Mega M1009 update..truck finished...

[linx310]

If you do not have a clue what I am talking about read the past threads starting with the first one.

Past threads here:
http://www.gunsnet.net/showthread.php?1937
http://www.gunsnet.net/showthread.php?1862
http://www.gunsnet.net/showthread.php?2744
http://www.gunsnet.net/showthread.php?2954
http://www.gunsnet.net/showthread.php?3220
http://www.gunsnet.net/showthread.php?4720
http://www.gunsnet.net/showthread.php?5299
http://www.gunsnet.net/showthread.php?5505
http://www.gunsnet.net/showthread.php?5980

Well after months of work my M1009 project is nearing the end. All I have left to do is install the Turbo and some Radios.

The last update I left you guys off on was me finishing up some painting on the main body of the truck. Since that time I have busted my ass off in the cold weather (it snowed in hel..I mean Texas) to get it done before the spring.

After painting the main body of the truck I reinstalled the front grill and bumpers. I highly recommend if you do this you have some one help. I did it alone and it sucked.

Did I mention that anti-seize paste gets all over the place? I used this stuff on the grill bolts so they don’t seize up again.

Once I got the grill and bumpers put back together I painted it black and brown to match the rest of the truck.

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish1.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish2.jpg

I removed the old tires and rims so I could paint the chassis and install the new mud guards. With the rims off it also offered the perfect opportunity to paint the rims themselves along with more parts I did not get a chance to paint earlier.


http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish3.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish4.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish5.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish6.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish7.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish8.jpg

[linx310]

Once I had the parts I painted I rebuilt the pintel assembly. I had to find a new cannon plug because a forklift or some other vehicle broke it. With the parts painted and reassembled I think it came out great!

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish9.jpg

Here are some pictures of the freshly painted chassis and mud guards installed. I used rustoleum hammered on the axels and parts of the frame and used rustoleum bbq paint on the exhaust. Looks much better now!


http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish10.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish11.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish13.jpg

Got some of the front accessories installed.

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish11.jpg


At this point I decided to deal with my steering wheel problem. When I am going down the road the steering wheel is 90 degrees off center. I went to remove the steering wheel to exam it and noticed private pyle had already tried and broke it in the process. In attempt to fix it he glued it back together!


http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish14.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish15.jpg

Luckily the problem was not with the wheel, it was the draglink that was way out of adjustment. I tried to adjust it with a pipe wrench but it was frozen solid. Frustrated I went and got a “hot wrench” and had the thing turning freely within a few minutes. Now my steering wheel points straight!


http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish16.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish17.jpg

The next day the weather was still very nice so I removed my floor vents to replace the leaky seals. I also took the time to paint the vents to match the rest of the black interior pieces.


http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish18.jpg

[linx310]

I also discovered why my truck smoked and idled badly at start up. I only had 3 of the 8 glow plugs working properly. I removed them with a special tool. 3 of them where mushroomed badly! Two more tested non functioning but had not mushroomed yet.


http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish21.jpg

I replaced them with AC Delco 60Gs, a much better glow plug. I had to install new spade plugs, the old ones were worn out anyway.


http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish20.jpg

I also noticed I had an injector return line leaking. I need to fix that!


http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish19.jpg

I moved on to the tailgate. I was having problems with it leaking badly into the back of the truck so I replaced the window seal, the tailgate seal, the access panel seal, and drilled some drain holes in the bottom of the tail gate to let the water drain out so it doesn’t rust up. When I finished I closed the tail gate but could not get it to open. I discovered that my tailgate handle was so bent with the new seals it could not open the tailgate. Got to order one of those now…err


http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish25.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish26.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish27.jpg

I read online that a lot of these trucks had nylon bushing around the door strikers, but most brake off after a few years and this is what makes the doors so hard to close. Instead of buying a $10 set of bushing I purchased a piece of PEX tubing, cut a slit on one side and slid them on. Now the doors close by barely pushing them. If you have an eighties GM truck you should try this!


http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish29.jpg

Well I spoke to soon, sorta…I installed new door seals and I have to shut the doors hard again until the seals break in. In a few weeks the doors should be shutting easy again.

Next I installed the driver side radio mount, guard, and antenna. I am going for a “phase 1” install so they will be mounted to the rear with the antennas tied forward. And if you have not noticed I got my Treadright tires installed.

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish24.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish23.jpg

Well thanks to mother nature…I was delayed on getting the parts I needed to complete my truck. What’s all this white stuff! We never get that here….the last time I think I saw it stick was 1990 here…

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish28.jpg

[linx310]

The weather warmed up and the parts I need still have not come in! So I am going to installing the spare tire carrier. First I had to weld up this crack. After welding it and adding paint it looked brand new. I forgot to take a picture of the part after the weld.

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish31.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish32.jpg

I also installed a switch for the yellow strobe light that is installed on top. It was wired up to come on any time I turned the lights on, which I have a feeling would have led to me getting a ticket! Now all I have to do is flip the switch to turn it on and off. Since I was messing with the wiring I channeled all the loose wires running every place neatly with wire shield and mounts.

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish66.jpg

Parts finally came in! Bout dang time UPS! Since finding new replacement injector lines is expensive I used 5/32 Tygon line which is quality stuff. My old lines were all dry rotted.

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish22.jpg

I installed the new tail gate handle and my tail gate now opens and shuts again.

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish33.jpg

I painted the stencils on my truck and installed the passenger side antenna.

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish37.jpg

[linx310]

I also put together a custom license plate hold so I did not have to drill into the truck. I used a harbour freight 100 lb magnet to hold the base on. The two nuts on the top have LEDs that light up the plate. I wired a cig lighter into the lights so it only provides power when I have the headlights on. I used a car accessory cable because it can stretch down when I lower the tail gate if I forget to take the plate holder down. I ran out of spade connectors so I had to use twist caps until I can pick up some more.

When I took the truck to get inspected the guys at the inspection station that this was one of the coolest ways to mount a plate they have seen.


http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish39.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish40.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish41.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish42.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish49.jpg

Picked up a new oil filter, new fuel filter, new (better) glow plug relay, wipers, and changed them all out along with the oil.


http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish34.jpg

I got my new US Army water cans in. Found a place that had new ones for $18 and if you bought 3 or more shipping was free!

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish45.jpg

[linx310]

Various pics below

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish43.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish44.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish45.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish46.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish48.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish49.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish50.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish51.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish52.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish53.jpg

[linx310]

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish54.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish55.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish56.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish57.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish58.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish59.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish61.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish62.jpg

[linx310]

A couple pics of me with my M1009

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish63.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish64.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/finish65.jpg

A few Before and After pictures


http://i180.photobucket.com/albums/x222/linx310/cucvfin/baf1.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/baf2.jpg

http://i180.photobucket.com/albums/x222/linx310/cucvfin/baf3.jpg

[cevulirn]

Nice! What do you suppose you have invested in it?

[deth502]

awwww, loved the whole project till i got to the lic plate. dont like the idea of having to take it off/put it on when working the gate. why not bolt the bracket to the side where the wires are, behind the tire, so its not in the way of operating the gate?

[linx310]

awwww, loved the whole project till i got to the lic plate. dont like the idea of having to take it off/put it on when working the gate. why not bolt the bracket to the side where the wires are, behind the tire, so its not in the way of operating the gate? .

I designed it like that so you can remove it completely at a military vehicle show quickly.

[skorpion]

Awesome job, Linx! You put a lot of work into this project and it shows for sure! And thanks for the reminder that I have to replace my glowplugs, too! Real trucks don't have spark plugs. :)

[FunkyPertwee]

Kick-ass truck! And great job on a project well done.

I'd love to finish a big project like that.

[GunWorm]

I'll drop mine off next week so you can do it too.

:D

[JTHunter]

Linx - I have a question for you regarding the use of the Tygon tubing. Is it chemically resistant enough to withstand several years of exposure to the diesel fuel? Also, will they be able to withstand the heat of close proximity to the engine without deformation or rupture?

[Bettendorf]

Really nice job, Linx. I think you have set a Worlds Record for the Most amount of time spent on a CUCV! Turned out pretty nice.

I sold mine back in December. Oh, well.

[NewbieAKguy]

Very well done! :clap:

[linx310]

Linx - I have a question for you regarding the use of the Tygon tubing. Is it chemically resistant enough to withstand several years of exposure to the diesel fuel? Also, will they be able to withstand the heat of close proximity to the engine without deformation or rupture?

Tygon tubing is used in glow plug engines, chainsaws, and other high rpm motors as the fuel line and it is resistant to diesel, nitro, and gas. There are several people who have CUCVs that have had it on there M1009s for a couple of years now.

[L1A1Rocker]

What a great project! Thank you for taking us along.

[El Laton Caliente]

Great Job!!!

[deth502]

I designed it like that so you can remove it completely at a military vehicle show quickly.

i take it that was a reply to my post? lol

well, in that instance, i suppose i can let it slide....

[Richard Simmons]

Very, very nice! Congrats on a job well done.

[O.S.O.K.]

Wow! I wonder what you could get for it if you decided to sell? I bet you'd make a nice profit.

Very well done!

[Penguin]

Very cool, nice job.

[linx310]

Nice! What do you suppose you have invested in it?

Probably $5,500-$7,500 - figure includes the tools, parts, and the truck.

I spent $1,200 on a mig welder alone....

The figure for just the parts and the truck is probably $3.5k-$5k

I have a huge pile of receipts i need to add up and put into excel.

If you think about it thats a bargain considering what a brand new 4x4 with a diesel cost.

[63DH8]

You got lucky with those glow plugs. I've worked on a 1008 that the glow plug swelled to the point where we couldn't get the plug out. It broke off in the head. Fortunately, we were able to fish the remains out through the injector hole. There's a pre-combustion chamber in the head that caught the glow plug end.

[linx310]

You got lucky with those glow plugs. I've worked on a 1008 that the glow plug swelled to the point where we couldn't get the plug out. It broke off in the head. Fortunately, we were able to fish the remains out through the injector hole. There's a pre-combustion chamber in the head that caught the glow plug end.



There is now a tool to help out with that. Mine were stuck too, but the tool got them out for me. The tool is currently being evaluated by the US military to be issued to depots that work on the humvee.

http://jjandaracing.com/en-us/dept_9.html

[skorpion]

There is now a tool to help out with that. Mine were stuck too, but the tool got them out for me. The tool is currently being evaluated by the US military to be issued to depots that work on the humvee.

http://jjandaracing.com/en-us/dept_9.html
Awesome! Might have to order one of these. Thanks, Linx!

[JTHunter]

Tygon tubing is used in glow plug engines, chainsaws, and other high rpm motors as the fuel line and it is resistant to diesel, nitro, and gas. There are several people who have CUCVs that have had it on there M1009s for a couple of years now.

Thanks for the follow-up. That's good to know.

[slamfire51]

Great job Linx.
The Government might see it and try to reclaim it. LOL

[cevulirn]

Great job Linx.
The Government might see it and try to reclaim it. LOL

Nah, nothing the Government has looks that good!

[1 Patriot-of-many]

You got me hooked Linx. Tomorrow I'm going to preview some M1008 pickups as well as two more M35A3's, an M35A2 and a 5 ton dumptruck at Camp Ripley..My wife thanks you.....NOT
I'd rather have a M1009 like yours, haven't seen any in my area up for auction.

[linx310]

You got me hooked Linx. Tomorrow I'm going to preview some M1008 pickups as well as two more M35A3's, an M35A2 and a 5 ton dumptruck at Camp Ripley..My wife thanks you.....NOT
I'd rather have a M1009 like yours, haven't seen any in my area up for auction.

Your welcome...M1008s are some serious pickups if you can get them for decent price.

[deth502]

we just got rid of all 3 of ours at work. the pickup went for $600, the blazer went for $450, and the parts blazer went for $300.

[1 Patriot-of-many]

we just got rid of all 3 of ours at work. the pickup went for $600, the blazer went for $450, and the parts blazer went for $300. WHAT? Were they rust buckets.
/ not running?

[deth502]

the blazer had some rust, not too bad, structuraly sound. needed a complete exhaust and 4 tires.

truck needed some tranny work, were gonna throw the tranny from the parts blazer in it but never got to it. other than that and a dent in the door from when somebody (cough*) hit a trailer tongue with it (10 min worth of bondoing) it was very solid.

the parts blazer had the motor out of it, the truck had a blown motor when we got it, and put that one in.

keep an eye out, you might find them around yet. we are a municipality, so we were able to buy them as surplus right from the govt. they were $500-700 when we bought them. watch your local municipalities. im sure there are MANY more out there like ours.

[MDE]

Great job.

Mike

[Partisan1983]

VERY AWESOME Linx!!!!


Ever since working on a few of the pickups at random fire dept's, I have wanted one like no other.


Edit: They were M1008's. The FD's use 'em as grass rigs.

[1 Patriot-of-many]

Linx, I ended up bagging a M1009 at Sparta, WI. M1008's went a little too high for my liking, got one for $1461 showing 32,000 miles, driven to lot. I see some rust, but I imagine that comes with the territory for an 1985.