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 Hits: 2162 Size: 88 KB Posted: 9/14/08 Just to see how difficult it is & how the spray cans turn out, I scuffed the fender that I plan to r... |  Hits: 1808 Size: 93.56 KB Posted: 9/14/08 Just to see how difficult it is & how the spray cans turn out, I scuffed the fender that I plan to r... |  Hits: 1776 Size: 80.26 KB Posted: 9/14/08 Just to see how difficult it is & how the spray cans turn out, I scuffed the fender that I plan to r... |  Hits: 1807 Size: 85.08 KB Posted: 9/14/08 Using state-of-the-art masking & paint booth technology, I put a few light coats of primer on. |  Hits: 1838 Size: 89.9 KB Posted: 9/14/08 After a few seconds, I put on the first topcoat. |
 Hits: 1811 Size: 88.28 KB Posted: 9/14/08 Then another topcoat. |  Hits: 1708 Size: 96.31 KB Posted: 9/14/08 After a few minutes, it looks OK.
...at least as good as the rest of the truck. |  Hits: 1707 Size: 83.87 KB Posted: 9/14/08 I picked this beauty up at a local junkyard for ~$30. What a steal! |  Hits: 1678 Size: 89.17 KB Posted: 9/14/08 The used 120-grit pad wasn't cutting it, so I switched to a used 80-grit. When that started coming ... |  Hits: 1701 Size: 87.3 KB Posted: 9/15/08 It took ~3/4 can of primer to get a few light coats on both sides & inside. |
 Hits: 594 Size: 72.64 KB Posted: 3/13/16 This isn't marketed for paint, but it's good enough for this truck. |  Hits: 2113 Size: 102.64 KB Posted: 9/15/08 I didn't expect show-quality from this, but I thought it might save some time. |  Hits: 2027 Size: 104.8 KB Posted: 9/15/08 It's actually a REALLY good-looking spatter finish. :)
Too bad that's not what I want. :(
**... |  Hits: 1781 Size: 83.54 KB Posted: 9/15/08 After a failed attempt with the mighty Wagner HVLP deck stain gun on the inner face, I switched back... |  Hits: 1735 Size: 68.23 KB Posted: 9/15/08 It's building up slowly, and not as bad as I expected. |
 Hits: 1883 Size: 87.43 KB Posted: 9/16/08 I've emptied & pressure-washed this '95 door, and I'm about to sand it. The factory trim strip remo... |  Hits: 1672 Size: 88.83 KB Posted: 9/16/08 The clearcoat is surprisingly tough - it stood up to the 80-grit sanding better than I thought it wo... |  Hits: 1745 Size: 84.86 KB Posted: 9/17/08 Since this paint was in MUCH better condition than the fender, I only primed where I hit metal. |  Hits: 1669 Size: 97.95 KB Posted: 9/17/08 Since this paint was in MUCH better condition than the fender, I only primed where I hit metal. |  Hits: 1722 Size: 48.82 KB Posted: 9/17/08 The first LIGHT coat of paint. |
 Hits: 1644 Size: 95.94 KB Posted: 9/17/08 The first LIGHT coat of paint. |  Hits: 1651 Size: 84.7 KB Posted: 9/19/08 Finished with the black. The light, hazy areas are reflections. I'll (probably) do the tan after i... |  Hits: 1618 Size: 91.45 KB Posted: 9/19/08 Finished with the black. I'll (probably) do the tan after it & the fender are installed. |  Hits: 2024 Size: 65.08 KB Posted: 9/20/08 The lower rear bolt (13mm) and the one in the door jamb (10mm) are out. With the hood supported, re... |  Hits: 1906 Size: 107.34 KB Posted: 9/20/08 First, I removed the battery, tray, starter relay, PA, coffee can, 2ndry air intake, & wheelwell for... |
 Hits: 1682 Size: 69.88 KB Posted: 9/20/08 With the wheelwell gone, the six 8mm (5/16") bolts at the front of the fender are much easier to acc... |  Hits: 1767 Size: 106.28 KB Posted: 9/20/08 The core support rotted out long ago, due to leaking batteries. But that section only holds the for... |  Hits: 3255 Size: 101.22 KB Posted: 9/20/08 The fender then comes off easily. While it's off, I'll fix the exhaust leak. But the original reas... |  Hits: 2286 Size: 92.04 KB Posted: 9/20/08 The cardboard on the body horn is the shim for adjusting the height of the fender to the door body l... |  Hits: 1737 Size: 112.29 KB Posted: 9/20/08 This is the only reason I'm replacing the fender - the nuts for the battery tray ripped out years ag... |
 Hits: 2240 Size: 49.25 KB Posted: 9/20/08 With the fender removed, the hinge bolts are EASY to access.
For door alignment, see this post:
htt... |  Hits: 1867 Size: 83.19 KB Posted: 9/20/08 The last time I worked on the hinges, the fender was in-place, and apparently, I forgot to tighten t... |  Hits: 1717 Size: 93.79 KB Posted: 9/20/08 The door has been emptied, and the wiring is loose inside it. It's ready to come off.
For more abo... |  Hits: 1731 Size: 100.42 KB Posted: 9/20/08 The door has been emptied, and the wiring is loose inside it. It's ready to come off.
This is an '... |  Hits: 1558 Size: 94.37 KB Posted: 9/20/08 The wiring connectors fit out the hole in the door, but the harness can also be unplugged from the p... |
 Hits: 2304 Size: 75.26 KB Posted: 9/20/08 The doors use captive nut plates for the hinge bolts. The body's hinge nut plates are similar, as a... |  Hits: 1622 Size: 73.32 KB Posted: 9/20/08 The '92-96 door panels interfere with the '80-86 dash slightly, which is why the pad is dimpled & di... |  Hits: 1814 Size: 89.41 KB Posted: 9/20/08 I got the orange-peel almost PERFECTLY even. :D
With the fender off, aligning the door will be VERY... |  Hits: 2019 Size: 73.99 KB Posted: 9/20/08 This is just about where I want it. The weight of the internals should bring the door down just to ... |  Hits: 1867 Size: 73.64 KB Posted: 9/20/08 The door doesn't fit the opening exactly right, but considering what the body has been through, it's... |
 Hits: 1566 Size: 84.89 KB Posted: 9/20/08 After a little massaging, the door fits even better.
For door alignment, see this post:
http://www.... |  Hits: 1584 Size: 45.24 KB Posted: 9/20/08 It's barely visible, but there's a tapering gap between the door & body seal, indicating that THIS e... |  Hits: 1799 Size: 50.11 KB Posted: 9/20/08 I've re-adjusted the hinges so the lower front edge of the door seals evenly. To make the rear edge... |  Hits: 1506 Size: 52.31 KB Posted: 9/20/08 To complete the alignment, the latch & strike must be installed. This later style of lock motor mus... |  Hits: 2240 Size: 95.68 KB Posted: 9/20/08 The '95 door lines match the '82 body lines perfectly. There was actually NO change to the door lin... |
 Hits: 2224 Size: 66.33 KB Posted: 10/2/08 PERFECTION!!! |  Hits: 1702 Size: 51.94 KB Posted: 10/6/08 I got sick of seeing the all-black door & fender faster than I expected, so after hunting through ~5... |  Hits: 1646 Size: 65.6 KB Posted: 10/6/08 I didn't feel like painting the whole thing at once (& I couldn't find enough newspaper), so I just ... |  Hits: 1584 Size: 66.81 KB Posted: 10/6/08 The door was easier than I thought, so after supper, I moved the masks to the fender & shot a few qu... |  Hits: 1682 Size: 69.27 KB Posted: 10/6/08 The door was easier than I thought, so after supper, I moved the masks to the fender & shot a few qu... |
 Hits: 1572 Size: 54.67 KB Posted: 10/6/08 After a few minutes, I pulled the masking off. |  Hits: 1780 Size: 65.97 KB Posted: 10/6/08 Good enough for me! |  Hits: 1577 Size: 49.5 KB Posted: 10/6/08 Good enough for me! It'll be spread across the rocks & trees at the SuperLift park in Hot Springs s... |  Hits: 1576 Size: 54.96 KB Posted: 6/13/09 For the past ~5 years, I haven't been able to open my tailgate. I knew what caused it - these 2 & a... |  Hits: 1316 Size: 75.98 KB Posted: 6/13/09 For the past ~5 years, I haven't been able to open my tailgate. I knew what caused it - these 2 & a... |
 Hits: 1599 Size: 80.56 KB Posted: 6/13/09 The polyurethane body mounts aren't collapsed or compressed, but the body crossmember that rests on ... |  Hits: 1438 Size: 78.56 KB Posted: 6/13/09 This is the L outboard end of that body crossmember. It holds the bedrail upright & supports the qu... |  Hits: 1471 Size: 74.66 KB Posted: 6/13/09 The polyurethane body mounts aren't collapsed or compressed, but the body crossmember that rests on ... |  Hits: 1459 Size: 81.18 KB Posted: 6/13/09 This is the R outboard end of that body crossmember. It holds the bedrail upright & supports the qua... |  Hits: 1503 Size: 60.48 KB Posted: 6/13/09 Before the frame shop worked on it, I couldn't get the t/g this far open (which still isn't all the ... |
 Hits: 1493 Size: 36.79 KB Posted: 6/13/09 The main bend in the body crossmember is close to the R body mount, where the visible kink is. |  Hits: 1511 Size: 68.09 KB Posted: 6/13/09 To repair it, I'm going to use this I-beam (because I have it), but it has to be the right length. ... |  Hits: 1490 Size: 47.97 KB Posted: 6/13/09 The hooks on this ratcheting cargo strap fit perfectly, and the body crossmember is strong enough to... |  Hits: 1568 Size: 56.97 KB Posted: 6/13/09 I laid the long beam across the bedrails & put my heaviest ratchet strap over it. The strap is just ... |  Hits: 2003 Size: 64.83 KB Posted: 6/13/09 As tension rises in the strap, there's a lot of groaning. The short beam is directly above the kink... |
 Hits: 1573 Size: 64.14 KB Posted: 6/13/09 The strap started off just snug, so it's stretching noticeably. The rags are being cut by the immen... |  Hits: 1545 Size: 59.03 KB Posted: 6/13/09 Yes, the beam is bending, too. And there's a real risk of the jack shooting out from under the beam... |  Hits: 1408 Size: 80.12 KB Posted: 6/13/09 But the body is bending the way I planned, so it's working. For the first time in 5 years, the cabl... |  Hits: 1643 Size: 65.01 KB Posted: 6/13/09 Despite the progress I made with the first pull, I decided to reset & use another jack. This time, ... |  Hits: 1443 Size: 76.44 KB Posted: 6/13/09 I was surprised at how easily I was able to bend this 48" Gorilla Bar. Maybe it wasn't designe... |
 Hits: 1534 Size: 74.82 KB Posted: 6/13/09 This isn't making as much visible progress as the first pull, and I eventually put so much pressure ... |  Hits: 1475 Size: 62.54 KB Posted: 6/13/09 After the explosion, I reset the cribbing & put a laminated wood board under the short beam to allow... |  Hits: 1434 Size: 78.74 KB Posted: 6/13/09 The rubber pad on the bumper lid is now barely touching the t/g trim panel, just like when I install... |  Hits: 1406 Size: 55.65 KB Posted: 6/13/09 It's not visible, but the rubber pad on the bumper lid is now barely touching the t/g trim panel, ju... |  Hits: 1381 Size: 43.48 KB Posted: 6/13/09 The apparent change is 1/2" on the L & 1" on the R. |
 Hits: 1542 Size: 88.23 KB Posted: 6/13/09 A vast improvement. |  Hits: 1626 Size: 61.2 KB Posted: 6/13/09 It's obviously better, though not quite as flat as I had hoped. But the gap between the t/g & bumpe... | | | |