Saturday, Aug. 14, 2004  -  Spent the day in the shop today getting the front end put back together....well, most of it, anyway.

I started out by installing the PST polygraphite suspension bushings into the I-beams and connecting the radius arms to them as well. Once I got started actually installing each set onto the frame, it dawned on me that I'd neglected to sandblast the coil spring retainers, so I had to fire up the sandblaster again for a few minutes to get those cleaned up and painted. Got the two sides pretty much installed, and was ready to hit the parts store to get the last items I really needed: the rotors. However, I'd neglected to check their Saturday hours, and both stores in town were closed by that time.

I did run run by local farm supply store and stocked up on Grade 5 bolts, nuts and washers. I needed these for various things, like the front crossmember, the tranny crossmember and the auxiliary tank mounting brackets.

Fig. 1  -  These are the PST polygraphite front suspension bushings. Each bushing set is actually a total of five pieces.

Fig. 2 - Here's a shot of the front suspension mostly installed. After this pic was taken I also installed the front shocks.

I then got started doing a final complete mockup of the auxiliary fuel tank and skid plate. This is the inboard tank that sits under the back half of the cab and the front half of the box, with the filler opening in the box. I wanted to completely install it, to make sure I had all the brackets and that anything that needed to be modified or fabricated was noted. I'd done a quick mockup a while back, but I wanted this one to be complete. I did have to make a few changes. Since this tank was originally installed on a long bed, the rear mounting arm for the skid plate had to be moved towards the rear of the truck several inches to clear the rear crossmember. Since this tank setup is used on both long and shortbox trucks, the necessary holes were already there. I also had to remove one rivet from the rear crossmember to mount the tank's rear retaining strap bracket. Here are a few shots of the installation mockup:

Next on the agenda is to get the new front brake rotors and rear brake drums and to assemble the rear brake assemblies. I'm also going to be picking up some steel brake line so I can start plumbing those lines, which will enable me to do the final install of the fuel tank, once the brake lines are mounted along the inside frame rail. I'm hoping to get back in the shop tomorrow to get started getting the fuel tank and hardware cleaned up. I've got a full day's worth of work ahead of me just getting the tank and skidplate sandblasted and painted.

I'm actually getting VERY close to having a rolling chassis! Stay tuned!