LFD's 4dr Tahoe Build
 

OK so after a few months of running thru different ideas for a new shop truck the wife and I have decided on building the Burb for this vehicle. I am looking for a vehicle for towing our car trailer to shows as well as picking up and dropping off customer vehicles. We also wanted something to haul more people when we head to the shows that are out of town. Right now I use Low Buck for this but being a SWB standard cab it is hard to fit all three of in their and it is a bit rough towing with the WB. I was looking into finding a dually frame and building a 4dr crew cab. But the amount of time and money to do that just did not make sense when we have a rust free 3/4ton Burb sitting in the shop getting a 4th door added to it right now. So after convincing my wife that it would look great and tow well when finished so gave me the go ahead to build and keep it. No I am not whipped but we make all our business plans together and since she has stated on several occasions that she hates Burbs I just figured it was not worth even going their. But after describing to her my vision on the build she came to like it and thru in a few ideas of her own that we will work into the build.


Well here is the basic (or not so basic as this may seem) build plan. It will start off as a stock 3/4ton Burb and I plan on keeping it 3/4ton for the better brakes and other stronger components. It will get a few body mods like the addition of a 4th door, 12-18" removed out of the rear end with out changing the WB of the Burb. It will also get a 68 front clip with a few LFD touches as well as new rear tail lights. We both agree that the stock Burb lights just don't flow very well and we want to smooth out the over all look of this Burb. Their was a member on this site (now removed for what ever reason) who put lights in his Burb out of a newer SUV of some sort but I can't remember what they were from. I am sure someone here has pic's or info on what they were so feel free to post the info up. We are also looking into grafting on a new roof skin that would be a few inches shorter than the high crowned Burb roof and maybe even have a power sunroof as well. I will look into the larger SUV's and Vans to see if I can't come up with a nice ribbed roof that has a more pleasing look to it. I feel this will give the Burb a slimmer look with out taking away from the classic look of these vehicles. We will also mold in the cowl, shave the fire wall, add front and rear A/C and newer seats out of a Tahoe or something. We want buckets in the front with a center consul, a second row bench and if room allows a third row seat that can pop in and out. I am planning on a Porter Built DropMember for the front and a custom notch out back so we can drop this thing down a foot or so. It will not be set up to lay frame but a few inches up from their all the same. This will require a step notch out back (the reason their may not be room for a 3dr row seat) and new inner fenders front and rear. I will probably on run 17or 18's so I can still get an "E" rated tire for towing but I need to look more into that before we stick to one size. I have a 22k mile 05 DOD 5.3 Vortec with a 4L60 AOD that will be the main power for this ride.

Well this should give a good over view of what we have in store for this ride. When it is all said and done or real close to being done then Low Buck will go on the market to make room for it's replacement. So if you are looking to get a good deal on a custom C10 start saving your penny's.


OK for starters this was a $1500 rust free 72 Burb with new body mounts, cleaned and painted frame, fully rebuilt barn doors (including latches, hinges and door slided) with 3/4ton running gear. So the first plan of attack was to do a 4dr conversion to it. I started off by marking and removing the section were the 4th door will go.
http://i16.photobucket.com/albums/b20/rokcrln/burb3.jpg
http://i16.photobucket.com/albums/b2...ln/tahoe10.jpg
http://i16.photobucket.com/albums/b2...ln/tahoe15.jpg
http://i16.photobucket.com/albums/b2...ln/tahoe17.jpg

Then came the fun part! Trying to recreate the passenger side B pillar but for the drivers side. I started by cutting up a nice but rusted California cab in order to get the jamb's of the truck B post to use as the C post of the Burb. I used the passenger side truck B post for the back side of the Burb's B post. Then I used a few more pieces of the cab to start the rest of the door opening.
http://i16.photobucket.com/albums/b2...ln/tahoe28.jpg
http://i16.photobucket.com/albums/b2...ln/tahoe29.jpg
http://i16.photobucket.com/albums/b2...ln/tahoe30.jpg

I have made alto of templates from the passenger side post to help with the construction of the new drivers side B post. It is not real hard but it is very time consuming to get it just right. If you have ever really looked at the factory B post on a Burb's passenger side you will see just how involved it is and let me tell you every little notch, crease and indention is their for a reason. If you do not put them all in you will pay for it as you build the door and have to change things around to get it all to work just right.
http://i16.photobucket.com/albums/b2...ln/tahoe42.jpg
http://i16.photobucket.com/albums/b2...ln/tahoe44.jpg
http://i16.photobucket.com/albums/b2...ln/tahoe45.jpg


Kevin
LFD Inc.

Re: LFD's 4dr Tahoe Build
 

Then it was time to start making filler plates for the B post that would end up getting cut and sliced a few times as the post takes shape. I also added stiffener plates to the inside of the new post for the hinges just like the factory did.
http://i16.photobucket.com/albums/b2...ln/tahoe59.jpg
http://i16.photobucket.com/albums/b2...ln/tahoe60.jpg
http://i16.photobucket.com/albums/b2...ln/tahoe64.jpg
http://i16.photobucket.com/albums/b2.../tahoe41-1.jpg
http://i16.photobucket.com/albums/b2.../tahoe43-1.jpg


I had to make a few of the sections to complete the door open up around the top of the door. Their were not any areas on the donor truck cab that would work and look stock so I pulled out my little sheet metal brake and started bending.
http://i16.photobucket.com/albums/b2...ln/tahoe37.jpg
http://i16.photobucket.com/albums/b2...ln/tahoe40.jpg


One other big difference is in the drivers side front of the B post were the front door latches. The strike needs to be sliced and diced to work with the new B post. The new B post is almost 1/2 as think as the stock B post in a Burb or truck so things need to change a bit. I just used the Passenger side strike as my template and built a new on but in reverse.
http://i16.photobucket.com/albums/b2...ln/tahoe54.jpg
http://i16.photobucket.com/albums/b2...ln/tahoe53.jpg
http://i16.photobucket.com/albums/b2...ln/tahoe56.jpg


Kevin
LFD Inc.

Re: LFD's 4dr Tahoe Build
 

So this gets us to the point of the rocker panel. Since their is not one out their that will just fit and weld in I had to take two regular truck rockers and start cutting them to fit. The rear of the rocker fits great but the front is another story. It requires alto more work then you would first think to get it all correct so their will be no problems with the door opening and scrapping on the rocker or worse binding up. So I cut the rocker a bit long and then starting removing pieces bit by bit until the main section fit correctly. Then I cut up a passenger side rocker just for the rear end of it were it rolls up to the truck B-post but in this case it will roll up to the front of the Burbs B-post. I still had to cut most of it away and then build a filler panel using a card board template I traced from the passenger side of the Burbs 3rd door. Then using my shrinker and stretcher I started forming this piece to fit.
http://i16.photobucket.com/albums/b2.../tahoe44-1.jpg
http://i16.photobucket.com/albums/b2.../tahoe45-1.jpg

Well this is were I have left off as far as fabrication goes. I will be back on it this weekend to finish up the complete door opening and get started on the door it self. For building the 4th door I will be using sections from a 3rd door, Burb passenger front door and a truck drivers side door. Then to finish it off I will re-use the stock Burb inner panel I cut out in the first step of this build and that will give it a stock look inside as well as the window regulator and door panel attachment points.


Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

Wow! Great work as always. I wish I had the courage to jump into something that ambitious!

Re: LFD's 4dr Burb Build
 

Can't wait to see it done. I wish I had the time (and energy, :D) to do that to mine.

R/

Re: LFD's 4dr Burb Build
 

Awesome.

I think my next build will probably be a burb for pulling, but I think I'm going to go with a diesel engine of some sorts. Don't think I'll go to the extreme effort that you are by making a 4th door......just don't have the time (or probably the skill) to tackle something like that.

Re: LFD's 4dr Burb Build
 

Kevin are you keeping the barn doors or switching to the tailgate? If you decide to do something similar to mine as far as the tail lights, let me know, I have a few ideas that might save you some time. Also, I know they make a passenger side 3rd door rocker. It looks pretty symmetrical, I wonder if it would have worked with less modifications.....I know, I know, it's a little late now.......:).

Re: LFD's 4dr Burb Build
 

I think you made a Wise Choice in keeping & Making the Burb into your Hauler

Signing on for the Ride...............

Rick

Re: LFD's 4dr Burb Build
 

Yes I am keeping the barn doors but I will do some form of a truck tailgate that will split when the doors open. I like how yours turned out but I think I will use the stock skin off a gate so I get the upper indention as well as the Chevy script. Yes I know of the 3rd door rocker but if you remember the rear and front upward slopes are different widths and the front section has a small dog leg that lets the front edge of the door tuck in when it is opened. I will only have 2-4hrs into this rocker and it will look dead on stock down to the over lap and spot welds on the B-post.

I have the 5.3 sitting just collection dust but down the road I would love a 12V Cummins!



Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

Wow... this is going to get interesting! Subscribed!

Re: LFD's 4dr Burb Build
 

Awesome! I had the idea first though....meanie.

Re: LFD's 4dr Burb Build
 

Me too!

Re: LFD's 4dr Burb Build
 

Look'n good bro !!

:metal:

Re: LFD's 4dr Burb Build
 

Me 2

Re: LFD's 4dr Burb Build
 

Ok, I am excited and totally tuned in.

Re: LFD's 4dr Burb Build
 

Dang you all are easy, just wait until the fun stuff starts. I have a great vision for the barn doors and rear corners now but you will have to stay tuned for more info! I even drew me up a little sketch today of what it will look like and me likes it:lol:

Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

OH You are such a TEASE!!:drama:

Re: LFD's 4dr Burb Build
 

this should be an interesting build. love watching your projects and workmanship. keep us posted!

Re: LFD's 4dr Burb Build
 

Well I just talked with Nate From PorterBuilt Street Rods today on my way home from work and found out about a new design he has comming out soon. After thinking about it for a few moments I decided the Burb would be a perfect platform for one. So as soon as Nate decides to give up the info we can figure out the best way to do a How-To artical to show just how it all goes:metal:

Another design up date is I have been looking into doing power windows and I think I have it all figured out just how to do it. Now I just need to see were the 6 switches will fit!

Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

I'll be watching this one too! Wish I would have had time to stop in & see the master at work! I was working in Corning for a few days & flew out of Sacremento yesterday. First time I had been out there. Now I know what heat w/o humidity is like... I wish I could of bottled up your air & brought it home :lol:

Re: LFD's 4dr Burb Build
 

Heck the last few days it has been cool out here (high 80's low 90's) last week we were 103+:devil:

Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

6 Switches? :uhmk:

Re: LFD's 4dr Burb Build
 

Wow! You're going to make the rear side windows roll down................. ;).

Re: LFD's 4dr Burb Build
 

Yeh but I will have to put a big notch in the glass to fit around the inner tubs:lol:

Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

I only had a few hours this morning to work on the rocker. I have the upper section done and ready for final smoothing but I had to section the rocker and add a new lower half. It was about 1/4" to short so the ends did not line up with the body. I took a second rocker and ripped the the lower half off it and lined it up the the rocker bottom edge and made sure the side curves lined up with the body how it should be. Then I sliced through the two rockers and removed the bottom half of the top rocker and tacked the new lower into place. Sunday I will finish it up, prep it and weld it in so I can start on the door.


http://i16.photobucket.com/albums/b2.../tahoe46-1.jpg
http://i16.photobucket.com/albums/b2.../tahoe47-1.jpg
http://i16.photobucket.com/albums/b2.../tahoe49-1.jpg
http://i16.photobucket.com/albums/b2.../tahoe48-1.jpg



Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

always like to watch how esy you make things look...

are you doing trucks 100% now?

Re: LFD's 4dr Burb Build
 

No I still have about 5yrs before I go full time. I am waiting for my son to start 1st grade and by then I should have the rest of the tools I want along with the second story on my shop. I am taking a class from Ron Covell next week end and then a class from Lazzy http://www.lazze.us/ two weeks after that. I am wanting to get more proficient with a few more things before the big plunge as well. Like everyone else I am always learning;)

Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

I would love to build trucks full time. You have some amazing skills. I can't wait to see this one.

Re: LFD's 4dr Burb Build
 

Yes it Will be fun but allot of work at the same time. Remember no matter how fun it is one day you will still wake up and have to go to work! Most of the work I will be doing Will be metal work on 30's-50's street rods with a few trucks from now and then I am sure. Their is allot more $ in the street rod world than in the truck market, people are just willing to spend the big $ on a 33 3window coupe but not as much on a 71 C10. At least not yet;)


Had a few hours in the shop today and I got the rocker all finished up, primmed inside with a weld through primmer and welded up. Then I started to work on the 4th door and getting the front half of the structure all lined up and trimmed out so the rest can get placed.

My father in-law was over so he gave me a quick hand pulling the front end off so I can get access to the fire wall for shaving and hole filling. At the same time now I have plenty of room to get at the frame for the new PorterBuilt Bling that will be heading my way in a few weeks. I hope the have the door all tacked and swinging in the next few weeks since next weekend will be two days of school with Ron Covell so the weekend after I should be hard at it.

http://i16.photobucket.com/albums/b2.../tahoe50-1.jpg
http://i16.photobucket.com/albums/b2.../tahoe51-1.jpg
http://i16.photobucket.com/albums/b2.../tahoe52-1.jpg


Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

Kevin, the one thing I love about your builds is you can really knock the work out its like a week ago "well I just decided im gonna punch a hole in that there suburban and put a door where the factory never did" then you do, And it looks factory. :crazy:

Re: LFD's 4dr Burb Build
 

Well to this point I am into it about 45hrs but that does include building temlpetes and paterns out of alum plate for the next time I do one of these. It will save a good 8hrs off the next one I think.

To finish the door 100% I am going to guess about 40 more hours:waah: But then the real fun gets to start;)

Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

Well since the cats out of the bag now I can let you all in on the new Bling coming soon. You can read about it here http://67-72chevytrucks.com/vboard/s...d.php?t=307009 But is on of the new designed DropMembers:devil: It is the same great design as the old one but with a few small changes Nate was able to knock off $400 from the old price This will let me keep the 3/4ton and still slam it to the dirt. It will get a medium C-notch in the rear to bring things down to earth.

I will be doing a full right up and How-To on the DropMember install for anyone who wants to check it out.

Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

Hooray! Another LFD build!

Re: LFD's 4dr Burb Build
 

once again another great build.. wish i had the money to buy the truck when it goes on the market...nice job on the 4th door.. keep up the great work..
billy

Re: LFD's 4dr Burb Build
 

Wow, that looks great. I will be watching this one. Just a thought. why not sell the 5.3 and buy a 5.9 cummins with the cash? I think that would be the final touch to send this one over the top. Plus it is a tow rig, right?

Re: LFD's 4dr Burb Build
 

I thought about it but this will be so low I don't think a cummins would fit very well and Nate does not recommend that much weight on a power rack & pinion. With out his DropMember their is now way to get a 3/4ton that low and handle so well. Yes it will be a tow rig but it will see more cruising than towing but when towing is needed.


Here are a few pics from Fridays work. I got allot done but it does not look like anything was done at all.

This pic is with the door skin lined up just to make sure the body lines are are all right before completing the hinge post.

http://i16.photobucket.com/albums/b2.../tahoe53-1.jpg

All looked good but I still need to change out the inner door structure from a hinge post to a strike post. You see the door does not have the same profile from the front to rear. The front of the door is thicker as seen in this pic. The inner structure sticks out more then the rear of the front door.

http://i16.photobucket.com/albums/b2.../tahoe55-1.jpg


So after the hinge structure was all welded up and braced I drilled out the spot welds and placed the structure into the rear of a passenger side front door. What this gave me was a profile that is the same as the rear of my front drivers door. The hinge area will need some dress up work so it looks right and the door skin will need to be split and shrunk so it flows right.

http://i16.photobucket.com/albums/b2.../tahoe59-1.jpg
http://i16.photobucket.com/albums/b2.../tahoe58-1.jpg
http://i16.photobucket.com/albums/b2.../tahoe56-1.jpg


Here are 2 pics showing the new door front and how well it aligns to the front skin.

http://i16.photobucket.com/albums/b2.../tahoe60-1.jpg
http://i16.photobucket.com/albums/b2.../tahoe61-1.jpg


Now for just a few pics from Ron Covells class this weekend out at Dominator's shop. It was worth every cent!

http://i16.photobucket.com/albums/b20/rokcrln/ron1.jpg
http://i16.photobucket.com/albums/b20/rokcrln/ron3.jpg

This is one of the cars being built by Dominator that was not part of the class but I had to get allot of pics just the same. It is a 37 Cabrio.

http://i16.photobucket.com/albums/b20/rokcrln/ron2.jpg

Kevin
LFD Inc.

Re: LFD's 4dr Burb Build
 

Dang !!!

Re: LFD's 4dr Burb Build
 

WOW Kevin, you're doing an awsome job on that burb. Makes me want one even more now.

Re: LFD's 4dr Burb Build
 

Sooo, after seeing your builds, I'm wondering: "Why's this guy taking a class!? he should be teaching!"

But seriously...
Kevin, I'm sure you have some pics somewhere else on the bb, but I'm wondering what your shop set up is like? I know you were redoing your house and stuff a long time ago, but I just am curious what you're working with.

btw, I have a good friend in Fairfield, one of these days I'll have to come bother you up in Winters!

Re: LFD's 4dr Burb Build
 

Thanks. I know allot but I always feel I have even more to learn from others around me. A day that I don't learn something was a half waisted day!

My shop is just a 25x45 concrete building that was built around 1920 or so. It was the original carriage house for working on horse and buggy's back in the day. It is very cluttered (full of tools, parts and cars) and needs a second story added on soon. I have the plans drawn up for the second floor and over half the metal for it but I just don't have the time to do it right now or the break in builds to be down for as long as it will take. I will happen in the next few years before I go full time at fabricating because I will need a place for the other sheet metal fabricating tools I need to get like the English wheel, power Bead roller, shrinker and stretchers and so on. My classes next week will be with Lazzy who is an amazing metal former and it should be a great class.

Also I have Friday off so I hope to get the door just about finished up so I can start on the back half chop:devil:


Kevin
LFD Inc.


Here are a few more pics from my last class. It is a 37 sedan, glass body, tube chassis, 2000 Norstar rear mounted V8 and way too much time. This car was not built by Dominator but by a home builder that spent 7yrs and I don't even want to know how much money.

http://i16.photobucket.com/albums/b2...n/Norstar2.jpg

http://i16.photobucket.com/albums/b2...n/Norstar5.jpg

http://i16.photobucket.com/albums/b2...n/Norstar1.jpg

http://i16.photobucket.com/albums/b2...n/Norstar3.jpg

Notice the radiator hose's and were they go!
http://i16.photobucket.com/albums/b2...n/Norstar4.jpg