Chassis, Suspension, and Brakes
Choosing the Level of Restoration
Preparing Your Workspace
NOS Versus Reproduction Versus Aftermarket Parts
Purchasing a Parts Vehicle
Organizing and Cataloging Your Parts
Tools and Equipment
Welding and Metalwork
Consumable Materials and Supplies
Making Your Own Tools
Installing New Cab Mounts
Body Trim
Stripping the Finish
Inspecting for Rust
Panel Replacement Procedures
Repairing Bed Rust Damage
Repairing Cab Rust Damage
Repairing Dents and Dings
Applying Body Filler
Gapping the Panels
Fixing Factory Issues
Prep for Paint
DIY Versus Paying a Professional
Equipment
Paint Types
Paint Colors
Priming
Sealing
Painting Basics
Analysis of Work Required
Engine Removal
Engine Installation
Rebuilding Basics
Transmission Types
Tools and Equipment
Removing the Transmission
Disassembling the Transmission
Rebuilding Basics
Axle Identification
Gearing
Rebuilding an Axle
Remove or Replace
Brake Lines
Front Disc Brakes
Wheel Bearings
Rear Drum Brakes
Bleeding the Brakes
DIY Versus Paying a Professional
Removal and Installation
Rebuilding Basics
Tools and Equipment
Full-Chassis Harness
DIY Versus Paying a Professional
Trim Removal
Interior Disassembly
Interior Reassembly and Refurbishment
Chapter 12: Miscellaneous Mechanicals
Fuel System
Badge and Emblems
Long-Bed to Short-Bed Conversion
DEDICATION
To my son, Kevin Jr. (KJ), the little boy who sits by my side whenever I’m turning a wrench.
To my daughter, Kaylee, the little girl who sits by my side whenever I’m turning a wrench.
And to my wife, Kirsten, who loves wrenches.
I love you all.
A lot of books have an acknowledgments section where the author claims that the book “couldn’t have been done without the help of XX people,” and the reader’s skepticism sets in. But when I say that I couldn’t have done this book without these people, I mean it. There’s no way it would’ve happened because they were invaluable.
Thanks to Dino and Dino (Little D) at Dino’s Chevy Only. Although their specialty is 1960–1966 Chevy trucks, they certainly know the 1973–1987 market, and they hooked me up with numerous contacts that helped me get the job done.
Thank you to Joe Yezzi, Rob Yezzi, and all of the Squarebody Syndicate crew. Not only did they reorganize their schedules around mine to help out with the book, but they also worked on their trucks specifically for me. That was invaluable.
A big hug and thank you to Troy and Jimbo at Borne Customs. Troy didn’t know who I was when I cold-called him, but he was cool with me taking a camera into his shop and practically