RattleTest01.JPG
2063 hits | 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...
RattleTest02.JPG
1703 hits | 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...
RattleTest03.JPG
1678 hits | 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...
RattleTest04.JPG
1707 hits | 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.
RattleTest05.JPG
1741 hits | 89.9 KB | Posted: 9/14/08

After a few seconds, I put on the first topcoat.
RattleTest06.JPG
1705 hits | 88.28 KB | Posted: 9/14/08

Then another topcoat.
RattleTest07.JPG
1604 hits | 96.31 KB | Posted: 9/14/08

After a few minutes, it looks OK.

...at least as good as the rest of the truck.
Fender01.JPG
1606 hits | 83.87 KB | Posted: 9/14/08

I picked this beauty up at a local junkyard for ~$30. What a steal!
Fender02.JPG
1583 hits | 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 ...
Fender03.JPG
1605 hits | 87.3 KB | Posted: 9/15/08

It took ~3/4 can of primer to get a few light coats on both sides & inside.
WagHVLPstain.jpg
495 hits | 72.64 KB | Posted: 3/13/16

This isn't marketed for paint, but it's good enough for this truck.
HVLP1.JPG
2020 hits | 102.64 KB | Posted: 9/15/08

I didn't expect show-quality from this, but I thought it might save some time.
HVLP2.JPG
1931 hits | 104.8 KB | Posted: 9/15/08

It's actually a REALLY good-looking spatter finish.


Too bad that's not what I want.

**...
Fender05.JPG
1685 hits | 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...
Fender06.JPG
1638 hits | 68.23 KB | Posted: 9/15/08

It's building up slowly, and not as bad as I expected.
Door01.JPG
1774 hits | 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...
Door02.JPG
1572 hits | 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...
Door03.JPG
1643 hits | 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.
Door04.JPG
1579 hits | 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.
Door05.JPG
1623 hits | 48.82 KB | Posted: 9/17/08

The first LIGHT coat of paint.
Door06.JPG
1553 hits | 95.94 KB | Posted: 9/17/08

The first LIGHT coat of paint.
Door07.JPG
1564 hits | 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...
Door08.JPG
1518 hits | 91.45 KB | Posted: 9/19/08

Finished with the black. I'll (probably) do the tan after it & the fender are installed.
Fender09.JPG
1923 hits | 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...
Fender07.JPG
1799 hits | 107.34 KB | Posted: 9/20/08

First, I removed the battery, tray, starter relay, PA, coffee can, 2ndry air intake, & wheelwell for...
Fender08.JPG
1575 hits | 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...
Fender12.JPG
1661 hits | 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...
Fender10.JPG
3129 hits | 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...
Fender11.JPG
2176 hits | 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...
Fender13.JPG
1639 hits | 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...
Door09.JPG
2146 hits | 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...
Door10.JPG
1768 hits | 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...
Door11.JPG
1619 hits | 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...
Door12.JPG
1626 hits | 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 '...
Door13.JPG
1457 hits | 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...
Door14.JPG
2202 hits | 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...
Door15.JPG
1524 hits | 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...
Door16.JPG
1717 hits | 89.41 KB | Posted: 9/20/08

I got the orange-peel almost PERFECTLY even.

With the fender off, aligning the door will be VERY...
Door17.JPG
1913 hits | 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 ...
Door18.JPG
1775 hits | 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...
Door19.JPG
1473 hits | 84.89 KB | Posted: 9/20/08

After a little massaging, the door fits even better.

For door alignment, see this post:
http://www....
Door20.JPG
1474 hits | 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...
Door21.JPG
1691 hits | 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...
Door23.JPG
1394 hits | 52.31 KB | Posted: 9/20/08

To complete the alignment, the latch & strike must be installed. This later style of lock motor mus...
Door24.JPG
2122 hits | 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...
Fender14.JPG
2116 hits | 66.33 KB | Posted: 10/2/08

PERFECTION!!!
Tan01.JPG
1610 hits | 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...
Tan02.JPG
1547 hits | 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 ...
Tan03.JPG
1485 hits | 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...
Tan04.JPG
1585 hits | 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...
Tan05.JPG
1476 hits | 54.67 KB | Posted: 10/6/08

After a few minutes, I pulled the masking off.
Tan06.JPG
1685 hits | 65.97 KB | Posted: 10/6/08

Good enough for me!
Tan07.JPG
1485 hits | 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...
TG01.JPG
1463 hits | 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...
TG02.JPG
1202 hits | 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...
TG03.JPG
1453 hits | 80.56 KB | Posted: 6/13/09

The polyurethane body mounts aren't collapsed or compressed, but the body crossmember that rests on ...
TG04.JPG
1339 hits | 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...
TG06.JPG
1373 hits | 74.66 KB | Posted: 6/13/09

The polyurethane body mounts aren't collapsed or compressed, but the body crossmember that rests on ...
TG05.JPG
1362 hits | 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...
TG07.JPG
1406 hits | 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 ...
TG08a.JPG
1399 hits | 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.
TG10.JPG
1414 hits | 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. ...
TG11.JPG
1395 hits | 47.97 KB | Posted: 6/13/09

The hooks on this ratcheting cargo strap fit perfectly, and the body crossmember is strong enough to...
TG23.JPG
1465 hits | 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 ...
TG11a.JPG
1898 hits | 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...
TG11b.JPG
1482 hits | 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...
TG11c.JPG
1449 hits | 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...
TG12.JPG
1305 hits | 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...
TG13.JPG
1540 hits | 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, ...
Gorilla.JPG
1341 hits | 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...
TG14.JPG
1432 hits | 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 ...
TG21.JPG
1370 hits | 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...
TG15.JPG
1334 hits | 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...
TG22.JPG
1312 hits | 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...
TG16.JPG
1284 hits | 43.48 KB | Posted: 6/13/09

The apparent change is 1/2" on the L & 1" on the R.
TG25.JPG
1441 hits | 88.23 KB | Posted: 6/13/09

A vast improvement.
TG26.JPG
1526 hits | 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...

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