• We performed a once over final inspection of the truck, noting final punch list “to-do” items. The goal of the inspection was to secure any last loose wires and prepare for starting the engine.
  • We started the engine for the first time in ~10 months.
  • While the engine was running, we evaluated air pressure, air dryer, brake lights and brake function.
  • We test drove the truck; all worked well.

A brief recap of the highlights of our rebuild:

  • Removed bed from truck
  • Cleaned frame, cab, and cab interior
  • Removed spare tire crane and lowered air filter assembly to aid in integrating hab as close to cab as possible.
  • Replaced corroded air tank
  • Replaced air dryer
  • Repainted frame
  • Repainted cab
  • Refurbished many truck parts by removing, sand blasting, and powder coating or painting them (front bumper, rear bumpers, fenders…)
  • New marker lights
  • Installed new under bed box for storage aft of fuel tank
  • Created custom roof rack with integrated ladders
  • Added stiffeners to forward fenders to flatten their side profile
  • Repaired door hinges and straightened cab doors
  • Powder coated rims, rebuilt wheels, and put on new Michelin XZL “0 mile” tires (including spare)


  • Installed air filter cover
  • Installed forward trailer power plug
  • Installed door weather stripping
  • Installed windshield wipers
  • Connected batteries
  • Tested lights


  • Installed rear marker lights using stainless hardware
  • Installed front and rear reflectors
  • Installed cab door over travel stops
  • Finalized connection of air dryer
  • Wired reverse / brake lights
  • Removed jack stands
  • Torqued lug nuts (425-475 ft-lb)
  • Painted air filter cover
  • Painted forward towing power plug
Truck Configuration - 4pm 5/7/2017
Truck Configuration – 4pm 5/7/2017


  • Retrieved wiring for marker lights on cab
  • Soldered new positive connectors on all cab marker lights
  • Started body work on air filter cover
  • Soda blast cleaned:
    • Door weather stripping
    • Cab door over travel stops
    • Power steering reservoir band clamp
    • Pit pins
  • Inspected and cleaned wiper blade arms
  • Installed cab marker lights
Retrieved Cab Marker Light Wiring
Retrieved Cab Marker Light Wiring
Installed Cab Marker Lights
Installed Cab Marker Lights


  • Installed battery box cover
  • Installed driver side forward fender
  • Installed driver side ladder
  • Installed rubber grommets to fill oversized holes in cab exterior
  • Installed roof rack
New Fender Hardware
New Fender Hardware
Lifting Roof Rack
Lifting Roof Rack (Thanks for the help, Yuri!)
Vehicle Configuration 9pm May 2nd
Vehicle Configuration 9pm May 2nd