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#1 |
Registered User
Join Date: Jan 2017
Location: Sandy, UT
Posts: 193
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Military Blazer Build
Over the next couple months I'll hopefully be finishing up building my M1009 Blazer. I'm going to post up all the pics I have from the build up to this point, and document the remainder of the project as I go.
The truck was a factory 6.2 diesel backed by a TH400 and NP208, with 10 bolt axles and 3.08 gears. When I bought it from the national guard it was on 33" Goodyear MTRs. Today it has a 2 speed aux trans (Advanced Adapters "Ranger"), SM465 and NP205. Axles are 10/12bolt with 3.73 gears and ARB lockers in both ends. Still on 33" MTRs and still has the 6.2 diesel. The first project was the floor replacement. I bought it with bad floor pan rust, like to the point the seats were about to drop out onto the road and I would not allow a passenger to ride in the truck. Here's some photos of the carnage. 3 of the 4 bolt locations on the passenger side were cracked through, and there was >2" of vertical motion of the seat every time the truck hit a bump.
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1988 "Crane Truck" C30 - 350, SM465, with a 15' knuckle crane - thread 1986 M1009 - 6.2 Diesel, SM465, 2 speed aux trans, NP205 - thread 1979 Corvette - 350 T5 1977 Jimmy - 350, TH400, NP203 1982 Blazer - 350, 700R4, NP208 - Totalled, now a parts truck ![]() Scratch built 16' flatbed trailer - thread Last edited by 79vette; 07-23-2021 at 02:41 AM. |
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#2 |
Registered User
Join Date: Jan 2017
Location: Sandy, UT
Posts: 193
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Re: Military Blazer Build
First step was to torch out the rotten metal and make a carboard template, and then transfer that to new 16ga steel. As you can see the rockers are pretty bad and I should have done them at the same time, but this was my only daily driver and I needed it back on the road ASAP. Rocker replacement will be a later post...
There's an annoying upward bend in the frame which I had to box around, since I was working with flat sheet. After fixing that it fit up, and it was easy to drill and plug weld into place. Then cut the hole for the 24v panel wiring (the military had a power distribution point near the rear bench seat for radios and other gear) and made a couple patch sections for the rear cargo area. Ignore the lousy welding here ![]()
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1988 "Crane Truck" C30 - 350, SM465, with a 15' knuckle crane - thread 1986 M1009 - 6.2 Diesel, SM465, 2 speed aux trans, NP205 - thread 1979 Corvette - 350 T5 1977 Jimmy - 350, TH400, NP203 1982 Blazer - 350, 700R4, NP208 - Totalled, now a parts truck ![]() Scratch built 16' flatbed trailer - thread Last edited by 79vette; 07-23-2021 at 02:44 AM. |
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#3 |
Registered User
Join Date: Jan 2017
Location: Sandy, UT
Posts: 193
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Re: Military Blazer Build
I wasn't able to reproduce the stamped ribs in the replacement floor, so instaead I used a 1"x3"x.060" rectangle tube cut in half to make a 0.5"x3" C channel, and welded that to the floor as a stiffening rib. This spans from the front floor support to the rear floor support and provides a load path from the seats into the underlying cab structure, so the flat sheet metal floor isn't supporting the weight of the seats.
I dont have photos, but there is a piece of thick wall pipe welded between the C channel support and the floor sheet metal to allow the seat bolts to clamp up on a solid piece instead of crushing the channel. Repeat process on the other side. At this point I took a quick break to go pick up some new toys. Still no center section built to connect the 2 sides of the floor and the transmission tunnel cover was installed installed with one bolt, so I almost lost the turbo on the interstate... After picking up the turbo, I raised and extended the tunnel cover to accommodate the SM465 and auxiliary trans.
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1988 "Crane Truck" C30 - 350, SM465, with a 15' knuckle crane - thread 1986 M1009 - 6.2 Diesel, SM465, 2 speed aux trans, NP205 - thread 1979 Corvette - 350 T5 1977 Jimmy - 350, TH400, NP203 1982 Blazer - 350, 700R4, NP208 - Totalled, now a parts truck ![]() Scratch built 16' flatbed trailer - thread Last edited by 79vette; 07-23-2021 at 02:46 AM. |
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#4 |
Registered User
Join Date: Jan 2017
Location: Sandy, UT
Posts: 193
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Re: Military Blazer Build
Built a raised section to clear the driveshaft and connect the 2 sides of the floor, made a couple more patches for the extra rusty spots, welded everything solid, and sprayed primer
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1988 "Crane Truck" C30 - 350, SM465, with a 15' knuckle crane - thread 1986 M1009 - 6.2 Diesel, SM465, 2 speed aux trans, NP205 - thread 1979 Corvette - 350 T5 1977 Jimmy - 350, TH400, NP203 1982 Blazer - 350, 700R4, NP208 - Totalled, now a parts truck ![]() Scratch built 16' flatbed trailer - thread |
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#5 |
Registered User
Join Date: Jan 2017
Location: Sandy, UT
Posts: 193
|
Re: Military Blazer Build
Applied Peel-n-Seal from Lowes to the floors to help reduce vibration and echos, cut out some rubber floor mats, reinstalled the interior (and rifle rack!), and its like a whole new truck. At least I dont have to wear safety glasses to keep road gravel out of my eyes when I drive now...
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1988 "Crane Truck" C30 - 350, SM465, with a 15' knuckle crane - thread 1986 M1009 - 6.2 Diesel, SM465, 2 speed aux trans, NP205 - thread 1979 Corvette - 350 T5 1977 Jimmy - 350, TH400, NP203 1982 Blazer - 350, 700R4, NP208 - Totalled, now a parts truck ![]() Scratch built 16' flatbed trailer - thread |
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#6 |
Just here to tinker
![]() Join Date: Jun 2008
Location: Holland, MI
Posts: 3,692
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Re: Military Blazer Build
That thing is going to be rugged! Very nice.
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78 C10 SWB Diesel #1 (wrecked)http://67-72chevytrucks.com/vboard/s...1978+silverado 78 C10 SWB Diesel #2 (sold)http://67-72chevytrucks.com/vboard/s...d.php?t=650751 60 GMC Suburban (sold)http://67-72chevytrucks.com/vboard/s...d.php?t=445526 60 GMC 1000 (sold)http://67-72chevytrucks.com/vboard/s...d.php?t=298235 67 GMC 1500 (sold) http://67-72chevytrucks.com/vboard/s...d.php?t=803695 86 Suburban(summer unit) http://67-72chevytrucks.com/vboard/s...d.php?t=810697 88 Suburban 4x4(winter unit)https://67-72chevytrucks.com/vboard/...25#post8900725 |
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#7 |
Sb 400 club
Join Date: Nov 2005
Location: NH / MA
Posts: 2,741
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Re: Military Blazer Build
Would love to know more about the ranger. Have one ready to go in ny 77 (has a 6.2 from a 1028 and sm465) but the tunnel and drive shaft mods are slowibg me down
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![]() ![]() 77 K10 Project / daily driver "The Grinch" http://67-72chevytrucks.com/vboard/s...d.php?t=318363 1956 Willys Wagon (327 chevy) Project (Now Buick 225) 1980 Corvette L-48 4 speed 1992 Mustang GT built 5.0 5 speed ![]() 1985 C10 LWB Sold 1982 K10 SWB plow truck Parted out 1986 D30 M1028 fire brush truck Parted out |
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#8 | |
Registered User
Join Date: Jan 2017
Location: Sandy, UT
Posts: 193
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Re: Military Blazer Build
Quote:
You gotta cut a hole in the tunnel for the new shifter and offset all the driveshafts ~7" back (longer front, shorter rear). I did a bunch of tunnel work to raise the transfer case up a couple inches for better clearance, but I probably wouldn't have bothered if I hadn't cut the entire floor out already. Advanced Adapters recently discontinued them and I'm looking for another. If for whatever reason you decide to not install yours I'd be happy to buy it off you ![]()
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1988 "Crane Truck" C30 - 350, SM465, with a 15' knuckle crane - thread 1986 M1009 - 6.2 Diesel, SM465, 2 speed aux trans, NP205 - thread 1979 Corvette - 350 T5 1977 Jimmy - 350, TH400, NP203 1982 Blazer - 350, 700R4, NP208 - Totalled, now a parts truck ![]() Scratch built 16' flatbed trailer - thread |
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#9 |
Registered User
Join Date: Jan 2017
Location: Sandy, UT
Posts: 193
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Re: Military Blazer Build
Here's a few pics from my center console build. Everything was done with a grinder, because I didnt have a plasma at this point.
Water bottle holder was sized to fit a 1L Nalgene, which is my favorite water bottle of all time.
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1988 "Crane Truck" C30 - 350, SM465, with a 15' knuckle crane - thread 1986 M1009 - 6.2 Diesel, SM465, 2 speed aux trans, NP205 - thread 1979 Corvette - 350 T5 1977 Jimmy - 350, TH400, NP203 1982 Blazer - 350, 700R4, NP208 - Totalled, now a parts truck ![]() Scratch built 16' flatbed trailer - thread |
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#10 |
Registered User
Join Date: Jan 2017
Location: Sandy, UT
Posts: 193
|
Re: Military Blazer Build
The switches and switch guards are stainless look-alikes for the titanium hardware made by Rockwell for the Space Shuttle switch panels. A bit silly perhaps, but its the looks i was going for.
I also installed an intercom from a general aviation aircraft so I can run headsets on the highway. The military considered sound insulation to be optional equipment, and the diesel motor is too loud to yell over at freeway speeds Installed USB charging for all the latest gadgets and gizmos Headphone and mic jacks for the headsets Box all assembled and mocked up. Ready for exterior paint and final wiring
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1988 "Crane Truck" C30 - 350, SM465, with a 15' knuckle crane - thread 1986 M1009 - 6.2 Diesel, SM465, 2 speed aux trans, NP205 - thread 1979 Corvette - 350 T5 1977 Jimmy - 350, TH400, NP203 1982 Blazer - 350, 700R4, NP208 - Totalled, now a parts truck ![]() Scratch built 16' flatbed trailer - thread |
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#11 |
Registered User
Join Date: Jan 2017
Location: Sandy, UT
Posts: 193
|
Re: Military Blazer Build
I sprayed paint on the box, and left a masked off strip at the bottom. The plan is to wire everything from the bottom, and then weld in the bottom panel and touch up the paint at the end.
Here's some pics from wiring day. I made a spreadsheet showing all the needed connections and copied it to my tablet, grabbed some cold beverages and the soldering iron, and went to work. Made up a pigtail harness for the intercom box Here's everything wired up. Intercom, headset jacks, seat heaters, switches, USB chargers, and LED lights for inside the box. This milspec D38999 connector allows the box and all components to be removed from the truck. There's 37 circuits that connect to various hardware outside the box, and this connector packages everything in a compact and waterproof plug.
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1988 "Crane Truck" C30 - 350, SM465, with a 15' knuckle crane - thread 1986 M1009 - 6.2 Diesel, SM465, 2 speed aux trans, NP205 - thread 1979 Corvette - 350 T5 1977 Jimmy - 350, TH400, NP203 1982 Blazer - 350, 700R4, NP208 - Totalled, now a parts truck ![]() Scratch built 16' flatbed trailer - thread Last edited by 79vette; 07-31-2021 at 09:54 PM. |
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#12 |
Registered User
Join Date: Jan 2017
Location: Sandy, UT
Posts: 193
|
Re: Military Blazer Build
Got all the wiring finished, and made up the harness for the truck side
Made up some magnetic covers for the exposed wiring on the headset jacks and intercom box, welded in the bottom of the console and sprayed paint Here it is installed into the truck
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1988 "Crane Truck" C30 - 350, SM465, with a 15' knuckle crane - thread 1986 M1009 - 6.2 Diesel, SM465, 2 speed aux trans, NP205 - thread 1979 Corvette - 350 T5 1977 Jimmy - 350, TH400, NP203 1982 Blazer - 350, 700R4, NP208 - Totalled, now a parts truck ![]() Scratch built 16' flatbed trailer - thread |
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#13 |
Just here to tinker
![]() Join Date: Jun 2008
Location: Holland, MI
Posts: 3,692
|
Re: Military Blazer Build
Man that is some nice work. A man after my own heart with the wiring details. Well done!
__________________
78 C10 SWB Diesel #1 (wrecked)http://67-72chevytrucks.com/vboard/s...1978+silverado 78 C10 SWB Diesel #2 (sold)http://67-72chevytrucks.com/vboard/s...d.php?t=650751 60 GMC Suburban (sold)http://67-72chevytrucks.com/vboard/s...d.php?t=445526 60 GMC 1000 (sold)http://67-72chevytrucks.com/vboard/s...d.php?t=298235 67 GMC 1500 (sold) http://67-72chevytrucks.com/vboard/s...d.php?t=803695 86 Suburban(summer unit) http://67-72chevytrucks.com/vboard/s...d.php?t=810697 88 Suburban 4x4(winter unit)https://67-72chevytrucks.com/vboard/...25#post8900725 |
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#14 |
Registered User
Join Date: Mar 2018
Location: GA
Posts: 104
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Re: Military Blazer Build
Awesome work! The center console looks nice and very functional.
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#15 |
Registered User
Join Date: Oct 2015
Location: Ottawa, Ontario, Canada
Posts: 752
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Re: Military Blazer Build
Very nice work but the only thing that might give you trouble. Is if you ever need to replace the body mounts on the frame to body,( If the spot welds that are on the center floor patch are on the frame in this pic ) But very nice work on the consol. Keep up the good work.
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![]() Was a 77 454 w/308 gear. Taken out 550 lbs. up front with motor clip change. |
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