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  #61  
Old 05-05-2017, 03:58 AM
markfuga markfuga is offline
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Took the truck out for it's first test run. The VSS isn't hooked up yet so could only get to 2nd gear. Made a short video to share:

https://www.youtube.com/watch?v=bzLz...ature=youtu.be
  #62  
Old 05-12-2017, 04:04 AM
markfuga markfuga is offline
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Making good progress with "re-wiring" the inside of the cab. Normally I would keep the original trucks wiring harness for lights, gauges, horns, wipers, etc but this 78 truck was missing most of it's wiring when I got it. Typically I just cut down the mid-90s harness to be a "stand alone" harness for operating the engine and transmission, but instead I'm using it to operate the entire truck. I'm finding it's surprisingly easy so far to move all the 78 controls onto the wiring from the 96 donor. Wire colors and stripes haven't changed much between the decades. So far I moved the key switch without much issue. I added an extra relay to carry the load of the heater circuit versus running that through the key switch. The 78 key switch is "lighter duty" than the 96 which is why I added the external relay circuit. I moved the turn signals off the 96 multi-function switch onto the 78 turn signal switch, moved the high beam selector off the multi-function switch onto the 78 floor switch and I moved the wiper motor and controller from the 96 to the 78. The 78's wiper motor was MIA so rather than source a replacement I just moved over the 96. The only modification was turning the arm on the motor 180 degrees so the motor would clear the heater ducts of the 78. The last piece of the wiper puzzle is to move the control wires onto the 78 switch. I haven't compared schematics for the two years yet to see if the delay functions match but I'm sure they'll be close enough. Right now I'm working on moving the heater controls from the 96 to the 78. Only difference here is in 78 the resistor pack was between the battery and the fan motor and in 96 the resistor pack is between the fan motor and ground.

This is the "core wiring" update. After this is complete I have to figure out what I'm going to do with the gauge clusters. The goal is to keep everything looking like the original 78 stuff as much as possible.
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  #63  
Old 05-12-2017, 10:10 AM
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mandkole mandkole is offline
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cool, glad to see its still coming along.. carry on!
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  #64  
Old 05-12-2017, 10:12 AM
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dsberman94 dsberman94 is offline
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Have you looked into a custom gauge face for it. I'm sure you could get one printed to mimic the 78 gauges. It would be pretty cool but probably not cheap either.
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  #65  
Old 05-27-2017, 03:46 PM
markfuga markfuga is offline
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I was finishing laying the sound deadening on the floor and firewall when I realized it was somewhat a pointless exercise if I didn't also cover the heater/AC box. The box fits into a HUGE gaping hole in the firewall and is just (most hollow) plastic. All the floor covering I could add wouldn't help much because that box would just resonate all the engine noise into the cab. I first covered the box with the same sound deadening I used on the floor and then came over that with a fiberglass/mylar matting. This should significantly reduce noise and heat from entering the cab.
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  #66  
Old 06-19-2017, 04:40 AM
markfuga markfuga is offline
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Well the heater/AC box didn't fit like I expected. I "trial fit" everything a few months back and it seemed like it was good to go. Naturally after wrapping it up clean and tight in insulation is when I discover it doesn't fit

The problem is clearance around the valve cover. I had to cut a large section out around the fan and reconstruct it using sheet metal. The fit is still tighter than I would like but I have at least 3/8" clearance in there now.
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  #67  
Old 07-11-2017, 08:01 AM
markfuga markfuga is offline
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Inching along with this project still. Just finished the gauge cluster and wiper switch. I used the case of the original wiper switch and "grafted" the OBS switch to it and it works great. I did the same with the OBS gauge cluster and the 78 bezel. It was alot of plastic trimming of both the 78 bezel and the OBS gauge cluster but I'm pleased with the outcome. I also used the diesel indicator module to make a small insert where the P-R-N-D-2-1 went on the OBS cluster. I now have all the essential lights on the dash: left/right turn, high beam, battery, check engine and wait to start.
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  #68  
Old 07-11-2017, 08:03 AM
markfuga markfuga is offline
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Here's the finished installation.
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  #69  
Old 07-11-2017, 08:49 AM
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79jasper 79jasper is offline
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That looks pretty good.


Sent from my SAMSUNG-SM-G890A using Tapatalk
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  #70  
Old 07-11-2017, 08:51 AM
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I really do enjoy watch a build of this caliber unfold. Keep up the good work.
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