Re: My 83' Crew Cab Dually project
 

I stripped the front clip off the suburban today and started getting everything fit up on the truck. I've run into a pretty significant problem with the header panel. I had a bad feeling about this area, so I measured over and over again and thought I had it, but turned out I screwed up someplace...where, I'm still not sure. So I stopped focusing on what went wrong I'm trying to work out what it's going to take to get it fixed now. I trimmed back the frame at an angle to make a little more room and it looks like I may have to drop the horns 1/2" still, but that being said, I'm finding that the radiator is going to have to move to passenger side about an inch to clear the steering box. Even then, it's nosebleed tight. Anyone else run into this with a Z? I raised 4" and forward 1". I compensated for both when I did the front horns...?

http://i82.photobucket.com/albums/j2...73A51CA327.jpg

http://i82.photobucket.com/albums/j2...FD6DB44321.jpg

http://i82.photobucket.com/albums/j2...99449742B6.jpg

http://i82.photobucket.com/albums/j2...205039F92B.jpg

http://i82.photobucket.com/albums/j2...74938344F5.jpg

Re: My 83' Crew Cab Dually project
 

My horns ended up about an inch too high. Never figured out why... I did my body mounts at the same time though. I haven't fit a radiator in yet either.

Re: My 83' Crew Cab Dually project
 

I've searched and searched, but didn't find the answers I need. (It's very possible that I just suck at searching). So...I'm gonna move forward with the modifications I started and see how it pans out. I got the core support close enough to bolt up fenders. The big issue is radiator fitment at this point...

Re: My 83' Crew Cab Dually project
 

Did you move the frame horns back an inch to match the Z? If I understand the problem your having, it would actually make the problem worse but I'm pretty sure if you Z forward the horns will actually come back for the body mounts to stay in the same place/distance relative to the body. Only the portion of the frame that gets raised moves forward.


Like: _/--/_
Not: _/--l_

If you did this and I missed it then please disregard!

Re: My 83' Crew Cab Dually project
 

Yes. I took an inch out when I dropped the horns back down. I found what I think is causing all the trouble yesterday. The truck took a pretty hard hit to the driver side at some point. It looks like the b-pillar was replaced and the a-pillar was repaired. It wasn't done very well because the driver's door striker has like 15 frickin washers on it. When I swapped the burb door on, I could see where everything was shifted back.

I was trying to get the header panel lined up by bolting the fenders on and that was pulling it back. So what appears to have happened is, I leveled up and squared everything on my frame and I'm trying to connect everything with a crooked cab. (I was wondering why everything was shimmed so much on the driver's side)

The solution I've come up with that seems to be going to work, is to cut loose the perches that the header sits on and get all the body panels gapped and shimmed, then I'll burn the perches back in place. I've got it down to about 1/2" now. I have to put the hood on to get the clip squared up and I should be good to go....

Re: My 83' Crew Cab Dually project
 

Problem solved. Now back to making things shiny and new...

Cleaned and painted up the '91 header panel. Watching the paint dry.

http://i82.photobucket.com/albums/j2...058A97CB8F.jpg

Re: My 83' Crew Cab Dually project
 

Took care of Valentine's lastnight and the girlfriend gave me today in the shop as her gift to me...best gift I could have gotten. :)

I made a little progress. Both front doors are mounted, core support is in along with the radiator and I finished up the new air plenum. I got the lighting harness worked out and everything works as it should. If anyone has a schematic for the door locks and Windows wiring, it would be super helpful. I can't seem to locate anything...

http://i82.photobucket.com/albums/j2...774DBEA041.jpg

http://i82.photobucket.com/albums/j2...F1D7D440A8.jpg

http://i82.photobucket.com/albums/j2...3761C6C1A5.jpg

Re: My 83' Crew Cab Dually project
 

Awesome build and thanks for posting it. Please keep posting progress.

Re: My 83' Crew Cab Dually project
 

Send me your email. I got some pdf's

Re: My 83' Crew Cab Dually project
 

Good progress man. I wish I worked that fast.

Re: My 83' Crew Cab Dually project
 

Looking good bro.

Re: My 83' Crew Cab Dually project
 

Thanks guys.

I installed the stainless heater hoses and radiator hoses. I also put in a flexible trans dipstick (the stock one stuck up too high and the hood hit it).

http://i82.photobucket.com/albums/j2...1C255614E9.jpg

I need to build a shroud for the electric fans and get those installed in the next few days.

I just picked up a shear, press brake and a slip roller, so I'm going to build a handful of the air boxes like the one I did for this project. If anyone wants one, msg me or hit me up on Instagram.

Re: My 83' Crew Cab Dually project
 

Took a trip to AutoZone to get my fan belts...got back to the shop and dude gave me the 1/2" wide ones instead of 3/8" wide. Took another trip to return them and get the 3/8" ones. Dude gave me ones that were too short. Took another trip and *****ed at them for making me come back a third time. They finally gave me the correct ones....except one of them was the wrong belt in the right package! Took a fourth trip and finally got the right belts. What should have been a 30 minute deal including purchase and installation turned into almost four hours...so my fan belts are in now!

I finished up a little bodywork on the left fender and got it in primer and decided I really needed to see the grille on this pig. It's been too long since it resembled a complete front end. I'm gonna see about getting the front bumper mounted tomorrow. I expect the brackets will need significant modifications, but who knows; maybe I'll get lucky!

http://i82.photobucket.com/albums/j2...600AD38F06.jpg

Re: My 83' Crew Cab Dually project
 

I got one rear door on and aligned. Boy do I suck at panel alignment. Took me way too long and I've invented new swear words.

http://i82.photobucket.com/albums/j2...A10B0DB9A5.jpg

And my power windows all stopped working suddenly. I'm kind of at a loss. Fuses are good. Grounds are good. Anybody have the knack for these things that can point me in the right direction?

Re: My 83' Crew Cab Dually project
 

one tip I learned about aligning panels is to start with the first adjustable part that meets up against a non-adjustable part.

For a crew cab or suburban, that would be the rear door to cab alignment, then on to the front door, then to the front fender. Once both front fenders are aligned with the doors, then the hood.

For the windows, the switches are crap in those years. but if none of the switches work at all, it could be the main switch on the driver's door...

Re: My 83' Crew Cab Dually project
 

The switches are indeed crap. I found the issue. The battery itself had a bad connection and mounting the doors up apparently jarred it. It seems that my passenger rear window motor is shot though. I'll have to source a replacement.

The electric fans arrived and I got them installed along with building a filler panel for above the radiator.

http://i82.photobucket.com/albums/j2...4B2DBDD7AF.jpg

Re: My 83' Crew Cab Dually project
 

Well this little bastard has quickly become a big thorn in my ass.

http://i82.photobucket.com/albums/j2...6AA1EC5EB0.jpg

I bought an aluminum transmission pan for the th400 because the stamped steel always leaks (just like all of the rest of the stamped steel parts I replaced). Now I've found out that these trans had two different length filter pickup tubes. Mine has the long one, so my new pan won't fit. Not one of the auto parts stores can find either length of the tubes and even the dealer is scratching thier head. I remember buying filter kits years ago and they always came with a new tube...the kits now are just a filter and a gasket.

Does anyone know which vehicles had the shallow pans or where I can find a short tube?

Re: My 83' Crew Cab Dually project
 

Might check with these guys the show a couple different ones

Re: My 83' Crew Cab Dually project
 

Seems like you are a pretty proficient TIG welder.

Have somebody with a lathe turn some .120 wall 6061 tube to the correct size for the slip fit ends, then cut / weld them together.

Re: My 83' Crew Cab Dually project
 

I found one company online that has them. Set me back $40, but it should be here tomorrow. I considered trying to build one, but with the double flares on each end, it would have been a huge PITA, since my flaring tool doesn't go that big. Chevy_mud_truck - that site looks to have a lot of stuff, but it's terrible to navigate!

Re: My 83' Crew Cab Dually project
 

Acquired a different fuel tank through some dealing. This one fits a lot better...almost perfect actually. My frame rails are 27.5" inside and the tank is 27.25".

I had to cut a new hole and install the original sending unit because the one that came with it was functioning at different resistance (240-30 vs 0-30 ohms) fortunately, the original sending units have a large o-ring that sits in a relief around the top...I peeled that out, made a simple retaining ring from .125 aluminum and bolted it all together with stainless...looks like it will work great!

http://i82.photobucket.com/albums/j2...7E80C28F3F.jpg

http://i82.photobucket.com/albums/j2...92F47EC856.jpg

http://i82.photobucket.com/albums/j2...9AB465317E.jpg

Re: My 83' Crew Cab Dually project
 

Yes it is

Re: My 83' Crew Cab Dually project
 

How many gallons is that tank?

Re: My 83' Crew Cab Dually project
 

22.5

Re: My 83' Crew Cab Dually project
 

Looking good man!

Re: My 83' Crew Cab Dually project
 

I added some crossbars in front and behind the tank and built some tank straps. I picked up a slip roller and press brake a few weeks ago and it makes things like this soooo much easier.

http://i82.photobucket.com/albums/j2...3B712A8544.jpg

http://i82.photobucket.com/albums/j2...5D4E3EE721.jpg

Oh...and I stabbed myself in the eyeball with a zip tie yesterday. It feels pretty awesome. ��

http://i82.photobucket.com/albums/j2...735DD1EED4.jpg

Re: My 83' Crew Cab Dually project
 

You shouldn't put acid in your eyes.

Re: My 83' Crew Cab Dually project
 

It's all fun and games until....well, someone gets stabbed in the eye with a zip tie. That looks a little tender. Since I have a permanently screwed up eye i can relate. My eye doc recommends "Tears Naturale" eye drops. There are no preservatives and apparently the preservatives in other drops are a bad thing.

Re: My 83' Crew Cab Dually project
 

Thanks for the tip, Dad...I found some and the eye seems to be getting a little better. It still hurts, but not the raw feeling that I had before.

I spent a little time today buttoning up unfinished things; filled the trans, wired the electric choke, wired up the electric cooling fans with the temp probe and tried to start the truck. It took several cranks (as expected to get the fuel lines primed) then it just backfired instead of starting. After a little problem solving, I realized that I had the distributor 180* off. Getting the distributor out with a 4" Z is a *****! I finally got it where it needs to be and tried again...it stumbled and fired up...ran like **** because I still need to time it and adjust the carb, but at least it's progress and I expect to have it running very soon. Nothing blew up, and no strange noises, so that should be a good sign.

I did notice when I ran the air up and down that the pinch welds are supporting the full weight of the truck when it's aired out which is concerning. I'm left with two options; add blocks to the bottom of the frame or get rid of the pinch welds. What is the method for doing the latter? Do they get folded in or just cut off. Cutting seems like it will compromise the structure of the rockers...

Re: My 83' Crew Cab Dually project
 

You can get rid of the pinch one or two ways. Drag them off or cut them off. If you cut them. What I did with one of my trucks was cut a little at a time and weld it. That way you don't loose support. Also after its all welded but you don't think it doesnt enough support you can weld a strip of 1/8th strip to the bottom and add a 1/8th washer to your cab bushings to offset it.

Re: My 83' Crew Cab Dually project
 

I know a low of guys fold them (no cutting, welding, etc). I saw on the Cannonball C10 they cut and tig welded them. I don't have a pic of it but it does look much cleaner. I will probably do the same.

I honestly think I will lay a bit lower than the rocker. I think I am going to add either polyurethane bumpstops to the bottom of the frame and/or to the suspension. I don't want to scratch up all the nice paint I did underneath.

Re: My 83' Crew Cab Dually project
 

Thanks fellas...I think I may try folding them in and see how that works to start. If I don't like it, I can always cut them off. I don't know about TIG welding overhead, contorted and on my back. Lol

Re: My 83' Crew Cab Dually project
 

Today's progress:

It runs! I love how the flowmasters sound.

http://youtu.be/VqdyG7pj9SQ

Nearly asphyxiated myself with all the smoke from the header paint burning off. Topped off all of the fluids, no leaks and the electric fans kicked on at temp.

Now that it runs, I can get it out of the garage and set the bed back on so I can get the floor cut out and raised. Figured I should actually paint the back half and permanently install all of my hard lines, tanks, compressors, etc. So, I pulled all of the suspension and the fuel tank and laid down some black and clear coat...

http://i82.photobucket.com/albums/j2...38D4DF8120.jpg

I'm still trying to work out how to do the shocks out back. I'm afraid that a cantilever may be my only option...

Re: My 83' Crew Cab Dually project
 

Slick looking paint. I like how the "covers" look now that they are painted.

Re: My 83' Crew Cab Dually project
 

I also like how the paint looks. How is the eye?

Re: My 83' Crew Cab Dually project
 

Thanks guys. Eye is feeling much better. Pride is still recovering, but that not the first time I've done something stupid...

Re: My 83' Crew Cab Dually project
 

Moving things along...

http://i82.photobucket.com/albums/j2...178B72A515.jpg

http://i82.photobucket.com/albums/j2...BF6316CC0C.jpg

http://i82.photobucket.com/albums/j2...1FC65D7A33.jpg

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http://i82.photobucket.com/albums/j2...96D3E69909.jpg

http://i82.photobucket.com/albums/j2...BB93765A6B.jpg

http://i82.photobucket.com/albums/j2...FA5651D83E.jpg

Still have to do some trimming on the inner fenders to get it to sit all the way down. I'm hoping I don't have to mess with the outer fenders at all. I'm not a fan of fiberglass work...

Re: My 83' Crew Cab Dually project
 

Trimmed and trimmed...and then some more trimming. Got the bed set correctly and it clears everything. Also hooked up the bags, tanks, etc. I even took it for a spin...across the yard. :)

http://i82.photobucket.com/albums/j2...4CC0824168.jpg

http://i82.photobucket.com/albums/j2...C85C76EFEA.jpg

http://i82.photobucket.com/albums/j2...C34F560177.jpg

http://i82.photobucket.com/albums/j2...A7B6BF9BA4.jpg

http://i82.photobucket.com/albums/j2...A5478F03DE.jpg

It seems that since I'm running 15gal of tanks, the twin 480's are just not enough. It takes over 15 minutes to get up to pressure. I'm looking for suggestions on what to do.

I could:

1) add two more 480's
2) try to figure out a belt driven system
3) use the big ass inverter that I have and hook up a 120v compressor
4) ???

Thoughts?

Re: My 83' Crew Cab Dually project
 

Your cheapest and fastest route would be running a york.

Re: My 83' Crew Cab Dually project
 

Looks great! :metal: :metal: