Re: NV4500 swap is underway
 

Have you looked here?

I talked to them a few months ago. IIRC a disc for the 205 flange, this caliper, and a couple pieces of hardware were around $250. They said they didn't have a specific bracket to put it to a 205 but the particular salesman I spoke with said he personally put one on his lifted ford bronco with an np205. Just a couple pieces of strategically placed square tubing and angle iron for a bracket and it worked great.

Re: NV4500 swap is underway
 

No, didn’t look at those guys and can’t remember where I saw the kit that was like $700. Thanks for the link… I’ll keep them in mind.

Man, it sounds like you guys have gotten great service out of those unitized bearings. I used to handle a bakery customer based in Ft. Wayne, Indiana that a fleet of bread vans with NV4500’s. They ended up swapping all them over to the external slave like the earlier NV4500s had. In fact, that is where I got the bell housing. They were going to throw it away so I talked them out of it and dropped it off at the UPS store on my way to the airport.

Re: NV4500 swap is underway
 

Awesome! Glad to see you're rolling on this project. The AA kit actually looks top notch (it had better be $$$). Have you thought about grabbing a 2000+ 14 bolt housing and keeping the stock style disc brakes with the internal drum parking brakes? While you're at it, you could rotate your pinion up and reweld the spring perches so you can run a CV rear drive shaft... Snowball effect? Can't wait to see the result!

Re: NV4500 swap is underway
 

you will have to reinforce the aa tc handle bracket. it flexes and make it difficult if not impossible to shift the tc case with fresh seals

Re: NV4500 swap is underway
 

I'll see if I can take pics of my C-10's firewall tomorrow.

Re: NV4500 swap is underway
 

That would be great! Thank you

Re: NV4500 swap is underway
 

DirtyLarry
NV project is looking sweet!
I put a slave cylinder firewall shot in my K10 album. See if it helps.

Re: NV4500 swap is underway
 

http://i272.photobucket.com/albums/j...y/100_0509.jpg

http://i272.photobucket.com/albums/j...y/100_0508.jpg

http://i272.photobucket.com/albums/j...y/100_0507.jpg

There you go! Dont mind the mess, the truck is all original and I haven't got around to cleaning up under the hood yet

Re: NV4500 swap is underway
 

I really appreciate the pictures! That will really help me determine the right spot.

Thanks again!

Re: NV4500 swap is underway
 

Thanks for the firewall pictures Edge and MalibuSSWagon!

Well, I haven’t gotten a whole lot done lately other than continuing to collect parts.

While searching for studs to use in the AA transfercase adapter we determined AA misdrilled the holes. I thought I was going crazy as there wasn’t a bolt in the world that would fit their threads. One quick call to them and they quickly sent me a replacement. As it turns out they had a few of these adapters that were machined wrong.

http://farm6.static.flickr.com/5045/...df287119_b.jpg
3/8 bore on the left and goofed up M10 something or another on the right.
http://farm6.static.flickr.com/5243/...d35a29d5_b.jpg

Oh, I am in dire need of a hydraulic clutch pedal assembly! If anybody has one that needs a home please let me know. I am not having any luck finding pedals around here. Everything I find in the bone yard is an automatic.

The column and pedals are out. Poor interior looks like hell.
http://farm6.static.flickr.com/5201/...067f9eb6_b.jpg

Re: NV4500 swap is underway
 

Larry, I am going to PM the pics of my pedal in a min, not sure if you determined that a hydro pedal is necessary or not at this point. I couldn't get great shots of under the dash anyhow.

I will keep a lookout at the local yards for you however.

Re: NV4500 swap is underway
 

Had a chance to sneak by an all-truck salvage yard about 40 minutes from my house this morning. Man, I think I just found my new favorite salvage yard! I have never seen more trucks for ripe pickin’s in one location in my life! I was like a kid in a candy store. Hard to believe this place is only 40 minutes from where I grew up and I never heard of it before. Actually, the yard is in my wife’s home town of Canon City but of course, she had no idea it existed.

Anyway, I scored a hydraulic clutch/brake pedal assembly from a 1989 chassis cab as well as the rod and other doodads that go between the brake hydrobooster and master cylinder that I needed. Then on my way out I found the NV4500 shifter stick that I really wanted…… A 1992-1994 shifter, as the knob matches the 73-87 tcase knob! Pretty happy about that. Got a bunch of other little things too.

Hydraulic pedal assembly on the left.
http://farm6.static.flickr.com/5168/...3919943d_b.jpg

http://farm6.static.flickr.com/5047/...fffa826a_b.jpg

Check out this yard (terrible Blackberry pictures)...... this dude has more Squares than Home Depot! I haven’t seen this many square trucks in one spot since I was a kid in the 70’s/80’s drooling at the local GM dealer. He claims to have over 250 squares and 150 88 to ’09 trucks. I love this place!

Chassis cab that I pirated the pedals from….
http://farm6.static.flickr.com/5167/...63f6ed08_b.jpg

http://farm6.static.flickr.com/5002/...dc8d8632_b.jpg

http://farm6.static.flickr.com/5005/...1cc8ed39_b.jpg

http://farm6.static.flickr.com/5206/...3ae550d4_b.jpg

http://farm6.static.flickr.com/5203/...d738701a_b.jpg

http://farm6.static.flickr.com/5086/...e19a005d_b.jpg

http://farm6.static.flickr.com/5248/...01b5a202_b.jpg

Got a lot of work to do this weekend now that I have parts!

Re: NV4500 swap is underway
 

VERY NICE! Always fun to find a new honey-hole. I agree with you about the 92-93 nv4500 shifter, the ones like I have (95+) look like they came out of a space ship in my opinion. And while they look fine in the vehicle they came in they look out of place in an older model. Congrats on the parts score!

Re: NV4500 swap is underway
 

What a yard (beds and tailgates!!!!). Nice pedal assy. Your set for now.

Re: NV4500 swap is underway
 

Dang. Any more of those mechanical pedal assemblies out there? How much did he charge for the complete tunnel?

Re: NV4500 swap is underway
 

Should have nabbed that 73/74 grill. I should be picking one up today actually.

Re: NV4500 swap is underway
 

Hey that looks like Canyon TRuck!!! They used to have A LOT more trucks, but when scrap was over 300 per ton guess what. Can you believe they had more trucks!!!!!

Re: NV4500 swap is underway
 

Yeah, they had tons of mechanical linkage type clutch/brake pedal assemblies as well as at least 1 more hydraulic clutch/brake pedal assembly. About the only thing I could not find there was a front Dana 60.

I got out for $60 for a bunch of stuff. Pedals, back up light harness, shifter stick, tons of screws, bolts, clips, etc, hydroboost to m/c rod and a dome light bezel. It was hell carrying all of that stuff out as I have a broken foot and hobble around like an 80 year old man.

Re: NV4500 swap is underway
 

Yep, Cañon Truck. I would have loved to gone there when they had more trucks. I am a Pueblo native, aside from a 6 year hiatus in Detroit, and surprised I never heard of this place before. A buddy from a local salvage yard here told me about them. The guys at Cañon Truck were really friendly too whereas most of those type guys usually act like junkyard dogs.

Re: NV4500 swap is underway
 

Man, if I'm ever out there I'll have to make it a point NOT to stop there. I'll never have enough money to get home.

Hope the foot heals before you're done. Would suck to be done with it, and not be able to enjoy it.

Re: NV4500 swap is underway
 

Very nice parts scores! Yards around here have very minimal trucks in them anymore due to scrap prices.

Re: NV4500 swap is underway
 

you said you had to carry all the stuff out, are you not allowed to drive in anymore?

Re: NV4500 swap is underway
 

I know where i'm going for vacation!

Do you still need that stick then Larry?

Re: NV4500 swap is underway
 

Not sure, I didn't ask and they didn't offer. Although, they did give me a lift down to the squares in an old beat up G-van.

Re: NV4500 swap is underway
 

It doesn’t look like it, but my buddy and I got a lot done Saturday. He tackled the rust in the floorboard and I went after retrofitting the clutch master cylinder, which turned out to be an all day event. Got the clutch m/c and hydrobooster mounted, installed the pedal assembly and reinstalled the steering column. Also tied up and rerouted several wires under the dash.

Made a template from the donor truck at the junk yard. It was easier to follow the template from inside the truck
http://farm6.static.flickr.com/5210/...b1df7e6b_b.jpg

After the firewall, pedals, and steering column was put back together. The clutch m/c almost looks factory! Pretty slick the way the GM engineers had the clutch m/c mounting studs connected to the clutch/brake pedal assembly via 2 rods. It will sure be nice to have a straight clutch pedal again too! The old one was so badly bent, I often hit the dimmer switch when stepping on the clutch.
http://farm6.static.flickr.com/5042/...c1a81cf1_b.jpg

The brake master cylinder won’t be here until Tuesday. All of the wires going into the cab that run the dual battery isolator, fuel transfer pump, etc have been wrapped with vacuum hose. I prefer to use vacuum hose to protect single wires more than split loom when possible.
http://farm6.static.flickr.com/5285/...1f0944d1_b.jpg

Bill cut out the rusty floor board and cab support brace. The truck doesn’t have an ounce of rust on the body but the floor board corners and front cab supports were in need of attention. The floor will be sprayed with Rhino once complete.
http://farm6.static.flickr.com/5044/...7f81e090_b.jpg

Once the rust repair is complete next weekend we'll start stabing the trans/tcase and modify the crossmembers. Until then I am going to start installing the ZF P/S pump this week and get ready to have the medium duty truck P/S lines I purchased from work tweeked to fit the Saginaw steering gear. Wait until you see the size of the P/S reservoir I got! :lol: Don't know where in the hell I am going to mount it but it will be awesome, especially when ever I get a hydraulic winch!

Re: NV4500 swap is underway
 

I'm just stumbling onto this build now so I appologize if its mentioned in another thread, but...

What are you doing for a ps pump and lines to the steering box?

I have a gen6 454 in my engine bay which has the hydraboost pump, but I'm stumped at how to plumb it to my steering box. (my truck is an 82 K20)
I might just end up going to a 1/2 ton vortec ps pump instead just to keep it simple as I don't have anything else from the hydraboost setup.

Sorry for the hijack. :ito:

Re: NV4500 swap is underway
 

I am using a late model medium duty truck P/S pump and lines. Although the lines will need to be modified to fit the old Saginaw steering gear. Pictures of the pump are on the first page of this thread.

From what I can tell your hydroboost pump just has two return ports. Plug one off and you should be fine.

Re: NV4500 swap is underway
 

GM 1ton step vans have hydro boost and use a factory t in the return line to the pump verse having 2 returns ports on the pump. FIY

Re: NV4500 swap is underway
 

Yep…. in fact, that is what I am using is the modern P-chassis, which is now a Navistar product called Workhorse. That is the company I work for.

I could have kept the original P/S pump that is on the 8.1L now but I wanted the ZF pump for its durability, especially once I get a hydraulic winch. Since this truck is in pieces anyway, now was as good as time as any to throw it on.

Here is an engineering layout of our lines for a 2010 Workhorse 14,500 GVWR stepvan chassis with a L96 Vortec 6.0L and ZF P/S Pump and ZF P/S gear. The ZF pump only has a pressure and return port with a T in the return side. I am planning to use this exact P/S cooler and as much as these lines that I can but using a P/S reservoir from a larger vehicle for added capacity....If I can make it fit. These lines will need to be modified where they screw into the original K10 Saginaw steering gear. One of these lines may come up short as the engine sits closer to the firewall in a stepvan chassis than on a pickup.

http://farm6.static.flickr.com/5123/...807a5462_b.jpg

Re: NV4500 swap is underway
 

DO I gota stand on my head to understand what im looking at?:lol:

Re: NV4500 swap is underway
 

Where or how are you getting the custom hoses made up?

I went to several places here, even a hydraulic hose company and they said "good luck with that..." =\

Only thing he could thinking of was using high pressure hose (1500psi) and some crimp style clamps but he didn't doubted that I'd be able to squish the ends of the hose enough for the clamps to prevent the hose from popping off the pump fittings.

Re: NV4500 swap is underway
 

Check your local agriculture and heavy equipment implement shops. There are a few around my area that build high pressure hoses for logging equipment that have small diameter hoses and make crimps good for 5000psi+.

Re: NV4500 swap is underway
 

That's what this place specalizes in. lol

I brought the original lines in a told him that I'd like longer hoses made up with ends that match the originals.
He took one look and said "I don't have anything like those...

Re: NV4500 swap is underway
 

Sounds like a really crappy shop then...

Re: NV4500 swap is underway
 

Yup. Just a regular mom and pop's place...have a look:

http://www.redl.com/profile/represent.html

Re: NV4500 swap is underway
 

Larry,

Attachment 668040

Attachment 668041

Re: NV4500 swap is underway
 

Steve,

That is perfect! I’ll take it!

Progress is being made albeit slower than I would like. Saturday my buddy got the passenger’s side floorboard and cab support patch panels all welded up while I wasted a boat load of time messing around trying to fit the ZF pump and hydrobooster lines. As it turns out, the ZF power steering pump assembly is bigger than my ambition to start cutting up the frame to make it fit. The ZF pump with the GM style adapter bracket makes the pump sit 3 inches lower than the stock P/S pump, which would drive the pulley right into the frame. That said, the ZF pump plan got canned as well as the huge class 8 truck P/S reservoir. The bummer was I had to pull the radiator out to gain access to the p/s pump pulley in order to remove it to get the pump off. Only to reinstall it a few minutes later once the ZF pump didn’t fit. The 8.1L package makes everything a pretty tight fit where 10 things have to be moved to gain access to one thing.

http://farm4.static.flickr.com/3276/...52705748e7.jpg

The plan now is to use the original p/s pump with OE style hydroboost hoses with a T in the return side being the original pump only has 1 return port. Of course that project, turned into a fiasco as well being the fitting on the hydrobooster is metric while the steering gear is standard so one hose had to be reworked. I am still waiting for the other hose to show up at Napa tomorrow.

Other than that, I installed the Super Bright LED bulbs in the cluster and the seats are getting dropped off at the upholstery shop tomorrow. Probably stab the transmission and tcase in sometime this week so I can start measuring the shafts to get them ready to be dropped off at the driveline shop. Next weekend we’ll start cutting up the floor and cab support on the driver’s side to get it ready for patch panel then it will be off to the Rhino Lining shop to have the interior floor sprayed.

Oh, yeah…I found the original grill brackets and an original 1977/78 Scottsdale grill in my attic that I scored a few years ago. I am kind of tired the 80’s chrome tube grill and anxious to see how the truck will look wearing it’s factory face again. :chevy:

Re: NV4500 swap is underway
 

Lookin good! Those are some of the more affordable LED's I've seen. Do they still work with the dimmer?

Re: NV4500 swap is underway
 

Dunno yet :lol:

Another buddy just put some of these in his S10 and told me about them. They work great in the S10 but I doubt they will work with the dimmer. Prolly just be like an on/off switch. We'll see. Heck, they might not even work at all.

These are the ones I got. http://www.superbrightleds.com/cgi-b...-x5.htm#photos

Re: NV4500 swap is underway
 

Hmmmm... what hydroboost are you using? can you post some pictures of the h-boost and the ports? This is an area I amy be able to help you out in!