




Got the wheel tubs built and put in







Built my new battery box hope to get it situated soon and wiring ran.





Also got the main harness from the motor reroute through the firewall. Don't have any pics but I'm sure I'll have some soon. Also have been deleting unnecessary brake lines and re routing new ones. Same with wiring.

Doesn't seem like much but lots of hours when everything is hand build. Don't have much time as this truck will need to make layd out 2015. Got some new parts and have been collecting more air parts, going to be redoing all the air lines and valves from how it was done last year. Waiting on parts still to come in and yada yada yada.

 

All these little tasks really add up to saved time when your trying to button it up later on ! At least that's what I tell myself. I'm jealous of the plastic welder though...I used fiberglass resin...

 

She slowly becoming a truck again, not much but something. Starting the "wire tuck", not a full just what's necessary but it seems like it's most of it.





Running the new battery cables for the battery relocation, and a little look at the wheel tubs from the inside.



Was going to weld up the battery box to the chasis but I plan to make some chasis changes next year so for now I'll run it in the bed but wires will be run so both setups can be done without requiring.


And my almost finished battery box I made.

 

Nows when all the little things start taking more and more time, but you have to keep your head down...

 

Yup, I probably have a few hours of cutting and extending/ shortening wires on the drivers side to do still. Still have air lines to run and valves to place and more and more. Got some seam sealer in shipment and my ac regulator ordered. Still a lot to do but I have fun doing it. Found a cool old school way to shape complex curves so I'm also going to have a go at making inner fenders and rear wheel tubs. She might not be the best out there but I can say I built it.

 

Small update, tried to start the clutch flip build today. After reading the thread on how to do it and consulting with mike on my confusions, I realized my pedal assembly is totally different. This is what mine looks like.



After a little reaserch I found a few new Smaller master cylinders that might work. After calling my local autozone, I talked to the manager who didn't have the part I needed but went into the back and pulled almost an identical one to an 86 Toyota carolla. This will (I hope) give me the clearance I need. The new one is about an inch and a quarter shorter than stock. It's off an 85 Toyota but not sure the model. Mike says it's an 85 pickup. So here is the new compared to the old one.



I'll hopefully fit it tomorrow if we have decent weather.

 

Let us know how this works out. Shorter on the reservoir side but looks longer on the inside.

Thanks

 

Installed it tonight, seems that the shaft is shorter as well. I had to unscrew the mounting plate all the way to the very end, I almost thought it was going to be to short on the inside. I'll get some pics of how it sits both inside and outside.

 

So you clear now?

 

Haven't put the wheels on, was freezing my ass off last night. In theory it should clear. I needed 1 1/2" clearance I got about that with the new master cylinder. The tire size I have now is a 205/75/14 I plan to run 205/45/18 this would mean an additional 1/4" of clearance. 205/75/14 is 26.1" tall and the 205/45/18 is 25.6" tall. As long as my calculations are correct I should have just about enough room.

 

I know you drive yours alot but a 45 looks really thick when the trucks laid out...i know on mine the rear tire looked great and it was a 40 series, but the lil bit of neg camber up front made it look realy thick...

my 20s are gonna run on 30s!

 

Well alittle more tonight. I did get to check the clearance of the wheel and...


Still F-Ing hits.
I'll get that figured out soon enough...

Well I got the wiring harness cut and extended. Yes the wires I used are the same color accept for the really thin wires, but, I cut it in the middle and extended from there. This will still allow all the wires to be traced if ever need be.





Went to install the heat and AC blower box back in and DOH! for got I have to seam seal the wheel tubs lol so I did the passenger side so I can start buttoning this side back up.





Tomorrow hopefully I'll get the heater box back in and get the distribution block setup and start putting some of this stuff back together. Still a lot to do but it's coming together.

 

Truck looks great!! Thanks for all the pics, will definitely help me on mine.

 

Got alittle more done last night. Didn't touch her tonight, cleaned up the shop instead it looked like a tornado had gone through it.

Alright... Got the passenger tub seam sealed and put some primer on it, I do use paint lock steel so it won't rust on its own but what the heck why not. Never going to see it again after the carpet is on it...



And then this... They said "you can't have STOCK ac and heat with wheel tubs for a body drop on a v6". So, I did it anyways. I have probably 40+ hours into cutting, plastic welding, and bugging the hell out of mike on my questions. But she's all done and put back. Decided to put a new blower regulator after I dropped and broke mine and placed it in an unacceptable spot.



Most guys, and girls, run their computer in their glovebox cause there is no room now due to the wheel tubs. After some messing around and putting, cutting pieces of metal and a little finessing I came up with this braket that will hold the computer behind the glove box. When the glove box is mounted the wires and computer are tucked up just enough not to be seen.



A little further back with all of it in 1 pic.



Got the battery distribution block mounted where the computer used to be. 1/0 in to (2) 4awg and (4) 8 awg out.



That it for the weeks work. Tomorrow is Saturday and hopefully I'll get ALOT done this weekend!!!

 

awesome! some more great shots of the heater! keep em coming!

 

Thanks so much for taking the time for pics. I'm more a visual type person and they help very much.