K5 Rust Repair

[sonicbluezx3]

Hopefully I have this in the right spot, but I just acquired a 1978 K5 Blazer from my father in law. He bought it from the dealer back then and is the only owner (well, until me). He takes very good care of the things he owns. For whatever reason, I guess gas prices and the fact that he bought a newer truck, back 5-10 years ago he parked it at his neighbor's house back in the woods and let it sit.

Now, I'm sure some of you are familiar with my K10 that I did a frame off restoration on. He saw that and figured the K5 would be better off with me than sitting in the woods.

It has a 400, 4wd, red interior with a white exterior. It's actually in very good condition other than a few problem areas. I literally just had it delivered on Friday and so far have just cleaned out the engine bay (there were a bunch of squirrels in there apparently eating nuts) and the interior (and mouse poop...yuck). I have more cleaning to do tonight, and then I'm going to see if the motor is any good.

My question relates to rust repair. On my truck, I ended up replacing most of the body because the rust was so bad (it was an Illinois truck, even the frame was rusty...). This truck has a solid frame... still painted actually. I know there are some patch panels out there, but I haven't found any for the panels I need to replace. How should I go about fixing those?

Here are some pictures:

 

[sonicbluezx3]

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[sonicbluezx3]

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[sonicbluezx3]

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[sonicbluezx3]

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[sonicbluezx3]

Is it worth trying to fix all of the rust on the sides? Or should I just buy new bed side panels and install?

Obviously the cowl parts and the windshield are the ones I am most worried about. Just looking for some direction on the patch panels and what other options I have.

I'm not going for a show truck here... assuming the engine is good I want to try to get as much horsepower as I can out of it without going crazy on engine work. This is just going to be a once in a while toy, not a daily driver.... but I do want to take care of the rust and get it painted eventually.

 

[kleedus]

as much rust that it has I would change the whole bed side that way you can get behind it and fight the rust from the inside

you could probably find a truck cab somewhere to cut the cowl panel patch pieces out of. or you can build what you need I rebuilt the cab mounts on my crew cab cause no one makes patch panels for them

lmc lists the bed side

and I would buy some por 15

 

[Old77]

You have got a LOT of work ahead of you

 

[sonicbluezx3]

You really think i should spend that much on sides when its just that one area mainly that has a hole? How hard is it to replace? Obviously on a truck its bolted on but isnt this completely welded on?

 

[Old77]

You really think i should spend that much on sides when its just that one area mainly that has a hole? How hard is it to replace? Obviously on a truck its bolted on but isnt this completely welded on?

Once you start getting into it you'll find that the rust on that is MUCH worse than what is pictured. Just cuz there's paint on it doesn't mean it's not rotted. I'd agree with replacing the entire side.

 

[sonicbluezx3]

Once you start getting into it you'll find that the rust on that is MUCH worse than what is pictured. Just cuz there's paint on it doesn't mean it's not rotted. I'd agree with replacing the entire side.

True, that's what I've heard. Well first things first... gotta make sure the engine is good. If it's good I'll start looking for sides.

How is it attached? I am very familiar with the K10 but I haven't even pulled the carpet up yet on the Blazer. Ive been doing a little research and it looks like maybe on the newer ones they are mostly welded, but these may be bolted mostly. Do you know?

 

[Old77]

I believe they are spot welded from the factory.

 

[sonicbluezx3]

Good news... The engine isn't seized up at all. So now I'll be changing fluids and checking electrical parts so I can try to get the engine running. I also looked under the truck and found that it has the TH350 transmission.

 

[sonicbluezx3]

Plan B.... I found a 1989 K5 body and frame (no axles, transmission, or engine) somewhat close to me and they are only wanting 400 for it. It includes doors too. It's worth that in scrap I'm sure... so I think I'm gonna grab it up even if I don't use it.

My question here is... how compatible is the 1989 to the 1978? How hard would it be to take the good body off the 89 and replace the rusty 78 body?

 

[sonicbluezx3]

I should add that I've never really welded before... nor do I even own one. The good news is I have a 1200 sq foot shop now that I can keep everything dry in and work whenever I want to (before all I had was a muddy carport... hence why I haven't worked on it much since I got it).