Stovebolt.com Forums Project Journals Project Journals Rusty Rod's 67 Suburban "the Kogai"

I found this gem on the "Market Place" a couple weeks ago (Nov 2019). Mrs. Rod said "NO WAY" are you bringing that piece of junk to our house. I was somewhat dejected, since I've been hankering to get a new project. The PO sent me a message a week later saying he dropped the price to $2000. I asked Mrs. Rod if I could get it, and after a bit of hemming and hawing, it is now in my driveway. Mrs. Rod is Japanese, so I figured that I better give it a Japanese name. Kogai means suburban in Japanese. The Kogai started its life as one of 120, 3/4 Ton K20 4x4 Suburban's built in 1967. The PO replaced the body with an apparent 1968 body tub and absconded with the right front fender, inner fender and hood hinge.

Condition as bought on November 24, 2019.
Not currently running. Engine turns by hand (and a strap wrench).
Rusty quarter panels. two flat tires. Rusty front floors.
Many loose parts; seat, steering column, the entire body, hood. Front bumper is (bent) and off the truck. One rear hatch support is loose. Cowl off. Wipers off. Right exhaust manifold is off. Drivers door hangs down a bit (along with the wonky latch).
Missing parts: Right front inner and out fenders, one hood hinge, rear seats, jack and handle, air cleaner lid wing nut, rear bumper, gas tank, ignition switch. Door locks. keys.
Broken parts: Both front door latches and handles are wonky. Left rear window broken. Windshield cracked.

Components:
Trim level: It looks pretty basic, no extra chrome on the sides, metal inside door panels.
Engine: Is out of a 68 Nova or Chevelle 275HP 327. The engine suffix is T??09EE Vin code next to suffix is 1???09230 (it's hard to see because I'm afraid the loose hood will fall on my head). Casting number 3914660.
Heads: Camel hump 8917291 GM4.
Transmission: 4 speed Manual SM420.
Transfer Case: (According to PO) is a Rockwell T-221. (See picture).
Rear End: Eaton ?? Bolts.
Front Differential: Unknown.

Replacement parts:
24 Nov 2019 -- 68 Right front fender, two door handles, door hinges, this came with a w/spare 68 left front fender, cowl, another bent front bumper, a grill, and a bucket of loose parts.
Door Locks.
Key.
Emblems.

25 Nov 2019 -- Inner fender (wheel house).

27 Nov 2019 -- 72 bed trailer w/ 3/4 ton axle, two nice tires and a rear bumper.
I found that my radiator support is missing quite a bit of metal under the battery box. I'll be using the one I got with the 68 front clip.
I found a set of 2004 Chevy alloy rims tonight and will pick them up in the AM.[img]https://www.stovebolt.com/ubbthreads/ubbthreads.php/ubb/download/Number/13089/filename/IMG_4360.JPG[/img]

A friend of mines mother had a '68 Caprice with a 327. Another friends dad had a '68 Suburban with a 307. That was back in the mid seventies. Looks like a fun project.

John

And you told me you were a Marine now I am wondering.

November 27, 2019. I dusted off 15 inches of snow, pulled back the tarp and did a bit of exploring.

The engine suffix code is definitely "EE". I can't get to the block part number to verify if it's a 327 or 350.
I found the radiator support is bent and rusted out under the battery box. I'll be doing a minor repair and paint to the spare I got with the 68 front clip.
I poked the exhaust manifold back where it belongs after chasing the threads. I need to acquire a set of studs before I put the final install on it.
The starter to battery wire was missing, so I bought a new one.
I thought I lucked out when I found an ignition switch key under the radiator support, but it no worky.
I wasted two cans of cheap paint on the previously blue, then orange and now white right front fender. I'll pound out a few dents whilst waiting for the replacement wheel house to arrive.

I picked up the 72 bed trailer this evening. It is beat up a bit which is to be expected. It has some gnarly tires on it though. It has the 16.5 inch split rims. I'll use them to roll the Kogai around on until I get it running in a satisfactory manner, then put on a set of mid 2000's alloy rims that I just bought.

Hi Ron, I AM a Marine!

November 28 - 30, 2019.

I picked up the 04+ wheels this morning and test fit them on the rear. The offset appears to be a bit different than the wheels (not stock) that were on it).

29th. The new wheel house appeared on my front porch. It is made in taiwan, but feels pretty good. I'll test fit it in a few daze.

30th. The new key switch came in yesterday and I installed it today. I got under the dash. OMG!... what a mess. There are NO fuses in the fuse box. There are connectors hanging all over the place.

I installed the battery cable and the solenoid wire to the starter. Re-wired the distributor (it's an HEI), I had to hot wire from the ignition switch to the distributor battery connection. My spare battery was run down, but it did kick the starter. I'll let the battery charge at 2 amps all night and see what happens in the morning.

December 1, 2019.

I finished bolting the exhaust pipe back to the manifold, which has one hole stripped out. I put in a longer fresh stud with a nut on top.
The engine starts and runs! I had to "borrow" a fresh battery and used my Jeep to jump it.

December 2, 2019.

I changed a couple of the hard cracked fuel hoses and plumbed in a temporary "fuel cell". The engine cranks right up and purrs like a kitten, an angry kitten.
A coupe lbs of mouse nest and poop came out of the exhaust pipes! There was another nest inside the bell housing.

I was able to make it drive forward and then in reverse under its own power. I almost rammed my jeep! The brakes no worky.

December 3, 2019.

I flushed and bled the front brakes. There was a lot of black goop in the master cylinder. I used half a bottle of fluid before it started coming out somewhat clean. Apparently, I'll be replacing the master cylinder and brake cylinders before it's on the road. I have a set of new hoses inbound as well, since they definitely need to be changed. The front brake shoes look nearly new.

I found that the clutch linkage was missing the half round doo-hickey that fits into the end of the clutch arm. I popped in a suitably sized nut until I can locate the proper piece. The clutch seems to work just fine. The disk looks fairly new. (Update: I found the doo-hickey for the clutch arm in the box of parts 8 Dec).

I spent about an hour in class today drafting up a "to do" list, since the instructor was just reviewing the semester (non-testable information at that). The list is almost three pages long and I'm not done yet.

December 4, 2019.

The new brake hoses came in right on time. I got the rear hose replaced with no problems, then bled out all the nastiness inside the rear portion of the brake system.

Glad to hear you got it running. 68' was the last year for the 327, it would be great if that were the engine you have. I have always liked the 3 door Burbs and really like the 67' and 68' front end. Lots of work ahead of you, I'll be following.

December 5-10, 2019.

I am striving to work on The Kogai at least 15 minutes every day. I've been sanding scratches and beating the dents out of the replacement (1968) right front fender. It's almost ready for a light skim coat of bondo then primer. I'll be painting it a flat white to get it all one color (since that matters a lot to Mrs. Rod).
I removed the drivers door inner panel and replaced the drivers door handle. I found the missing headlight assembly, the bulb even works in high and low beam!
I moved all the junk from the front of the garage, pushed the 38 Coupe into the corner, moved the 24 Car out of my shop garage into Mrs. Rod's garage. Then moved the Kogai inside!
I was poking around and removed the side marker lights. There is a huge mouse nest in there.. yuck! It's time to get some lysol and bleach to disinfect it.
The gas pedal linkage was in the same box of parts as the headlight and several parts that hold the steering column in. I ordered a shop manual which I'll need to figure out how all those parts fit together.
I found a NOS tail light lens AND all four NORS side marker lights on Ebay! I'm going to be in trouble when Mrs. Rod gets the credit card bill next month!

December 10, 2019.
I pulled the rear side panels off. Yikes. Disinfectant time!

Better to beg forgiveness and face the wrath, at least you'll still have your parts....

December 12-18, 2019.

I finally figured out that the gas pedal linkage mounts from the OUTSIDE of the firewall, amazingly, the linkage matched up perfectly to the piece hanging off the carb.

I fixed the leaky temporary gas line and drove the Kogai around the block for the first time. I was wondering why it was revving so much... thinking maybe the clutch was slipping. Nope, I had the transfer case in Low. Duh. I got the hose out and started at the top (by golly the top of a suburban goes on forever!) and worked my way down to the under carriage. I got most of the dust, dirt, rust particles and mouse mess out of the truck and into the ditch.

I've been spending an hour a day working to get the outside sheet metal all the same color. ( Mrs. Rod automatically calls any vehicle that has body panels that are not the same colors "junk").

Dec 15-18. - The "new" right front fender is now satisfactory enough to hang on the truck.
I applied some direct pressure to several spots along the left rear quarter panel. I knocked out most of a pretty good dent near the back. I'll have to skim coat it with bondo, since I dinged it pretty good a couple times.
I pulled the outer fan / heater core housing off the firewall.