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I attached the running board to body seal. After I did one side I decided to paint the bolts, so that side had to be redone. I thought the running board seal went inboard of the running boards, but I could not push it back far enough to mount the running boards. The running board brackets may not be attached to the new frame in the correct position. I ended up tucking the running boards under the seal for now.
Then it rained for a week and I didn’t get much done. The weather got nicer and I was thinking about when I’m done with this I’ll be driving. I tried to start the engine but the battery was dead. I put a quick charge on it and an hour later started the truck. I let it idle, but it shut off after a few minutes. It was hard to start and I noticed the charge light was on. I checked the running voltage and it was close to 12v.
I purchased a new alternator. 60Amp, and 110Amp were the options, so I went with the 110Amp. I noticed the pulley was for 6 rib belt, my truck has 4 rib belt. I thought it would be easy to swap in a new alternator, but I got hung up on the pulley. I now know that I could just run the 4 rib belt on the 6 rib pulley, but at the time I was determined to do it right. I went to 4 different parts stores in search of the elusive special tool. I finally used the tools that I already have. I did have a hex driver set, so hex bit in the alternator shaft. Deep socket on the pulley nut, over the hex bit. 3/8 extension out of the ½ deep socket. Breaker bar and pipe wrench got the job done. With the new alternator the charge light comes on and then goes off while still cranking, so it looks like the old one was on it’s way out for awhile. The truck was still hard to start. I checked for trouble codes and got 33, MAP sensor. I swapped in the MAP sensor from my other truck and no change. I thought about checking the fuel pressure. I went to the junk yard and got some TBI related parts, and to a store and got a timing light, a fuel pressure gauge, and a fuel filter. I would need to T into the fuel line to check the pressure with the truck running. The next day I was set to go the hardware store to get some fittings to T into the fuel line. Before I left I wanted to try running the truck, it would not start. I checked the spark-good. I checked after the fuel pump relay-good. I tried some starting fluid, it responded to that. At this point I didn’t know what to do. I thought that the easiest solution is probably the right solution, so I went and got some fresh gas. 4 gallons into the tank and the truck started right up. Having put about 4 gallons in it over a year ago, I had run out of gas. I’m happy nothing is wrong with the truck.
Back on track I had forgotten to mount the charcoal canister before mounting the fender. I got down in the wet dirt and installed it from below onto the inner fender. Between rain storms I had fitted the bull bar and modified the supports. With that all painted I mounted the modified bull bar supports. In the picture you can see where the support had dented the grill. With the frame horn modified you can see how the new frame is wider and the support is shifted over. Mounting sequence went like this: Bull bar supports first, front splash apron set in place, attach bull bar to supports, Bolt on front bumper. I had purchased a bumper bolt kit, but those bolts were dinky. I found some ½” bolts locally, but at 2” they were just short. Another trip to the hardware store and I had that part of the build done.
Somewhere in there I had wired up the rear lights and am currently finishing up the cargo panels and the rear splash apron.