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  #1  
Old 06-30-2022, 09:58 AM
joedoh joedoh is offline
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Default 41-46 s10 swap pictures

I apologize for my absence, between spurious and fitful supply of parts for my 47-55.1 kits I have spent a large amount of what was supposed to be building time, and therefore personally enjoyable time, hunched over my small cnc table cutting parts for orders. because I am an idiot who loves misery I also insist on iterative design changes at every order, so the lead time for cut parts takes 3x longer because they have to change the nesting and update it instead of just cutting what i ordered last time.

i planned to do 48-52 fords next and even bought a couple 1/2 tons to start with but the incessant cutting and all the rental problems... ugh. i keep getting asked for a 41-46 kit, i have pictures of the two I did in some of my ads. i had some patterns but they sucked and building it as 4 piece parts sucks too, i would rather have a cant-mess-it-up-on-a-bet folding set like the AD stuff. my friend had a 46 and kept it at my storage building as yard art when he took a contract job in florida, good enough to start with anyway.





I did the 3D on the mounts and popped out an improved set to try out the cab. worked wonderfully (the second time, as usual)




he had a 1 ton front clip that was in better shape and so I popped that on for a look too.




everything looking ok, I started on making the running boards fit. but a big problem, no matter how i moved the front clip and cab around the running boards were way below the cab. weird!



then i realized the problem, the one ton front clip had running boards taht were two inches taller than 1/2 ton. look at the vertical section under the door



that meant that the back of the fender dropped two inches lower than a 1/2 ton, even though the wheelarch measured almost the same radius. a quick section was needed. success!





so now the runningboards were sorted, i needed mounts for them and the front clip.

more in next post
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  #2  
Old 06-30-2022, 10:11 AM
joedoh joedoh is offline
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I had existing designs for the 47-55.1 running boards but they didnt fit between the frame and the running board mount, so I redesigned them and will use the same part for both kits now.




the front clip of the 41-46 mounts back at least 4 inches from where the 47-55.1 does though so I coulndt use those mounts, and where the core support falls is right over the power steering hoses too so it needs more room. I came up with a 100% bolt on setup that keeps the room over the power steering box.




everything fit well except the lower core closeout bracket, because i had welded in a piece of rectangle to keep the front clip square while building. i will trim this one and install it but the future trucks it will fit perfectly.



that one ton front end is really in poor shape but better than the 1/2 ton stuff which looked like someone had crumpled it then on reconsideration uncrumpled it.



since I have 4 pictures left in this post I will talk about the frame, it was an ext cab 123" wheelbase and the 41-46 is 115", so a longbed s10 118 doesnt really fit that well. i decided to take 8" out at the factory splice.







by doing it at the factory overlap you dont need any fish plates or reinforcements, as long as you get good penetrating welds, and I am pretty sure we did.

btw the frame shortening is the last thing my friend larry and I worked on before he went in the hospital for his second round of thyroid cancer. he died 6 weeks later. cancer is terrible.
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  #3  
Old 06-30-2022, 10:26 AM
joedoh joedoh is offline
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i could mount the bed and bumpers now but thats easy peasy work, the 47-55.1 parts fit, so i decided to tackle steering and pedals. start by removing the dash and marking the centerline of the steering on a straightedge clamped to represent the bottom edge of the dash.



hold your s10 pedal bracket up so that the upper column mount is centered on the mark you made and the booster side is flat against the firewall, then mark the 4 booster holes on the firewall.



i use a 5 degree plate I designed, welding it in strengthens the firewall like you wouldnt believe because it doubles the thickness and the bends make it stiffer too. the 5 degrees is for the s10 maser which is made to have that tilt so the rear reservoir doesnt go dry on hard braking (the rear cylinder is the front brakes on s10s and really most GM after 1970)




the s10 column has a lower closeout on it that wont fit in its current orientation so with some careful grinding you can grind gently through the weld that holds it on and reuse it.



I slotted the column mount holes a little more so that the steering wheel wasnt a nut smoosher and let the column go another inch or two into the dash. I tack welded in some bolts so I didnt have to hold them to get the column mounted.



I built an upper bracket to the original dash brace location on the firewall.



the columns in these work out nice if they have a more horizontal position than stock, if youput a modern column in at that angleit looks like a bus steering wheel. I also move it up a couple inches so that its more comfortable, this means trimming the bottom of the dash. I use a 3" holesaw as a pattern, rough cut it with a slicer and then sand it nice with a flap disc.



it looks like a ton in that picture but in the final shot you can see its really not raised much and has a great position in the cab.



i want this done and outta here on the 4th of july, should just make it. more tonight!
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  #4  
Old 06-30-2022, 11:48 AM
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05snopro440 05snopro440 is offline
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What did you do regarding the frame to running board clearance at the kick out on the frame?
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  #5  
Old 06-30-2022, 01:17 PM
joedoh joedoh is offline
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absolutely nothing. which is to say I planned it very carefully that the running boards just barely clear the frame, are level with the bottom of the frame, and there was no cutting of the frame needed at all. pretty neat eh?
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  #6  
Old 06-30-2022, 01:19 PM
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Nice work!!!

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  #7  
Old 06-30-2022, 09:08 PM
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Torchie Torchie is offline
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Welcome back.
Looks like you have it all under control.

Torchie.
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  #8  
Old 07-01-2022, 07:24 AM
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forbigpicture forbigpicture is offline
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Great stuff there joedoh !!! lots and lots of work I'm sure..
by the way good to hear from you again.



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  #9  
Old 07-02-2022, 05:32 AM
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BillM BillM is offline
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I wondered where you'd gone, but it sure looks like you've been busy JD! Sorry to hear about the loss of your buddy,
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  #10  
Old 07-02-2022, 11:11 AM
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Burgerman Burgerman is offline
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Welcome back Joe. Sorry you lost Larry. Nice work installing the 1 ton clip on your 41-46. Like those welds on the frame splice. Keep us posted.
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