Getting a little fancy... 1987 V10

[frotosride]

Fully rebuilt NP208. I haven't decided if I am going to paint it yet. If I do it will be the same blue as the engine and trans.
Let me know if ya'll think I should paint before final install.

I broke down and got out the old laptop...surprised it even works.

[frotosride]

Started rust repair. First it was time to clean up the firewall and check out the damages. I started with scrapers and razor blades to get off as much as possible or at least thin it out where I could. For the really thick spots a wire wheel on a grinder got it manageable. Then acetone and a greenie got it ready for a real inspection.

[frotosride]

For a while I debated on fixing the drivers side from the inside but I broke down and removed the steering/brake master cylinder firewall brace. From here it was a a very quick reminder that trying to do multiple compound shapes in one piece of metal isn't a good or easy idea. So I did the first repair in 3 pieces.

[frotosride]

Continuing on, I already knew that there was a good rust spot in the lower part of the cowl. I filled it in with some good weld years ago, the JB type. The cleaning revealed another hole in the cowl above the blower fan. After cutting that section out and seeing how much rust was nesting in the seam sealer, I decided to take it further and removed the entire lower pinch weld of the cowl on the passenger side to reveal...you guessed it, more rust.
The likely scenario will be removing it all the way across repairing the cowl and the firewall behind it as needed.
The last pic is the firewall behind the cowl cleaned up with a wire wheel on a grinder. Which reveals more holes...YAY 
I'm not sure if I will be cutting these out or just welding up the holes and dressing them down. This is mostly due to time... the first three patch panels I fabricated (just using simple hand tools, took several hours) factor into this equation.

[frotosride]

I have no idea how long ago I ordered this but the Vintage Air Kit finally arrived. I have seen these kits in trucks and cars before. It looks real nice and surely a huge  upgrade. The only concern I have is the condenser appears a good bit smaller than the OEM. Either way I'm a good way from  installing or even mocking it up. I will research for now and make a decision later. What I do know about the kit is that I do not like the firewall plate. At first, just seeing it online, I thought maybe it wont look that bad....wrong. No worries I do not plan on using it (at least on the outside) for now, nor do I have plans to route the hoses in the recommended locations. When I get to that point I'll let everyone in on my idea.

The pics for the compressor were thankfully though of before I took the engine and trans back out for rust repair. I do like the way the ICT Billet compressor brackets look and hold the compressor. I did run into the problem of having to find a new place for the PCM. This isn't really a big issue since my original plans were to put it in the cab and the new AC system should give me room. However, I am contemplating a more superior fuel management system and TERMINATE ( ) the OE system.

Current decision... to remove cab or not.

Pros:
1) Its hurricane season here in southeast Ga
2)The garage, though not cooled, is still more comfortable
3) I already have new body mounts so they are coming off anyway
4) More environment control for welding and painting.

Cons:
1) Taking the cab off
2) Bigger snowball, i.e. cab corners get mighty tempting!

[Captkaos]

IF you pull it apart STAY focused to get it back together!  It is easy to be distracted when you just have piles of parts laying around..  I am guilty of this...
Nice progress BTW!

[frotosride]

Oh boy don't I know that. It's another con I didn't list. The refer and new piles are getting big. I had to buy a project shelf. Its hard when I don't have some order.

[Shifty]

That's one of biggest fears, since my health isn't the greatest, getting it all apart, and being physically (or psychologically) unable to put it back together. 

Stay focused, and bring that baby back to life!

[bd]

It is easy to be distracted when you just have piles of parts laying around..  I am guilty of this...

Who isn't?   

As all of you noted, parts piles can grow in disarray to the point of being disruptive to progress, eventually making a project unconfrontable if only because of the sheer number of things to be done.  And then there is the, "I'm sure I bought one of those!  Where is it?"  Staying focused and making steady progress as materials arrive in a planned and organized sequence is crucial to avoiding project anxiety and enjoying completion while one is still interested and able.  If you have a spouse...  Well...  Let's just say a lot of time can be consumed explaining the delays....

So, take it from yet another who is guilty.   

I agree.  Nice progress!  Keep on truckin'.   

[frotosride]

Due to a lot of family things I've been real slow in making progress. I'm at the point where I'm likely going to patch the last part of the cowl, slap the drive train back in and drive to help motivate me.

I have fixed the firewall below the fuse box bulkhead connection. Also the few spots I found behind the cowl. There's still some grinding to dress down the welds and a few spot welds left.

The pic between the heater core penetrations and blower fan explains a lot about the water in the passenger floorboard and passenger kick panel rot. Didn't know that was there .













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[frotosride]

Tool of the day for this project. The Blair spot weld cutter. At first glance my thoughts were, " idk if I wanna drill a hole all the way through each spot weld". Well after braking 4-5 double sided harbor freight spot weld cutters I said what the heck, might as well try.
The tool is amazing...the angle of cutter on the centering bit needs good pressure to cut and since it is spring loaded theses no straight through holes! I added a link for those in need

In the pic you can see my floorboard watering hole a lot better. And where the metal was to thin for my Miller Matic 211 to glue holes back together.


Blair 11096 Cutter Set, Black https://www.amazon.com/dp/B002XML5HK?ref=ppx_pop_mob_ap_share

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[frotosride]

I've been tossing the idea around about the tacky plate that came with the Vintage Air kit. I really don't like it. I was planning on going through the old blower fan hole with all 4 lines(a/c, heater hose supply and return). The plan is to fabricate a plate, drill holes and insert grommets. Any thoughts?

The plate would cover the whole outline. All old holes will be filled with patch panels. The only exception will be the huge hole for the a/c evaporator. I'm thinking a two piece panel that's removal for easy access to the back side of the air box.

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[Mike81K10]

I had to do about the same rust repair on my firewall and just completed the Vintage Air Gen IV installation with the exception of some of the wiring. I used their cover plate on my firewall after I painted it to match and installed it to the installation instructions. Had to do some work to the radiator support for better line routing.

[frotosride]

I remember seeing yours and it looks good. It just bigs me to no end that all those holes are just chilling back there. I truly appreciate all the old things these trucks have/had buy the ac/heater box has never been one of them.
Hiding all these holes and drilling new ones seems criminal to me. I truly get the point of making a retrofit item that anyone can install.
To me it reminds me of old 90 "kit cars" where you get a can, glue some pieces to it and call it something it ain't.

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[Mike81K10]

The A/C Firewall panel actually uses most of the old holes with the exception of a  few. But it could probably be improved. Did you paint your transfer case or leave it bare. I like it bare, but would also look good painted. Either way would be good. Your truck is looking good.