Project Family Hauler
 

I bought this suburban for parts 4 years ago. Now I have a little girl that needs to come with and the standard cab truck is a tight fit. Decided to fix it. May go overboard just for fun. I know it looks bad but it was only $100. Some guy needed it out of his yard. It has a clean title too.

[IMG]http://i763.photobucket.com/albums/x...n/DSCN1481.jpg[/IMG]
[IMG]http://i763.photobucket.com/albums/x...n/DSCN1483.jpg[/IMG]
[IMG]http://i763.photobucket.com/albums/x...n/DSCN1484.jpg[/IMG]

Re: Project Family Hauler
 

Good luck with the Burb build Travis.... money well spent if I do say so myself. :D

Re: Project Family Hauler
 

Was that an ambulance or something at one time? Noticed the lights

Re: Project Family Hauler
 

Don't know what the lights were from, had amber lenses. Think I might keep them.:lol:

Re: Project Family Hauler
 

More pics

[IMG]http://i763.photobucket.com/albums/x...n/DSCN1487.jpg[/IMG]

[IMG]http://i763.photobucket.com/albums/x...n/DSCN1495.jpg[/IMG]

[IMG]http://i763.photobucket.com/albums/x...n/DSCN1482.jpg[/IMG]

[IMG]http://i763.photobucket.com/albums/x...n/DSCN1485.jpg[/IMG]

Re: Project Family Hauler
 

With those lights, you could chase down some serious UFO action.

Re: Project Family Hauler
 

That would explain the circular impressions in the grass in my back yard.:lol:

Re: Project Family Hauler
 

Nice score!

Re: Project Family Hauler
 

Well I got working on it. This is more in depth that I have done before. Have received patch panels for the floor, toe kick and floor brace. So much is rusted that there is nothing to base the measurments from.
Sorry about the small pics battery was dead in camera. Used phone instead.
The second pic show the floor brace replaced.
I have the floor tacked in and toe kick and lower fender mount cut to fit but the rear part of the floor isn't lining up. The rocker panel sits too high and hits the door.

[IMG]http://i763.photobucket.com/albums/x...1003091223.jpg[/IMG]
[IMG]http://i763.photobucket.com/albums/x...1003091602.jpg[/IMG]
[IMG]http://i763.photobucket.com/albums/x...100309160d.jpg[/IMG]

Re: Project Family Hauler
 

Here is some pics of the replacement floor. Figured out why the rocker panel was hitting the door. The floor is different in the suburbans. The patches are for a truck. Needed to section and reshape the rear section of floor. Other side isn't much to measure from due to rust, but I built a template for the shape and dimensions.

[IMG]http://i763.photobucket.com/albums/x...n/DSCN2539.jpg[/IMG]
[IMG]http://i763.photobucket.com/albums/x...n/DSCN2542.jpg[/IMG]
The area circled is different on a suburban. It steps down for the weatherstrip channel 1/2" sooner than on the trucks.
[IMG]http://i763.photobucket.com/albums/x...DSCN2541-1.jpg[/IMG]

Re: Project Family Hauler
 

Well I haven't done anything on the suburban for a couple weeks. Went to Portland for an Ale Festival. Then it got too cold to work in the garage. Morning tempuratures were 12* brrrrr. Afternoon got all the way up to 28*.
I did find parts for the project. I wanted something different for the front end so I bought a 1968 GMC for the front clip.

[IMG]http://i763.photobucket.com/albums/x...n/DSCN2544.jpg[/IMG]

The fenders aren't perfect but it came with all the brackets and pieces that I need. It was $300 and I can sell some parts to get money back. It has a V6 and is pretty much original, including the owners manual.

Re: Project Family Hauler
 

Nice score! That cold weather sure changes your mind about working on projects doesn't it? :lol:

Re: Project Family Hauler
 

Yes it does.

Spent some time fitting all the panels together. I could work on it because it has warmed up to 36*. Got the left front fender from the GMC and bolted it to the suburban (or should I start calling it a Yukon XL ?) Also found the door hinges from the GMC were in better shape so it is easier to align the door. Everything seems to line up now. Due to the short winter days and the suburban is under an awning behind the garage I was done by 4:00. It was also dark so no pics.:(
Will try to get pics soon.

Re: Project Family Hauler
 

I have taken some pictures of my progress. Got the toe kick welded in and it fits well. I painted all the areas that will be closed up with POR-15. Since it takes a little while to dry I think I am done for the day.

This shows how everything is lining up. I used the blue tape when the door was hitting the rocker panel. The tape scraped easy when the door touched.
[IMG]http://i763.photobucket.com/albums/x...n/DSCN2583.jpg[/IMG]

This is the front view of panels in place
[IMG]http://i763.photobucket.com/albums/x...n/DSCN2584.jpg[/IMG]

Picture of the toe kick in place and the weld ground and painted to prevent short term rust
[IMG]http://i763.photobucket.com/albums/x...n/DSCN2590.jpg[/IMG]

Outside view of toe kick
[IMG]http://i763.photobucket.com/albums/x...n/DSCN2591.jpg[/IMG]

[IMG]http://i763.photobucket.com/albums/x...n/DSCN2585.jpg[/IMG]

That last one is a taste of the direction of the build. Yes that is a 4th door hanging there. It will swing suicide. Once I get that one set up correct I will do the other back door to match.:metal:

Re: Project Family Hauler
 

Very cool keep us posted on the build...

Re: Project Family Hauler
 

Long overdue update. Spent 2 months shopping for bathroom remodel stuff and 2 more months remodeling bathroom
Before[IMG]http://i763.photobucket.com/albums/x...DSCN2601-1.jpg[/IMG]
during[IMG]http://i763.photobucket.com/albums/x...DSCN2638-1.jpg[/IMG]
after[IMG]http://i763.photobucket.com/albums/x...s/DSCN2689.jpg[/IMG][IMG]http://i763.photobucket.com/albums/x...DSCN2723-1.jpg[/IMG]

The good news is I am back working on the suburban. Not a lot of progress but at least I am outside working on it.
[IMG]http://i763.photobucket.com/albums/x...n/DSCN2729.jpg[/IMG]
[IMG]http://i763.photobucket.com/albums/x...n/DSCN2730.jpg[/IMG]
The lower fender support is on. Next I will work on the rest of the floor and get back to B pillar.

Re: Project Family Hauler
 

Updates two days in a row. Finished welding in the front part of the floor. Lots of tack, tack, tack move and tack, tack, tack. Over 3 feet of weld around patch panel. Then grind, grind, grind. Painted all finished welds with POR-15.
[IMG]http://i763.photobucket.com/albums/x...n/DSCN2731.jpg[/IMG]
[IMG]http://i763.photobucket.com/albums/x...n/DSCN2732.jpg[/IMG]

Then I turned to the "B" pillar. When I got the suburban it was rusted out up to the spot welds on the rocker panel. There wasn't anything to even copy in new metal. Looked at the other side to see what it looked like and there isn't much there either. So since it won't be visible I made my own parts to bolt to the floor support.
[IMG]http://i763.photobucket.com/albums/x...n/DSCN2733.jpg[/IMG]

Re: Project Family Hauler
 

Cool project, keep the pix comin' :metal:

Re: Project Family Hauler
 

Subscribed!

You are making more progress than me!!

http://67-72chevytrucks.com/vboard/s...d.php?t=380183

Re: Project Family Hauler
 

Very nice progress!

Re: Project Family Hauler
 

Not a lot of progress even for a three day weekend. Planned to do more but went shopping on Saturday.

[IMG]http://i763.photobucket.com/albums/x...r/16109_s1.jpg[/IMG]

Guess I will be camping more this summer. That will slow down the updates a little.

Will here is what I did finish. The rest of the floor panels for the front door are in. Had to modify the new panels a little to fit the suburban.

Before
[IMG]http://i763.photobucket.com/albums/x...CN2733-1-1.jpg[/IMG]

After
[IMG]http://i763.photobucket.com/albums/x...n/DSCN2734.jpg[/IMG]

Re: Project Family Hauler
 

Ok, update after 2 months. Sorry, at least there are pics. Have been camping 3 times in new trailer already.

This is what the 4th door opening looked like.
http://i763.photobucket.com/albums/x...n/DSCN2586.jpg

This is what it looks like now.
http://i763.photobucket.com/albums/x...DSCN2782-1.jpg

I fully welded the new hinge setup. No flex at all.
http://i763.photobucket.com/albums/x...DSCN2781-1.jpg

The lower hinge is notched into the floor for clearance.
http://i763.photobucket.com/albums/x...n/DSCN2783.jpg

The inside view shows how I sectioned and boxed hinges from a 1966 F**d. There is something good from F**d.
http://i763.photobucket.com/albums/x...DSCN2786-1.jpg

I connected the hinges to the roof with a section of 2x2 steel tubing. I can't take credit for this idea. Frizzle Fry did this on his tahoe. Makes the side very ridgid.
http://i763.photobucket.com/albums/x...n/DSCN2785.jpg

Also connected the back of the B pillar to the floor. B pillar is not done but doesn't move anymore.
http://i763.photobucket.com/albums/x...DSCN2784-1.jpg

Then painted with POR 15.

Re: Project Family Hauler
 

Just found this. Nice work on the bathroom and 4th door!

Re: Project Family Hauler
 

frizzle fry knows how hard it is to make a 4th suicide door he is the man when it comes to fabrcating your doing a wonderful job to if i get a burb ii will be looking to both of your build threads for anwsers;)

Re: Project Family Hauler
 

Thanks. Its not easy balancing house and vehicle projects and have a job.

Have the door jamb and rocker panel clamped in so I can start to size the door. Strange to have it look like door opening.
http://i763.photobucket.com/albums/x...n/DSCN2788.jpg

Had to modify the door I was building. Since the body lines change on the front door from front to back I cut it off and used the back of a passenger door. Don't know if I can use the original latch yet. The back window channel is very close.
http://i763.photobucket.com/albums/x...n/DSCN2789.jpg

Inside view of window channel and latch.
http://i763.photobucket.com/albums/x...n/DSCN2790.jpg

Door is closed. Body lines seem to line up. The hinges have adjustment for when the door is heavier.
http://i763.photobucket.com/albums/x...n/DSCN2791.jpg

Some sacrifices had to be made.
http://i763.photobucket.com/albums/x...n/DSCN2792.jpg

Will use the skin to place the handle in the correct spot. My helper is in the picture.
http://i763.photobucket.com/albums/x...n/DSCN2793.jpg

Re: Project Family Hauler
 

Good stuff man. Looks like you might have to go with a bear claw style latch.

Re: Project Family Hauler
 

I am thinking about that. Will try the fitment of factory latch first. Want it to look like factory parts to match front. Or I will change fronts so they are all the same.

Re: Project Family Hauler
 

Got about 4 hours in yesterday. Wife is working this weekend and I am watching our 2 year old. I would have her help work on the suburban but she doesn't like loud noises.

Had to reshape the bottom of the door. The front of the rocker panel is fitted for the front curve of the door, but I used the rear part of a passenger door so the body contour is right but the curve is different on the bottom. So I had to blend the two.

Not only do I have to design the parts, I have to make them and put them together. This is the reason for the slow progress. This is the first time I have done something this custom. I spend a lot of time thinking about how I need to make a part.

http://i763.photobucket.com/albums/x...n/DSCN2807.jpg
http://i763.photobucket.com/albums/x...n/DSCN2808.jpg

Also found the original latch will fit. Tested the door skin and it lines up so the handle will work. Very tight inside. Am going to have handles together like old Lincolns. Using original truck handles.

http://i763.photobucket.com/albums/x...n/DSCN2805.jpg
http://i763.photobucket.com/albums/x...n/DSCN2806.jpg

Re: Project Family Hauler
 

Got to work on the suburban today. Fitted the door skin. Found the inside needed to be rearranged a little so everything lined up. This is the new view.
http://i763.photobucket.com/albums/x...n/DSCN2813.jpg

Gray door is the 4th door

http://i763.photobucket.com/albums/x...n/DSCN2817.jpg

Ended up mixing the door skin with the side of the suburban to get the curve right.

http://i763.photobucket.com/albums/x...n/DSCN2815.jpg

Distant view, crazy to look at.
http://i763.photobucket.com/albums/x...n/DSCN2818.jpg

Maybe tomorrow I will start fitting the window frame.

Re: Project Family Hauler
 

wow thats cool

Re: Project Family Hauler
 

Got the door frame in shape. Had to fit the angles to the suburban. Window rolls up and down. Corner window fits. Got the inside handle installed with linkage. The frame is straight. Just looks curved in picture.

http://i763.photobucket.com/albums/x...n/DSCN2820.jpg

http://i763.photobucket.com/albums/x...n/DSCN2822.jpg

http://i763.photobucket.com/albums/x...n/DSCN2821.jpg

Relocated the inside handle. Everything is connected to release the door.

http://i763.photobucket.com/albums/x...DSCN2826-1.jpg

Close up of window. The skin gets closer at this window.

http://i763.photobucket.com/albums/x...n/DSCN2824.jpg

Rear view of door open

http://i763.photobucket.com/albums/x...n/DSCN2819.jpg

Front view of door open

http://i763.photobucket.com/albums/x...n/DSCN2826.jpg

Still need to fill the gap between the doors. Passenger side is extended from the factory to fill transition.

http://i763.photobucket.com/albums/x...n/DSCN2823.jpg

Also started to finish off the door jamb.

http://i763.photobucket.com/albums/x...n/DSCN2825.jpg

More to come soon.

Re: Project Family Hauler
 

that looks good hope to see the gap closed a little more but i probably couldnt do what you did in such a small amount of time you got seious fab skills:metal:

Re: Project Family Hauler
 

Thanks. I have had this suburban for 5 years and have been working on it for over a year. The first 4 years was just getting the project done in my head. Making a door is the hardest thing I have done. You need to make everything fit from 12 different angles. It wouldn't be as hard if I didn't need to use hinges. Just this weekend I spent 16 hours fitting the door into the opening. It was already started and not even close to being finished. Still have lots of welding and grinding to do. Also need to hammer & dolly the skin. Some of the curve is gone around the weld.

Re: Project Family Hauler
 

very cool project! Just found it but read the thread and looking forward to following the progress. Great work so far!

Re: Project Family Hauler
 

Very nice work!

Re: Project Family Hauler
 

Slight distraction. Our friends were over for dinner and this car came flying down our street in reverse chasing some kids that were on the sidewalk. The driver wasn't looking and hit our friends Jeep Grand Cherokee at about 40 mph. After I chased them for about four blocks (I was on foot) they realized I had their license plate # and came back.[IMG]http://farm5.static.flickr.com/4111/...d09cf21248.jpg[/IMG]

[IMG]http://farm5.static.flickr.com/4088/...184aeb47f3.jpg[/IMG]

No one was hurt but the kids in the car had to be hurting today.

Re: Project Family Hauler
 

It might not look like I did much but it took all day. Finished around the door jamb at the top. Got the pieces from spare cabs so the shape was correct from the door seal to the outside skin. Plug welded the lip for the door seal.
[IMG]http://farm5.static.flickr.com/4084/...8eeb20fc3d.jpg[/IMG]

[IMG]http://farm5.static.flickr.com/4111/...1e21c45f23.jpg[/IMG]

Front and back door and the B pillar.
[IMG]http://farm5.static.flickr.com/4108/...02d3f33236.jpg[/IMG]

Back window frame.
[IMG]http://farm5.static.flickr.com/4112/...090762e6ee.jpg[/IMG]

Close up. Inside corner tough to grind.
[IMG]http://farm5.static.flickr.com/4085/...8fcc11fc52.jpg[/IMG]

B pillar with door seal lip.
[IMG]http://farm5.static.flickr.com/4091/...0f7e65cfef.jpg[/IMG]

Painted it because the rainy season has started and it is humid. Don't want surface rust to start in bad areas.

Re: Project Family Hauler
 

nice work sorry about those people

Re: Project Family Hauler
 

nice work...really coming together!

Re: Project Family Hauler
 

Lookin' good.