What have you done to your CUCV today/lately - Part 2

Recovered an m1009 that was half-buried in muck in a very remote village in Alaska, population ~100. Arranged transport back to the road system from Western AK and looking forward to bringing her back to stock! Really appreciative of all of the users on this site and the wealth of information and wisdom freely given.

35,500mi on the odo

What i've identified so far:
Rear window is intact but the up/down mechanism isn't working
Spring retainer rusted off on the driver's side of tailgate
Power steering fluid leaking into the driver floor pan
Missing battery retaining plates
Throttle cable retainer/bushing on IP is missing, zip-tie fix applied
Fuel gauge/sender not functioning
Some interior rust spots & holes
Passenger & driver 'wedge' windows are rotting & rusting
Dash in poor shape
Glow plug service
Hood deformations and a crack in the rear frame causing trouble

Once I wrapped my head around 24v it took a few charge cycles and a lot of cranking to get it moving, but definitely worth it!

wx33 said:

Recovered an m1009 that was half-buried in muck in a very remote village in Alaska, population ~100. Arranged transport back to the road system from Western AK and looking forward to bringing her back to stock! Really appreciative of all of the users on this site and the wealth of information and wisdom freely given.

35,500mi on the odo

What i've identified so far:
Rear window is intact but the up/down mechanism isn't working
Spring retainer rusted off on the driver's side of tailgate
Brake fluid leaking into the driver floor pan
Missing battery retaining plates
Throttle cable retainer/bushing on IP is missing, zip-tie fix applied
Fuel gauge/sender not functioning
Some interior rust spots & holes
Passenger & driver 'wedge' windows are rotting & rusting
Dash in poor shape
Glow plug service
Hood deformations and a crack in the rear frame causing trouble

Once I wrapped my head around 24v it took a few charge cycles and a lot of cranking to get it moving, but definitely worth it!

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Does the BL-XX on the door denote Bureau of Land Management?

Glad to hear that you got her fired up! Lots of TLC and it will be good to go for many more years...

wx33 said:

Recovered an m1009 that was half-buried in muck in a very remote village in Alaska, population ~100. Arranged transport back to the road system from Western AK and looking forward to bringing her back to stock! Really appreciative of all of the users on this site and the wealth of information and wisdom freely given.

35,500mi on the odo

What i've identified so far:
Rear window is intact but the up/down mechanism isn't working
Spring retainer rusted off on the driver's side of tailgate
Brake fluid leaking into the driver floor pan
Missing battery retaining plates
Throttle cable retainer/bushing on IP is missing, zip-tie fix applied
Fuel gauge/sender not functioning
Some interior rust spots & holes
Passenger & driver 'wedge' windows are rotting & rusting
Dash in poor shape
Glow plug service
Hood deformations and a crack in the rear frame causing trouble

Once I wrapped my head around 24v it took a few charge cycles and a lot of cranking to get it moving, but definitely worth it!

View attachment 875611View attachment 875612View attachment 875613View attachment 875614View attachment 875615View attachment 875616

Click to expand...

You have a lot of work ahead but for some reason these old trucks are fun to work on. Stubborn at times but rewarding in the end.

Mullaney said:

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Does the BL-XX on the door denote Bureau of Land Management?

Glad to hear that you got her fired up! Lots of TLC and it will be good to go for many more years...

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I'm planning on starting with glow plugs, getting IP rebuilt and putting in new injectors, but won't be surprised when (if?) every subsystem eventually gets attention.

Possible that the BL refers to BLM, not sure how the former owners acquired it. They were using it as a mail delivery vehicle but I don't think they liked the exhaust smell or finnicky 24v system..

finnicky 24v system..
No such thing. If maintained and not hacked it will last indefinitely. Don't follow all the instructions on this site and use the manual as your guide. I learned that the CUCV systems work. Rust was always my biggest enemy. If you can tolerate the ride, noise and lack of comfort you have a great vehicle. I drove and rode, off roaded several hundred thousand miles in CUCV's. Owned close to 100 of them and repaired everyone in stock form. No problem. Good Luck.

Getting the new fenders, hood and tailgate painted. Next time I spend a few extra bucks on the better grade replacement parts. Had to spend a few hours with filler fixing the dings from shipping.

Back when I bought new CUCV sheet metal from the GM dealer I was able to get a rebate for repairing any of the new dented replacement panels. Sometimes they were that bad that they would get credit and eventually just give me the new panel after they were credited. That was when new GM doors were $175. and front fenders were $96. So if they had a dent and 2 hours labor they would opt to discard the panel and replace it. Tailgates were the most damaged parts. They were heavy and poorly boxed. The new CUCV GM inner fender aprons were only $35. in 1995. So I say if you can find used rust-free OEM sheet metal that needs a little work you are ahead of the game. I have a guy buy a Taiwan tailgate and graph the CHEVROLET into it. He was an amazing body man. He has passed and the good guys that could do actual panel repair are few and far between. Everyone wants new and undamaged parts.

cucvrus said:

Back when I bought new CUCV sheet metal from the GM dealer I was able to get a rebate for repairing any of the new dented replacement panels. Sometimes they were that bad that they would get credit and eventually just give me the new panel after they were credited. That was when new GM doors were $175. and front fenders were $96. So if they had a dent and 2 hours labor they would opt to discard the panel and replace it. Tailgates were the most damaged parts. They were heavy and poorly boxed. The new CUCV GM inner fender aprons were only $35. in 1995. So I say if you can find used rust-free OEM sheet metal that needs a little work you are ahead of the game. I have a guy buy a Taiwan tailgate and graph the CHEVROLET into it. He was an amazing body man. He has passed and the good guys that could do actual panel repair are few and far between. Everyone wants new and undamaged parts.

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I was able to get carparts.com to give me a discount after showing them how the parts came. They were all capa certified parts. The tailgate new cost me 116 after getting price adjusted which I'm happy about because around here a rust free tailgate is 300-400.

Need a time machine to go back to 1995 and get those prices!

Fenders installed. What a pain to make these Taiwan fenders fit.

Getting there! I can feel the air in my hair!

Mattguy said:

Getting there! I can feel the air in my hair!

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WOW!!! Excellent, Excellent job. Well done.

ezgn said:

WOW!!! Excellent, Excellent job. Well done.

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Thank you! Hopefully the next pictures I post are of it all buttoned up! Still waiting on SF97 from USMC!

Sway quick disconnect and the rear winch FINALLY full operational on the 85 M1008... and trimmed the front fenders just a lil bit, so no more tire rub.

LT67 said:

Sway quick disconnect and the rear winch FINALLY full operational on the 85 M1008... and trimmed the front fenders just a lil bit, so no more tire rub.

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Did the quick disconnect come for the truck or did you have to modify something to work. Someone torched my swaybar off before I got my M1009. I've really never noticed it missing but if I do replace it I would like a quick disconnect setup.

I have a stock sway bar if you need one. I hope they saved the brackets and did not torch the bolts out of the clamping plates. If they did I have them also. Time to liquidate. 1 piece at a time.

cucvrus said:

I have a stock sway bar if you need one. I hope they saved the brackets and did not torch the bolts out of the clamping plates. If they did I have them also. Time to liquidate. 1 piece at a time.

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This is what they left me with

Hillbilly quick disconnect?

GunnyM1009 said:

Did the quick disconnect come for the truck or did you have to modify something to work. Someone torched my swaybar off before I got my M1009. I've really never noticed it missing but if I do replace it I would like a quick disconnect setup.

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Off Road Design part #GU37001

*it's designed for about a minimum 2-2.5in lift. Not sure if it'll work on a K5 frame with stock springs

Got the front end put back together. Hood tomorrow!

Had some rain last weekend. Decided to take the wifey out to the desert spots near our house and drive around the day after. Found a couple of puddles that were to fun to pass up and got a good pic. Wife got the video but I can't DL it So here are some pics. 33's & Stock suspension.