History, Teardown, and Rebuild 63 1-ton panel

[63_Rouss_Fire_Co_GMC]

Creating a thread on the history of my 63 GMC 1-ton panel truck. Old photos of it when it belonged to the Rouss Fire Company in Winchester, Va. Also photos of it afterwards when I first fell in love with the truck while in Boy Scouts as it was my scout masters and I always had to ride in it. It was later used in the movie Forrest Gump and painted a blue/purple. I bought it when I was in highschool and drove it awhile before the rust started to appear. As a teen I tried to repair it and eventully removed the many layers and colors of paint. I has been primer and spray bomb green for many years. Finally decided it need to be taken off the road and reworked. Here is it progress in photos n text..

Jeremy Cooper
Winchester, VA.

[63_Rouss_Fire_Co_GMC]

First two photos are black and white shots while at Rouss Fire Company. The first was taken at the rear of the truck of Donald "Gundy" Seabright. I was told the truck carried men, lights, fans, and generators to fire calls. It had bench seating down both sides in the back. It was used during the winter as fundraising for the fire dept as they used it to drive around and shovel driveways. Second photo is of my next door neighbor who was the chief at the time. He is being presented with an iron lung that would be carried in the truck along with the stretcher seen here. This is the second and final paint scheme that the truck carried. The name was removed from the doors and the new fire company seal added to the side of the truck. Third photo is the truck in its original paint scheme during the Shenandoad Valley Apple Blossom Parade in Winchester, VA.

Forrest Gump photos next... Jeremy Cooper

[63_Rouss_Fire_Co_GMC]

After Rouss Fire Company owned the truck it was then sold to Frederick County Virginia where it was used as a band wagon for the James Wood High School. It was later painted red/tan, then green/light green. In scouts it was this faded two-tone green/light green. I'll have to find a photo I know I have of it this color. My scout masters son saw an add in the paper looking for cars and trucks from the 1960's to be used in a movie. Turns out it was taken and body work and paint done, roof rack added, and painted this blue/purple color. It was used in the motion picture Forrest Gump. We were told is was cut from the released film but was used as a movie prop. Used as a film/news crew covering the protest/gathering at Washington D.C. that was in the movie.

The first photo is the day I bought it from my scout master, still had the movie rack/platform on top. Next two shots are shortly after the bondo used to redo the truck started to bubble and rust began to reappear.

Jeremy Cooper

[63_Rouss_Fire_Co_GMC]

Next set of photos were taken while sanding, scrapeing, and body panels were cut out and replacement welded on. Replaced the rusted front fenders with a fiberglass set that I got at a local body panel shop. Found a door off a big moving truck in a local junk yard that had no rust on it at the time. Drove around with the turquoise door that read "Manassas Transfer" "Manassas, Va". Eventually painted the truck primer red then later spray bombed almost the entire truck a similar green to its original color.

Jeremy Cooper

[63_Rouss_Fire_Co_GMC]

Next set of photos were taken as I began to tear the truck down. I had drove the truck to work, when I got to work I closed the door and the window dropped off its requlator and down into the bottom of the door. When I got off work I discovered it was raining, so I had a wet seat. Turns out I had no taillights or lights on my guages inside the truck. All I had was the headlights, I assume a safety feature of the truck. Well just before I got home the only one winshield wiper I had on the truck, decided to fly off while in the rain storm, at night with the window down and only headlights. Had to stop the wiper arm to avoid scratching the windshield. So when I got home I decided to park the truck and restore it myself, or do what I could then send to a body shop. The first photo is the next day before I took it apart. Then I removed the doors, carpet, trans cover hump. Removed the front clip as a single unit with the radiator and motor left alone so I could still start and move the truck as I needed. Removed the windshield and it ended up cracking is several spots, the rubbers were so hard I would come out as the maintence manual suggested. Notice the hose running thru the cab, that's my gas line for the fuel tank simply sitting on the floor behind the seat. I then got out the grinder and cut off and removed what b ody bolts hadn't rusted away already. It turned my grinder to the bolts that held the bed strips down and discovered that the truck did not have a wood plank floor but a wood plywood floor made up of two extremely long pieces. Got the wood floor out and only 1 of 4 cross sills were still good. Washed the dirt off the frame and begun to scrape at rust with a wire brush and wire brush attachment on my drill.

More to come don't wana overload anyone inbox, Jeremy Cooper

[63_Rouss_Fire_Co_GMC]

With the bed out of the body, I could get to the rusted frame mounts and inner body panels. Took a lot of photos and attached just a few here so you can see how bad the frame had rusted. Also for a look at a 1-ton panels frame since it is so diffrent than a pickup. First shot is the rear frame where it joins into the main frame also at the rear. The truck was so long it looks as if they extended the frames and joined them by rivets on the 1-ton panels. The rust had got between the two frame pieces where they were join and sorta split them apart. You can see the damage to the left side in this photo. I eneded up chiseling and beating the frame with a sledge to break up and removed the rust. Drilled another hole and bolted this top of the frame toeghter for added strength.

Next photo is looking towards the front of the truck from about the rear wheel well, notice the frame mount is rusted out, the other side was untouched by rust. Next two photos are a major problem and I will have to cut out this rear cross sill/tail pan and custom fabricate a new one. Both sides are just destroyed by rust. Others photos were taken looking into the taillight opening down inside the rear body of the truck. The metal that the wood bed screws up into to hold it in place has completely rusted away allowing water to get up inside the body panels. The last shot is of the four cross sills. Only one was reusuable and you can see just how bad the others are. I'm hopeing a fleetside cross sill is the same length. Anyone know if they are?

[63_Rouss_Fire_Co_GMC]

Jacked the body up and off the frame with the help of the kids swing set and some wood stumps. Pulled the frame out from under the body with my duece and a half. Winch got stuck and it flexed the body out some, I will have to deal with that when get to the cab and body. Here is a shot of the 305E with the body removed. Wired it back up and she starts just fine. Another shot from the rear of the extremely long looking rusted frame. Here is a trailer hitch that was put on the truck some time after the fire company had it. Hate this thing it always drug the ground when off-road. Next shot is the rear of the frame with the trailer hitch removed. I did leave one brace that connects both sides of the exteneded frame toeghter for strength. I will have to try and track down a rear bumper or modify a front bumper with new bolt holes to fit. Final 3 photos are the 1-ton panels fuel tank. This tank mounts on the outside of the frame on the drivers side. Now there are bolt holes in the frame to mount a second tank on the passenger side of the truck. I only had one bent original gas tank bracket. I looked everywhere for a replacement of something that would work. Ended up haveing a pair made at a local metal working business for I believe around $118. They work just fine, here they are bolted back to the frame after cleaning that section of the frame.

Anyone have any questions or a simialr truck I like to know what you think. As of 1-24-13 the frame has been painted, and it back toeghter, next step is the crosssills and rear cross sill/tail pan fabricatrion.

[63_Rouss_Fire_Co_GMC]

Trying to include a lot here so I don't have too many emails goin' out. So, after the body was off, I had cleaned what I could off the frame. Its was time to pull the motor so get to the built up gunk under the trans and on the control arms. First photo is the V6 pulled from the frame. It was so much easier to clean this way and you wouldn't believe how much grease was built up on the SM420. Used a wire brush, cleaners and degreasers and finally paint remover on the engine and trans. The next set of photos are just a quick look at the engines progress throught the paint stages and reassembly. Ended up using a red/orange paint for the V6. Back to the frame after lots and lots of brushing surface rust and dirt off, it was finally clean for paint. Used Eastwood's Rust Encapsulator instead of the Por-15. Turned out good and went a long way, finished up with Eastwood's Original Chassis Black. Other colors on seperate parts of the frame and engine/trans. Had to take off and redo the large tow hooks at the front of the frame.

[63_Rouss_Fire_Co_GMC]

Got the fuel tank cleaned up, painted then undercoated, bolted it on to the new brackets. Next photo is an original GMC V6 engine mount next to what I have been using for years now, an Energy Suspension Automatic transmission mount€. Just had to drill another hole in the bracket the the mount is bolted to. Same height and much stronger then the stock mount.

Ready to install the engine back onto the frame. Used a strap off my M35A2 to lift the engine again. Looks good with it all bolted back up and CLEAN. Next took off the rear wheels, cleaned and painted the rear axle. Installed the exhaust pipes until a proper/original plumbing exhaust can be installed after the truck has been painted.

There two rims show the diffference between a 16in rim that was off a 78 Checy 1ton. The rim on the right is an original to the 63 GMC, 17in split rim. I have 4 of these rims! Some have 17x700 tires, others have 17x750 tires.

Last shot is me pulling the GMC's frame complete back up out of my tarp garafe to the side of the house so I can get the body out of the kids swing set until I can work on the body in the spring.

[63_Rouss_Fire_Co_GMC]

Last post until I get more work done, or anyone wants so further info or photos on something I did here to this truck so far. Ok, photo of the body off the frame. Had to raise it high up to get the frame out and back under the body. Next photo is from inside the back looking at the cab floor. The cab floor will need both rockers and inner rockers replaced. There are a few rust holes where the floor braces under the cab are joined toeghter. Overall not a bad as I thought but gonna be a nightmare to straighten the cab back to where it should be.

Here is a shot during cleaning and removing pealing paint from the drivers side of the wood bed plywood. Next photos are the only one cross sill that was reusable. It has since been rust proof painted and new mounts made from solid hard plastic. Could not find anything to resemble the stock mounts. 3 of the 20plus mounts were still good. Next photo is the parking brake band I relined myself. I purchased two bands to have an extra along with the rivets. Wasn't hard at all, just finding the harware to put make the handbrake operational again. Here is the frame complete out front the house, since the photo was taken the body was set back on the frame till spring.

The truck started right up with the choke out and after getting gas up the empty fuel lines. Runs so quiet and smooth compared to my 327 V8 in my 63 Impala.

Jeremy Cooper,
Winchester, Va

[6066gmcguy]

That is a nice rig your restoring they, keep up the good work.

[FetchMeAPepsi]

Great chronicaling on your build! What a job. Did the kids swingset really hold it up ok?
I've been wondering what I was going to do with lifting bed and cab if I get that involved.
There aren't any good sized trees around here I can use

[Cayoterun]

Interesting project/w a great history.
When finished, you'll look back and see where all the blood, sweat, and mashed fingers were worth it.
Kid might be mad at ya' for stealing their swing set, tho.
Great Job!

[63_Rouss_Fire_Co_GMC]

Found two more images of the truck back when the fire department had it. One of the images was taken in 1971 just 2 years before the truck would be turned over the the local high school for their band wagon. Looking at that photo you also see what appears to be a red and white GMC. I can't seem to see any "V6" badges on the side of the hood tho. Also I believe a 62 Chevy truck is also in the photo.

Started the V6 up yesterday, man it runs smooth. I gotta figure out how to get this body pulled back to its shape at the rear of the doors. It stretched when the frame was out from the body, I didn't know at the time I had to brace it. Anyone have any suggestion on how to get the cab back to its "shape". I was think a come-a-long and pull it somehow after cutting the floor loose(needs replaced due to rust)?

[63_Rouss_Fire_Co_GMC]

Found some images on my railroad website of my GMC. I used to drive alongside the tracks and on the abandoned roadbed. The railroad, the Western Maryland Railway ran from Baltimore, Md. to Connellsville, Pa. It was mostly abandoned in 1975 by the Chessie System. Anyway like I said I used to drive the roadbed, here are some shots back around 2000, 2003 of the truck a some locations. If your wanting to know more about the railroad check out my website, <br><font color='red'>To view some links or images in this forum your post count must be 1 or greater. You currently have 0 posts. Maybe you should introduce yourself with a new topic?</font><br> I also drove my 63 Impala on a lot of the abandoned route also if the clearence wasn't too bad on the ballast.

As for the truck today, I ordered some 1962 fleetside cross sills from a Tuckers Auto Parts in Nevada. Was gonna go the Classic Industries route but shipping on 3 cross sills was 184 bucks, only 54 bucks other place. I'll see what I get for what I paid.

Jeremy Cooper
Winchester, Va

[63_Rouss_Fire_Co_GMC]

Great chronicaling on your build! What a job. Did the kids swingset really hold it up ok?
I've been wondering what I was going to do with lifting bed and cab if I get that involved.
There aren't any good sized trees around here I can use

Swing set did just fine. I had wrapped chains through the windshield opening to hold it up high off the frame. Wrapped the chains n heavy blanket to prevent bending of glass weatherstrip lip. But I here I should have hung it from door opening, much stronger spot I'm told. Make sure you weld up some braces in the cab, I didn't and mine stretched. But may not be as bad with a pickup compaired to an open panel/suburban body. Have more pics of it lifted also. Jeremy

[63_Rouss_Fire_Co_GMC]

Dug out some old slides I had, found some GMC photos. The first was taken during a Boy Scout Winter Jamboree here in Winchester. See the GMC in its 2-tone green next to a new military Humvee. Second and third photo taken after the truck had been painted for Forrest Gump. The CSX train is eastbound at Hanstrote, WV. The last photos were during removal of the many layers of paint. The first shot shows primer under the other layers from when it was in the fire department. I was told they had to sand off the lettering and primer over where they sanded before the truck was sold. Then a photo of a door I got off a big GMC moving truck. I hope that truck is still there, like to see what V6 is in it.

Jeremy Cooper
Winchester, VA

[Noproblemallis]

Jeremy,
Great work and photos! The only problem is that you make it look too easy.

[FetchMeAPepsi]

Trains and trucks just go together don't they? I don't know why. Thanks for all the great historic pics

[63_Rouss_Fire_Co_GMC]

Jeremy,
Great work and photos! The only problem is that you make it look too easy.

After I took the body off the frame I thought what did I get myself into. I had washed and brushed dirt off a lot before even taking the body off. Only took off the body to get to the frame under the cab. Wanted to do it right and removing the body made it easier to work with the frame. Then it was using a wire brush by hand. I bought some small wire brushes the size of tooth brushes to get into the small/tight areas. Also got some cleaner from work and used that a lot to scrub and brush off dirt and rust. Used a drill with a wire brush wheel on the big areas. I used a lot of brake parts cleaner too, to remove grease and to clean the metal before I painted it. Used the Eastwood rust encapsulator by the can. Then followed that up with the same paint in spray cans to get the hard to reach places. Topcoated with Chassic Black, can the spray bomb.

Trouble I have it body mounts for this truck. It originally used a retangular mount that had a metal plate one one side. Of the 20plus mounts on the truck, 2 or 3 are still good. I found some hard plastic material at work and I cut out and made some mounts. I will see how those work first if not a 70's Blazer mounts are same thickness just wider.

If interested in more photos during the cleaning, painting, or those mounts I have more photos. Just waiting on those cross sills I ordered to show up so see if they will even be close to what was original. Thinking about just goin to the metal shop that I got the gas tank brackets made and get some metal box tubing to replace the cross sills and custom make a rear cross sill.

[Noproblemallis]

Keep us undated. Some of us lazy folks just love to see others work. :)

[kieth]

Nice build, lots of work in the Suburbans, Those cross sills look just like a fleetside pick ups cross sills, only question would be which height of cross sill. They do vary in height. Hope you got what you needed......Kieth

[FetchMeAPepsi]

I'd like to see those cleaning photos. I powerwashed the frame on mine and it flash rusted :(
I think I'm going to try a little hand sandblaster on it this spring