Project Bare Bones - S-10 Forum
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post #1 of 97 Old 04-22-2015, 11:57 AM Thread Starter
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Project Bare Bones

I've had my S10 since May of 2007, and now finally getting around to the mechanical downgrades that I've wanted to do since forever.

I had bought a 1985 (pre 1/2 year facelift) Escort L that literally had no options other than dealer installed air conditioning, which I removed, but money and living situation changed and the car I saved from the crusher ended up crushed anyway.

Upgrades/Downgrades to my truck so far:

K&N intake / Quad4 throttle body / Gibson stainless catback exhaust

Bravada front clip / removed rear bumper

Manual steering / U-joint upgrade.

Working on removing the already defunct SIR and ABS systems.

Manual brakes are in the near future

Handbrake is being installed now, pictures soon.

Modifying engine bracket to delete fan pulley, electric fan from a Tempo, custom water outlet adapter

Minor mod but I ditched the dual tone horn for one out of an Isuzu mounted to the lower hole where the power steering cooler used to be.

1993 Toyota Celica seats. Tach cluster, removed most of the idiot lights.

Removed all unnecessary wiring from interior. Ran dome light, CHMSL wires through A-pillar. Standard rearview from my dad's 97 C1500.

Lowered 2/4 spindles/blocks. Monroe Reflex Monotube shocks. Michelin Premier A/S 205/65R15
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post #2 of 97 Old 04-22-2015, 12:55 PM
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Re: Project Bare Bones

Need pictures.

Of both this and the Escort.



I've had wayyy to many of these trucks. (Currently...on number 7)

1988 S-15 - 5.5/6 drop

1985 S10 Blazer 4WD

1998 Blazer ZR2 5 Speed!

Quote:
Originally Posted by fackinsteve View Post
3 doors for 1 and a half whores
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Originally Posted by svmcgover View Post
He only bought one wheel. So every picture we see is going to be a pic where either the rear or front is conveniently out of frame.

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post #3 of 97 Old 04-22-2015, 03:17 PM Thread Starter
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Re: Project Bare Bones

Handbrake installation: So far just the base plate and handle have been installed.

Base Plate

Handle Mockup

Installed



It's perfect luck that the SIR module was mounted right there. I cut the rear stud off, wallowed out the holes in the base plate and it fit right over the two front mounting studs. There is already a second layer of sheet metal to reinforce those studs in the floor board. Popped two holes through the floor for the handle itself and bam, it's in.

Now to cut a hole behind the seats for the cable pass through.
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post #4 of 97 Old 04-22-2015, 03:20 PM Thread Starter
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Re: Project Bare Bones

Manual steering post.




Belt routing (no efan yet)
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post #5 of 97 Old 04-22-2015, 03:32 PM Thread Starter
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Re: Project Bare Bones

I can't find too many pictures of the Escort, but here's the day I brought it home. Its last inspection was due in 1990 IIRC.



I know most people don't care for them but I've always loved this platform, and my first car was a Tempo.

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post #6 of 97 Old 04-22-2015, 03:39 PM Thread Starter
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Re: Project Bare Bones

Now for my truck. I had it looking pretty good but then someone cut in front of me in an intersection and I'm back to the patchwork look.




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post #7 of 97 Old 04-25-2015, 09:43 PM Thread Starter
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Re: Project Bare Bones

Put threads in my water outlet:


Ordered pipe fittings for new heater pipe.
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post #8 of 97 Old 04-27-2015, 03:22 PM Thread Starter
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Re: Project Bare Bones

Cable pass-through complete.




getting closer!
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post #9 of 97 Old 04-29-2015, 03:36 PM Thread Starter
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Re: Project Bare Bones

Started work on the radiator fan today. Shroud before...


Cut up.


installed.


Tried to mock up the electric fan, but the clutch fan is in the way, so I'll have to wait until the weekend to figure out what brackets I'll have to fab to get it in securely.
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post #10 of 97 Old 05-02-2015, 06:54 PM Thread Starter
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Re: Project Bare Bones

Started mocking up and figuring out how to mount the fan. I'm still unsure how I'm going to secure the bottom of it, it originally slid into little arms that were part of the radiator tank, but of course the S10 radiator has no such provisions.



Right side upper mount consisted of just drilling a small hole in the top of the radiator and installing a speed nut, as it was originally mounted.


Left side. You can see that the shroud covers the radiator entirely.


Combined with the absence of power steering, this really empties the bay. That fan pulley is next to go.


Another view. Spilled antifreeze all over playing with the reservoir hose.
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post #11 of 97 Old 05-02-2015, 09:18 PM Thread Starter
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Re: Project Bare Bones

my non-existent metalworking skills



The bend around back is for the upper left fan mount. Out of light now, more tomorrow hopefully.
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post #12 of 97 Old 05-03-2015, 05:28 PM Thread Starter
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Started the wiring for my electric fan.
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post #13 of 97 Old 05-04-2015, 07:28 PM Thread Starter
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goodies!
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post #14 of 97 Old 05-05-2015, 03:04 AM Thread Starter
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Re: Project Bare Bones

So I decided I am going to probably use a fan switch that is 1/2" NPT, so I went to Lowe's real quick and grabbed a brass T, but I also realized my barbed fitting is too small, so I'm going to have to go get a bigger one of those also. Then once everything is up and running I'll replace the brass pieces with stainless items.

Here's the mock-up, I still have to figure out how I'm going to mount the spark plug wire holder.


The pipe of course has to be cut down, but I'm pretty close to getting this part done, and then I'll be able to put in all of the wiring for the electric fan.
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post #15 of 97 Old 05-06-2015, 04:00 PM Thread Starter
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Re: Project Bare Bones

slow progress



Connor94 likes this.




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #16 of 97 Old 05-10-2015, 08:29 PM Thread Starter
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Re: Project Bare Bones

Got some destruction done today. Drilled out the front airbag sensors and removed the harness. Turns out those sensors hold water in the radiator support. When I popped them out a bunch of water came out with it. It had just got done raining though, not sure if it was holding long term.




Frame looks way better without wires running on it. Still dirty/rusty, but slow progress is still progress.




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #17 of 97 Old 05-10-2015, 10:32 PM Thread Starter
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Re: Project Bare Bones

I finally thought of a way to secure the bottom of my electric fan without it looking hacked. I cut two slots in the bottom of the shroud and used strip steel with 2 of the speednuts from the stock lower shroud. Drilled two holes for the bolts to go through. Just need to mock it up again so I can figure out where the bends will be and then drill holes in the bottom of the radiator support to put speed nuts in and then bolt it all down.

Of course, some pics of what I'm talking about.





I cut the original mounting "ears" off and am going to paint the steel brackets black. The goal was to find a way to make it look like it came stock with an electric fan. I'm not really happy with the hold down I made, I need thicker steel.




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #18 of 97 Old 05-11-2015, 02:47 AM Thread Starter
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Re: Project Bare Bones

I told myself I wasn't going to do this, but once I started filing the casting seams down, I knew there was no going back. Still have a long way to go too...






WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #19 of 97 Old 05-12-2015, 02:40 AM Thread Starter
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Re: Project Bare Bones

Have all of the pieces for my water outlet, but I had to order a bigger die handle in order to put threads in the pipe. So close!

All stainless hardware.

Also noticed one of my exhaust clamp/hangers rusted so bad that the exhaust pipe rattles against the clamp at a certain load and RPM. I thought it was all of the junk in my bed rattling!

Ordered from Summit on Ebay.
http://www.ebay.com/itm/331370406111
http://www.ebay.com/itm/390967030254

Going ahead and replacing all of my clamps and hangers with stainless parts. Of course the stainless exhaust system doesn't come with stainless hardware. The stuff it did come with has lasted 7 years or so though.




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #20 of 97 Old 05-12-2015, 10:10 PM
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Re: Project Bare Bones

Nobody ever takes me serial... Not sure if i missed it but whats up with the pipe your installing?

89 S10 2.5 5 speed 2wd
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post #21 of 97 Old 05-13-2015, 01:40 AM Thread Starter
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Re: Project Bare Bones

It's replacing the pressed in pipe that comes on 98+ 2.2L trucks. I've gone through two Dorman replacements, both leaked within a week. Said screw it, put the stock one back in because it was leaking less. Ripped the pipe out of the last Dorman part and tapped pipe threads into it. Added a second T for an electric fan switch. All stainless so it won't rust like the stock one.


Looks like this stock.





WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #22 of 97 Old 05-14-2015, 08:25 AM
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Re: Project Bare Bones

I like the way you used speed nuts for the bottom of our e-fan. I did something similar on mine. What I did for the top mount on mine was to just cut up and use the stock shroud. I figured since it was already cracked it wouldn't hurt to cut it up.


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post #23 of 97 Old 05-15-2015, 02:46 AM Thread Starter
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Re: Project Bare Bones

Yeah, I hacked up my upper shroud too, but it's an interim step. I'm still trying to figure out how I want to hold down the radiator. I'll have to check out your build thread.




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #24 of 97 Old 05-25-2015, 08:57 PM Thread Starter
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Re: Project Bare Bones

Man, this is taking way longer then it should. I finally got my die handle to thread the pipe, but after grinding it down and re-chamfering it three times I still couldn't get the threads to cut straight. My dad is going to take it to a buddy of his who has a transmission/machine shop.

Long story short I put the fan in anyway. I don't make any trips over 30 min or so, so for now it is just wired to come on with the key.

So pictures...
Passenger side mount to radiator.


Driver side mount to sheet metal hold down I made. I thought this was too flimsy but after mounting the fan to it, it is completely solid.


Driver side lower L-bracket.


Passenger side - bad pic because of the air pump.


I still need to clean things up, paint the brackets and the cut up sections of the radiator support, and of course finish the heater pipe to get my fan switch installed and wire everything up the correct way.




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #25 of 97 Old 06-03-2015, 02:22 AM Thread Starter
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Re: Project Bare Bones

Finally.


So cutting threads in stainless steel with minimal tools wasn't working out so much, so I ended up having a machine shop do it. If all goes well I should have this, a new water pump, and my fan pulley deleted tomorrow.




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #26 of 97 Old 06-04-2015, 02:26 AM Thread Starter
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Re: Project Bare Bones

I'm functional! I still need to hack the brackets up to make them look prettier, and paint them. I have a spare timing cover I'm thinking of polishing and having anodized.





WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #27 of 97 Old 06-07-2015, 07:32 PM Thread Starter
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Re: Project Bare Bones

Non-AC belt routing. I figure if I can go the whole summer without hooking it back up, the AC is coming off as soon as I find a non-ac donor truck.

I figure I'll need the blower box, the interior ductwork (no recirculation door), climate controller, and vacuum line harness.

Pic.




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #28 of 97 Old 06-07-2015, 08:08 PM Thread Starter
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Re: Project Bare Bones

Oh, I almost forgot. Part numbers...

The smooth pulley I used with AC is the same number as the tensioner pulley, Gates 38015. 76mm x 17mm x 25mm

Belt = 69.5 in

The grooved pulley used in the last post is Gates 36239. 70mm x 17mm x 23mm

Belt = 45.5 in




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #29 of 97 Old 06-16-2015, 05:47 PM
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Re: Project Bare Bones

If the A/C works, I wouldn't remove it. I had a '85 about 2 years ago that was a bare bones base model 2.5 truck, only options were A/C and an auto transmission. Which was kind of fun in away.

1998 S10 4.3/Auto daily driver.
1984 S15 2.2 Diesel.
1988 S10 2.5 5-speed lowered 4/4.
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post #30 of 97 Old 06-17-2015, 02:33 AM Thread Starter
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Re: Project Bare Bones

Well, it's a tad too late to follow that advice. I wanted to see how visible the exhaust manifold would be if I removed everything and once I did I decided to just disassemble the entire system, sans evaporator.

Once I get some money together a header is in store!


List of things to be done.
Reroute starter wire under engine instead of over.
Relocate battery... eventually.
Relocate coolant reservoir... in design phase.
Manual brakes
Header
Cavalier intake manifold
Custom alternator bracket... in design phase.


Things to look into
cutting down aluminum radiator support from fullsize
replacing metal inner fenders with plastic, adding tubular braces to maintain stiffness.
check junkyard for cars that use the same air pump, to see what different brackets exist for possible relocation.


I took it on my first long trip through the hills of southern Missouri over the weekend and it performed great. Definitely more light on its feet than before I started turning it into a stripper model. Also the new head and transmission I have added to the fun.




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #31 of 97 Old 06-22-2015, 12:24 AM Thread Starter
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Re: Project Bare Bones

Yesterday's junkyard find. Off of a 96-97 Hombre. Now to find the interior parts for a 98+ as I doubt the interior box is the same, and the controls... well, duh.





WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #32 of 97 Old 06-23-2015, 02:39 PM Thread Starter
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Re: Project Bare Bones

Saturday I also happened upon an S10 with manual steering, something that doesn't pop up often here. I grabbed the box with the pitman arm for 20 bucks. I mostly was interested in the plastic rag joint cover that it had, and the mounting hardware.

Instead of the cover that splits open on the second gen trucks, this one is a solid one piece design. I had to wallow out the hole to slide it over the steering shaft as the first gens was a bit smaller. This one also has a second piece that bolts to the box itself and blocks off the large opening. It fit on fine with the U-joint.



Now it looks a like a untouched factory item.




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #33 of 97 Old 06-23-2015, 04:32 PM
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Looks great! Ur doing a good job!
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post #34 of 97 Old 06-24-2015, 01:42 AM Thread Starter
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Re: Project Bare Bones

Thanks! I appreciate the compliment!

If things go as planned my wife and I will have a house soon, so I'll actually have a garage to work in and store my truck. Right now I live in an apartment so it kind of limits the kind of work I can do.

I hope to learn to weld and do the bodywork needed eventually. It will be a slow build, but I'm not in a huge hurry.




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #35 of 97 Old 06-25-2015, 08:48 PM
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Re: Project Bare Bones

My 94' has the one piece cover. Not sure when they started using the split one.


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post #36 of 97 Old 06-26-2015, 02:36 AM Thread Starter
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Re: Project Bare Bones

I do know that I like the one piece design better. Mine and I'm sure most in existence break where it folds apart.

I installed my non-AC blower box yesterday. I've found the easiest way to do it is:

1. Remove battery and tray, move computer to side, move reservoir to side.
2. Unbolt and remove inner fender.
3. Unbolt blower box, and the six bolts that hold the evaporator in.
4. Remove blower box.

It took me about two hours to switch out, taking my time and cleaning up stuff as I went, including waxing that half of the firewall.

A couple crappy pics.



Next trip to the junkyard will include picking up a Cavi intake manifold so I can see what all I need to do to swap over.




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #37 of 97 Old 06-27-2015, 12:27 PM Thread Starter
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Re: Project Bare Bones

Here it is! It was way easier to remove from the Cavalier than it was to remove mine when I did my head gasket, but now that I don't have that giant evaporator box, it should be a breeze.



The car I got it out of had a massive valve cover leak, so it was caked in oil. Also had a bad case of blowby, the runners are pretty disgusting, and degreaser didn't help that much. Going to get some carb and choke cleaner and drown this thing.

One thing I'm happy about is that it was a car without EGR so I don't have to make a plate to block that off.

Also playing with the different water inlet options I have.






WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #38 of 97 Old 07-05-2015, 05:56 PM Thread Starter
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Re: Project Bare Bones

Messed around at the junkyard today, picked up a 4.3L throttle cable for the Cavalier intake, some Cavalier pulleys to play with, and a spare radiator to take a stab a tank replacement. I bought a manual transmission passenger side tank so I don't have an unused cooler anymore.



Thought this had potential but I don't need anymore potential future project parts laying around.



Hung out with this guy:


Cavalier water pump pulley looks cleaner and works with the six rib belt to boot! Though I think I'm still going to go to five rib eventually just for the hell of it.




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #39 of 97 Old 07-08-2015, 05:25 PM
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Re: Project Bare Bones

That's right, why run with 6 ribs when you can run with 5?! The extra space could be the difference in reaching for a bolt you might drop someday.

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post #40 of 97 Old 07-13-2015, 12:47 AM Thread Starter
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Re: Project Bare Bones

Exactly!

Seriously though, I just get on these kicks where I'm like, let's change everything just because I can!

I got my truck inspected the other day and they asked me if it was still a 2.2L. I was thinking to myself "No, I swapped in another OBDII compatible OHV 4 cylinder!" Of course, no such thing exists.




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #41 of 97 Old 07-14-2015, 03:01 PM
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Re: Project Bare Bones

Project looks good I like the handbrake and manual steering.
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post #42 of 97 Old 07-16-2015, 04:46 AM Thread Starter
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Re: Project Bare Bones

Thanks! I still need to get around to routing the rear cables so it actually works, and the money situation has become unstable at the moment, so this might be at a standstill for a while.
I am quite the fan of your Blazer!

I did get my NOS non-AC climate controller though, and man, it is minty fresh!




I'm currently using Bravada knobs but these new ones look better and they are on there TIGHT so I'm going to leave them alone.




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #43 of 97 Old 07-16-2015, 11:50 AM
Dichotomy In One
 
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Re: Project Bare Bones

That's cool I didn't even know they made those, I like the ford escort too, you just need to drop in an ls1, I always call my friends mustang 5.0 a ford escort and he goes ballistic, but basically, it is.
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post #44 of 97 Old 07-16-2015, 12:36 PM
Maybe later.
 
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Re: Project Bare Bones

They look similar, the the fox body and escorts aren't related at all. lol.

And yeah. Strippers!



I've had wayyy to many of these trucks. (Currently...on number 7)

1988 S-15 - 5.5/6 drop

1985 S10 Blazer 4WD

1998 Blazer ZR2 5 Speed!

Quote:
Originally Posted by fackinsteve View Post
3 doors for 1 and a half whores
Quote:
Originally Posted by svmcgover View Post
He only bought one wheel. So every picture we see is going to be a pic where either the rear or front is conveniently out of frame.

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post #45 of 97 Old 07-16-2015, 03:53 PM Thread Starter
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Re: Project Bare Bones

I didn't get to keep the Escort long enough to do anything crazy to it, but I was reading that a Zetec head drops right onto the CVH motor. Plus, that car barely weighed 2000lbs... with 140 or so HP it would have been a nice little sleeper.

And yes, the Fox platform is RWD. The Escort and Tempo were on the CE14 platform, FWD with 4 wheel independent suspension. I hope to own one I can drive one day. Even if it's not a hotrod. I think the Fox is popular for the same reason S10s are, it's relatively cheap to get them going. Though if I were go the RWD Ford route, I'd get an XR4Ti or Sierra (if I can find one in the US anyway.). Better unibody design and IRS. I'm not a V8 guy though, so it would be a Cosworth YB all the way for me!

The 98+ non-AC models are not very common. I see quite a few 94-97 models at the yards but I have yet to see a 98+. I'm trying to figure out what they put in place of the recirculation door. I'm guessing it's just a "delete panel", but I'd like to see for myself.




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #46 of 97 Old 07-16-2015, 04:27 PM
Maybe later.
 
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Re: Project Bare Bones

The escort is alot better platform than Americans like to think. Theres a reason why they were so popular across the pond.

Also, I agree. The fox is so popular because of huge and cheap aftermarket and years of the same platform being used on many different vehicles...



I've had wayyy to many of these trucks. (Currently...on number 7)

1988 S-15 - 5.5/6 drop

1985 S10 Blazer 4WD

1998 Blazer ZR2 5 Speed!

Quote:
Originally Posted by fackinsteve View Post
3 doors for 1 and a half whores
Quote:
Originally Posted by svmcgover View Post
He only bought one wheel. So every picture we see is going to be a pic where either the rear or front is conveniently out of frame.

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post #47 of 97 Old 07-17-2015, 08:49 AM
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Re: Project Bare Bones

Hahaha my brother likes to tease fox body owners about it looking like an escort, he calls them a muscort. I thought he was the only one. Haha

-Chris
http://www.cardomain.com/ride/2267640
98 s10 extcab 5/6 drop 2dr2wd blazer front sway
2.2 auto AL's header, efan, acell plugs, msd coils, 56mm tb mod.
[Project]: OH NEVERMIND<- click here and check out my project thread
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post #48 of 97 Old 07-17-2015, 09:38 AM
In charge of the big door
 
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Re: Project Bare Bones

Ford escort EXP, this was what most people call the muscort



Q: How many people can you fit in one Honda?
A: Well, the Bible said that all 12 disciples were in one Accord.

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post #49 of 97 Old 03-20-2016, 07:28 PM Thread Starter
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Re: Project Bare Bones

Well, it's been a while since I've done anything with the truck. I've got it back to all white.

I'm slowly trying to put together a plan for the rear mount battery and Cavalier intake tube. I've decided I want to make it look as stock as possible.

Here's a pic of my friend's 1957 TR3



Gold parts off



"new" parts on



Intake idea as of now...



The thottle body box is from an Ecotec Saturn, The filter box is from a Dodge Intrepid. Picked that one because it looks like it will fit perfectly where the battery currently is, and easy to mount as well. Just need two holes on the inside of the fender and an "L" bracket on the radiator support.

Also did some cleaning up of the timing cover and tensioner. Going to paint the alt pulley soon. Still working on a new bracket for the alternator so I can ditch the rest of the stock accessory bracket.





WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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post #50 of 97 Old 04-01-2016, 11:06 PM Thread Starter
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Re: Project Bare Bones

Got my distribution block for the battery location today. Basically, I'm going to run either a 1 or 0 awg wire from the battery to the main, then connect all the stock wires to the tap. The ground is going to go straight to the frame and I'm going to use a braided cable from the frame to the engine.



tomorrow the new rear parking brake cables are finally going on so I can start determining where and how to make the brackets to make it all work.




WANTED: 98+ radio delete panel.
Looking for a 94-95 2.2L 5-speed Extended cab, preferably white.
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