Pete's (Now Nate's) 2003 Denali Budget Build thread

[Tonyrodz]

Filling Holes Without Welding

it was at this point i figured, man, i'm bout to paint this thing anyways so i might as well take it a step further.
In a perfect world i would cut out little metal circles, use a magnet to hold them in place and then tack weld them in etc..But i don't have a welder here. I used this stuff on my Lexus when i had to fill spoiler holes in my trunk. You basically put it on the inside of your panel and it gives your bondo something to adhere to. Otherwise your bondo is just going to droop into your hole.

So i cut pieces that covered the holes. (it has adhesive on the metal grate)
I scuffed the mtal and degreased it then stuck it on both sides. You can see it if you look close up under that hose

view from the top

both holes slightly coned and protruded like a boob so i used a big hammer and very lightly bounced the hammer aroundthe edge of the holes to flatten them. this was before i did that

sanded around the holes and degreased, then mixed up some good ol body filler and covered them up

But then it was Thankgiving and i had to roll this dismantled Denali all the way out to Phoenix for a get together.
Here's a pic in Gila Bend (half way to Phoenix)

Do you think the filler would be good enough not to sink or crack from age or vibrations?

 

[05Single]

Nice work. Always love your details explained and pics

I've been thinking of replacing mine with an actual radio shark fin. Painted to match. That way I still get reception and the antenna ain't laying in the fender anymore

 

[05Single]

Surprised you didn't use kitty hair.

 

[willinnashville]

I always kind of dug Gila Bend. On the way over to Phoenix from San Diego, I always stopped there for a cup of ****** gas station coffee. One of these days I want to stay at that spaceman motel.

But then it was Thankgiving and i had to roll this dismantled Denali all the way out to Phoenix for a get together.
Here's a pic in Gila Bend (half way to Phoenix)

 

[Sevenevez]

Drove all the way back to Yuma the next day. Denali covered in bugs but it gave the bondo a full 24 hours to cook in the AZ sun.(if you mix it with too little hardener it takes forever to dry but you can spread it with patience. Whereas if you put more hardener in it dries a lot faster but you dont have much time to get it on nicely.

Started sanding them puppies nice and flat.

taped off the sunroof and primed em, then scuffed that with a red 3M pad.

All done!

right? nah. i can already hear someone chiming in about this! haha

Remember these? got's to go!

Might as well do the same to the liftgate / rear-wiper delete
Pulled off the plastics and grabbed the DA to sand off all the glue/silicone leftover from the plugs

More panel patches

Degreased. ready for bondo

Filled and sanded smooth (i had to do the big hole 3 TIMES!) i was pushing too hard while sanding and slightly pushed the hole edge through.

3rd times the charm i guess

Primed and sanded

i still feel just a little lump on the big hole. i may or may not do a little more work to get it perfect. But maybe not. who knows. Ok, that's all so far

 

[Sevenevez]

Do you think the filler would be good enough not to sink or crack from age or vibrations?

it'll be fine. like i said, i did it on my lexus. that lasted 6 years without an issue. as long as the prep is right, it'll stay solid. it's just not as ideal as welding would be though

Nice work. Always love your details explained and pics

I've been thinking of replacing mine with an actual radio shark fin. Painted to match. That way I still get reception and the antenna ain't laying in the fender anymoreView attachment 187529

thanks man. and hmm, i didnt even know an aftermarket radio uses your OEM XM® antenna. But that might be cool on yours. i dont do satellite radio, residual bills arent my thing

I always kind of dug Gila Bend. On the way over to Phoenix from San Diego, I always stopped there for a cup of ****** gas station coffee. One of these days I want to stay at that spaceman motel.

haha, i know exactly what you are talking about. and yeah, i stop there everytime and at least grab a bite to eat in Gila Bend. It's half way and breaks up my trip

 

[05Single]

Nice. I think I'm doing this over winter.

And we don't even have satellite radio up here so in no way was I referring to satellite radio . I meant for local radio stations. This is what the European cars use. What my wife's old b6 passat had one.

 

[Sevenevez]

Nice. I think I'm doing this over winter.

And we don't even have satellite radio up here so in no way was I referring to satellite radio . I meant for local radio stations. This is what the European cars use. What my wife's old b6 passat had one.

ahh i see. yeah, that should work.
i dont have good radio reception since i removed my antenna but it does work in the city. i usually play CD's cuz i'm old school, haha. sometimes i use the Phone music apps through the radio. Sometimes i just like to drive with peace and quiet

 

[05Single]

ahh i see. yeah, that should work.
i dont have good radio reception since i removed my antenna but it does work in the city. i usually play CD's cuz i'm old school, haha. sometimes i use the Phone music apps through the radio. Sometimes i just like to drive with peace and quiet

Lol no the radio stations are trash up here anyway, I'm always using YouTube or pandora. But just knowing my antenna laying in the fender bugs me enough to change it lol
Just a thought I was sharing. You've already done the work, plus having the roof smooth of course looks way better.

 

[kwOH]

Thing is gonna look smooooove man! Lol. Might as well leave the rack off and fill in the holes, slap a roll pan on the back, and get an HD hood. [emoji6][emoji106]

 

[adventurenali92]

Damn... I’m so jealous! I would love to have you fix the tailgate on my truck to get rid of plugs and paint my tailgate up right! Looking good man! Keep us updated! I wanna see how everything comes out!

 

[TheAutumnWind]

Loving how this is coming along pete! I just skimmed a few pges and the hole filling is looking great. I still need to do the plugs in my tailgate... Rear wiper drives me nuts. Anywho i plan to dig deeper into your thread. Thanks for sharong!

 

[Fosscore]

Nice work man. The right choice since you are painting the whole truck after all. Going to look great!!

Shoot I went to school in Tucson and Chandler and then further south Casa Grande seemed like they were miles out of town.

As was the base in Litchfield Park and the Desert Sky pavillion (I think it is Ak Chin now). There were no ring roads to connect east and west.

So much growth.

 

[Sevenevez]

Thing is gonna look smooooove man! Lol. Might as well leave the rack off and fill in the holes, slap a roll pan on the back, and get an HD hood. [emoji6][emoji106]

thanks man! and none of the above are going to happen on this one. it's something about the big bulky color matched cladding and bumpers on the Denali's that just looks right to me. Most other Fullsize Chev's look great all smoothed out. Fosscore's is a great example of that.

Damn... I’m so jealous! I would love to have you fix the tailgate on my truck to get rid of plugs and paint my tailgate up right! Looking good man! Keep us updated! I wanna see how everything comes out!

Thanks man. Yeah i'm gettin close to paint day. i just have to choose a 3-day block where i dont have to work and the weather is right and then just bang it all out!

Loving how this is coming along pete! I just skimmed a few pges and the hole filling is looking great. I still need to do the plugs in my tailgate... Rear wiper drives me nuts. Anywho i plan to dig deeper into your thread. Thanks for sharong!

Thanks Chris. Yeah, the wiper didnt bother me until everyone here started mentioning it. Then it drove me nuts everytime i walked outside haha. And you dont have to paint the plugs cuz yours is already black. easy fix!

Nice work man. The right choice since you are painting the whole truck after all. Going to look great!!

Shoot I went to school in Tucson and Chandler and then further south Casa Grande seemed like they were miles out of town.

As was the base in Litchfield Park and the Desert Sky pavillion (I think it is Ak Chin now). There were no ring roads to connect east and west.

So much growth.

Yeah thanks for the push of motivation. That did it. And it wasnt bad at all to get them off. If i was using plugs probably only woulda been a 30-40minute job.

ha, yes, i lived all over arizona since migrating here in 2000. It's a wonderful state with a lot of different cities and options. I have been pretty much everywhere except North

 

[Sevenevez]

gotta handle this before i paint!

as much as i like the honeycomb, i feel the Billet horizontal bars match the lower better and give it a cleaner look

Billet Grille

cuttin'

removin'

why?
i want this overlay to sit as close and flush as possible so i completely removed the bulky GMC center

Installed.

this is a temporary install because i need to still tape off that chrome lip when i paint it (soon)
also i wanted to check it's fitment. I may actually turn this into an insert by cutting out all the honeycomb and making brackets for it. I dig it already though

 

[Tonyrodz]

gotta handle this before i paint!

as much as i like the honeycomb, i feel the Billet horizontal bars match the lower better and give it a cleaner look

Billet Grille

cuttin'

removin'

why?
i want this overlay to sit as close and flush as possible so i completely removed the bulky GMC center

Installed.

this is a temporary install because i need to still tape off that chrome lip when i paint it (soon)
also i wanted to check it's fitment. I may actually turn this into an insert by cutting out all the honeycomb and making brackets for it. I dig it already though

Looks good.

 

[Rocket Man]

gotta handle this before i paint!

as much as i like the honeycomb, i feel the Billet horizontal bars match the lower better and give it a cleaner look

Billet Grille

cuttin'

removin'

why?
i want this overlay to sit as close and flush as possible so i completely removed the bulky GMC center

Installed.

this is a temporary install because i need to still tape off that chrome lip when i paint it (soon)
also i wanted to check it's fitment. I may actually turn this into an insert by cutting out all the honeycomb and making brackets for it. I dig it already though

I like it. Where did you get the billet?

 

[Sevenevez]

I like it. Where did you get the billet?

good ol eBay.
this one is an overlay. just because i wanted both options.
if you want yours almost flush with the lines of the front end get an overlay (you cut out just the GMC section)
if you want yours more sunk-in then get an insert (you cut out all the honeycomb)

also, you can always add your GMC logo back on top of the billet bars if you want. The GMC logo unclips from the black base

this is the one i got.

https://www.ebay.com/itm/eGrille-Bl...e=STRK:MEBIDX:IT&_trksid=p2060353.m2749.l2649

 

[MadDogDelpho]

Looks good.

 

[Rocket Man]

good ol eBay.
this one is an overlay. just because i wanted both options.
if you want yours almost flush with the lines of the front end get an overlay (you cut out just the GMC section)
if you want yours more sunk-in then get an insert (you cut out all the honeycomb)

also, you can always add your GMC logo back on top of the billet bars if you want. The GMC logo unclips from the black base

this is the one i got.

https://www.ebay.com/itm/eGrille-Black-Stainless-Billet-Grille-Fits-99-02-GMC-Sierra-00-06-Yukon-Upper/262658163499?ssPageName=STRK:MEBIDX:IT&_trksid=p2060353.m2749.l2649

I'll be leaving mine as is. I have the rare Denali Down Under matching lower that I replaced the stock plastic piece with. And I need that lower one with the flow-through because that's where my Tru-Cool trans cooler is mounted since I installed my intercooler for the Whipple in front of the radiator and didn't want to triple-stack things. But yours looks good.