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  #21  
Old 09-03-2016, 11:41 AM
markfuga markfuga is offline
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So after completing the sheet metal work for the firewall, the front bumper was a gift

Fitting the 78 bumper to the 96 frame was as simple as cutting the first six inches of the 78 frame and turning those pieces into brackets to hold the bumper. The brackets bolt to the inside of the 96 frame and are the PERFECT width to align with the holes in the bumper. Couldn't be easier!

The 78 frame starts to widen soon after the tips of the frame so I had to cut at an angle along the frame to avoid the widening and add some 1/4" plate to extend the brackets. I also cut about 2 inches off the 96 frame to allow everything to align properly.
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  #22  
Old 09-03-2016, 11:42 AM
markfuga markfuga is offline
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Here's the bumper
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  #23  
Old 09-04-2016, 04:43 PM
markfuga markfuga is offline
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Finalized the installation of the bed today so figured I'd share the secrets.

The two rear bolts (near the tailgate) and the two bolts close to the shocks line up in the holes already in the 96 frame. The holes close to the front of the fuel tank do not line up but are easily re-drilled into the frame. Unfortunately the bolts move back and outward which puts them further into the "pocket" of the cross member for the fuel tank. The original location was already hard to access, so now it's a little tougher (see red arrow).

The forward two bolts are actually set inward in the bed (the 78 frame narrows) and don't line up over the frame rail at all. I had to weld some half-round tabs onto the frame to allow me to drill new holes. You can see the holes are right on the edge of the frame. I made the the tabs bigger than needed because I didn't know exactly where the holes would end up.
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  #24  
Old 09-05-2016, 06:31 PM
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gwunter gwunter is offline
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That muffler saddens me, lol. Everything else looks great.
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  #25  
Old 09-06-2016, 03:42 AM
markfuga markfuga is offline
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It's actually a good sounding muffler on these engines (Walker 21470). I put it on my 58 during that engine swap and I get compliments on the exhaust sound all the time. Here's a sample of what it sounds like.

https://www.youtube.com/watch?v=G3TKFQ5FJjc
  #26  
Old 09-06-2016, 08:23 AM
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I'm impressed with the positive channeling of your OCD. Lookin' great!
  #27  
Old 09-06-2016, 08:38 AM
JRLott JRLott is offline
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Yeah. That blue 58 is gorgeous and well done.
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  #28  
Old 09-07-2016, 02:45 PM
markfuga markfuga is offline
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Thanks guys, I appreciate the feedback. Now that the weathers cooling off it's time to take the 58 out for some cruising.

Here's today's progress. There isn't enough space along the two inner fenders for everything that needs to go on them so I had to improvise. The drivers side inner fender is consumed with a battery, the under hood fuse box and the IDM. The passenger side inner fender has a battery and the heat/AC box for starters. It also needs the coolant degas bottle and the wiper fluid bottle BUT there's not enough room. It occurred to me to try a "SD coolant bottle retrofit" as a possible solution. I made two brackets and cut out the corner of the fan shroud and problem solved. The only issue with this mod is the small top radiator hose. It's directly behind the bottle, so I had to space the bottle out some to allow for a "comfortable" bend radius with this hose.
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  #29  
Old 09-08-2016, 04:07 PM
markfuga markfuga is offline
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Couple more details resolved.

I cut a small section out of the 96 cab to graft into the 78 cab so I can add the boot assembly for the transfer case shifter. The boot with it's plastic enclosure has a very specific shape, so using the piece of sheet metal from the 96 was the easiest option. I covered all the welds, including the firewall work in a heavy urethane seam sealer.

I used a piece of 16 gauge to make a spot on the firewall for the computer and the two fire wall plugs on the 96 harness. As I mentioned earlier this 78 came with very little of it's wiring harness left so I'm using the 96 harness for everything.

I chopped up the bracket for the wiper fluid bottle and bolted it to the inner fender. I also added a plate to the side of it to hold the starter relay. I was mostly done with the bracket mod when I realized I had no space for the starter relay. The added plate was an after thought.
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  #30  
Old 09-08-2016, 04:09 PM
markfuga markfuga is offline
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Here's everything set in place. I believe all the work under the hood is now complete.
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