1991 1 Ton Crew Cab 4x4 Build

[91V3500]

Well we had a baby girl born 4 weeks ago, so not much has been done on this project lately! I did find another bed that's in alot better shape, so I hope to get that installed next week so I can at least drive it for the 4th! This bed has a rusty rollbar that I will be trying to sell, and I need to sell my other bed.

[Truck Guy99]

Sweet! Congrats on the baby! As for the roll bar, SOS pad it with some water and you'll get all that surface rust off. I had an identical one the I sold for $75.
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[91V3500]

Thanks! Yeah I figured I could scrub some of the rust off, but I would rather spend that time on parts that are going on MY truck lol! Spare time is short right now. I'm asking $45 for the roll bar and $250 for the bed.

[91V3500]

I spent all day yesterday scrubbing the underside of the bed, painting it underneath, and got the bed floor back on the frame.

[thirdstreettito]

Love the build, but why the D44? Max tire size is 38 for a D44, and you're running 40's on 22x14's. May I ask why?

[91V3500]

Originally Posted by thirdstreettito

Love the build, but why the D44? Max tire size is 38 for a D44, and you're running 40's on 22x14's. May I ask why?

Thanks, but who set the rule for 38"s being the max for a D44? It all depends on what you do with it, right? I think we have all been brainwashed into believing you have GOT to have a D60 for any 4x4 with big tires. Sure, 38's would be the limit for high horsepower rock crawlers and mud racers, but this is just going to be a clean street cruiser with very little off road use, with no high-rpm, high horsepower mud slingin!

It makes me cringe when I see big tires on a ten bolt, but I have seen 10 bolts hold up to 44" tires for years with just regular street driving. If the D44 causes any problems in the future, I can always find another D60 to swap back in.

The only reason I swapped the D44 in is because I swapped all of the running gear out of the K5 Blazer, these axles were rebuilt and ready to go, with matching lower gear ratios than what I had(4:10's, but I probably need 4:56), and the front was set up for crossover steering. I got a deal on the Blazer, and it just seemed like the right thing to do at the time to get the truck on the road as soon as possible and spending as little money as possible(time and money are always short). The D60 really needed a rebuild and had 3:73 gears, and I really wanted to run the crossover steering, but it was a crossover for the D44 not the D60.

[1968vetL-71]

Well said. We've all had to sacrifice here and there to compromise on getting a project going. It's the nature of the hobby. I love the build and think you've done a fantastic job!

...... After all, I was able too see it on a hoist gutted to being the really cool truck it is now. If you really want it, I can sell the 4l80/vss205 and D60 back too ya. But you'll have to come here this time.

Again, killer build so far!
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[91V3500]

Originally Posted by 1968vetL-71

Well said. We've all had to sacrifice here and there to compromise on getting a project going. It's the nature of the hobby. I love the build and think you've done a fantastic job!

...... After all, I was able too see it on a hoist gutted to being the really cool truck it is now. If you really want it, I can sell the 4l80/vss205 and D60 back too ya. But you'll have to come here this time.

Again, killer build so far!

Hey what's up stranger? If you're not going to use them I could definitely use them! Screw the D60, I didn't know that transmission and transfer case was so special lol. This whole build has been a learning experience for me! I didn't know that Chevy used anything but the Turbo400 and NP208 in these model trucks, shows how inexperienced I am. I still need to send you the harness, text me your address and I'll send it to you, unless you're serious about selling them back!

[thirdstreettito]

Originally Posted by 91V3500

Thanks, but who set the rule for 38"s being the max for a D44? It all depends on what you do with it, right? I think we have all been brainwashed into believing you have GOT to have a D60 for any 4x4 with big tires. Sure, 38's would be the limit for high horsepower rock crawlers and mud racers, but this is just going to be a clean street cruiser with very little off road use, with no high-rpm, high horsepower mud slingin!

It makes me cringe when I see big tires on a ten bolt, but I have seen 10 bolts hold up to 44" tires for years with just regular street driving. If the D44 causes any problems in the future, I can always find another D60 to swap back in.

The only reason I swapped the D44 in is because I swapped all of the running gear out of the K5 Blazer, these axles were rebuilt and ready to go, with matching lower gear ratios than what I had(4:10's, but I probably need 4:56), and the front was set up for crossover steering. I got a deal on the Blazer, and it just seemed like the right thing to do at the time to get the truck on the road as soon as possible and spending as little money as possible(time and money are always short). The D60 really needed a rebuild and had 3:73 gears, and I really wanted to run the crossover steering, but it was a crossover for the D44 not the D60.

Well said. I simply prefer to have it and not need it.

[indyrenegade4x4]

Nice truck and project. Good stance

[91V3500]

Originally Posted by indyrenegade4x4

Nice truck and project. Good stance

Thanks!

I found a turbo 400 trans with a NP203 out of a '78 chevy 3/4 ton truck that my buddy has that I could get for probably $400 or less. Another buddy of mine has a SM465 trans with a NP205 in a '72? Chevy 4x4 shortbed truck, he said I could take the whole truck with trans and case for $500. My truck now has a turbo 400 with NP208. I'm thinking about a NP203/205 doubler with a triple stick setup from Offroad Design. I know I don't NEED it, but I didn't NEED 40" tires either lol, but it would be cool! Or maybe I could just adapt the 205 to my 400 and run a twin stick setup? What do you guys think?

Also, I thought about making my own nerf steps like the ones from N-Fab ( http://www.n-fab.com/products/?searc...model=Suburban ). Has anybody ever attempted to make their own? I thought it would be cool to make the nerf steps airtight to make them a holding tank for compressed air for air horns or air springs.

[91V3500]

Got a few pics of the truck with the bed back on. I have 3 rust holes to fix, one in the bed, and a small one in each cab corner and it will be ready for paint.

[1968vetL-71]

Hey buddy, that thing turned out awesome! How do the mud grapplers drive on highway? I've been deciding between them or super swamper radials in a 38". I've had tons of swampers and never had a problem but want to do something a little different this time. Keep up the killer build man, you've done a fantastic job!
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[91V3500]

Originally Posted by 1968vetL-71

Hey buddy, that thing turned out awesome! How do the mud grapplers drive on highway? I've been deciding between them or super swamper radials in a 38". I've had tons of swampers and never had a problem but want to do something a little different this time. Keep up the killer build man, you've done a fantastic job!
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Thanks! I really wanted some TSL's but they mostly only go up to a 16.5" rim. I like the mud grapplers, they are noisy but I wanted people to hear me comin. They're not nearly as noisy as the TSL's I had on my suburban. If you plan to put a lot of miles on them, the Super Swampers will last longer, I see trucks all the time with Mud Grapplers that are worn slap out. These tires drive good and smooth, even without being balanced, once you get in this truck, you never know you're riding in a monster truck. I would recommend them, but 20,000 miles is probably about all you'll get out of them.

[91V3500]

Not a whole lot of progress on the truck lately, I did get my kick panels back from the upholstry shop.

Since I don't have any truck pics to share right now, for all you guys who like ATV's, here is a pic of a 1985 Yamaha Tri-Z 250 3 wheeler that I restored a few years back.

[Greenlee]

Cool three wheeler! I had a friend growing up who had a Kawasaki called a Tecate and I remember plenty of Honda's. Don't even remember the Yamaha version.
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[91V3500]

Thanks! I always liked the looks of the Yamaha Tri-Z but you're right, the Honda 250R and 350X were more popular. They only made the Yamaha for 2 years before the government cracked down on 3 wheelers. Now if my truck comes out half as nice as the Tri-Z I'll be doing good, this thing was a basket-case when I bought it!

[1968vetL-71]

Hey man, I see your crew cab on Craigslist forsale???

Great platform for a killer rig. I hope all is well.

[91V3500]

Originally Posted by 1968vetL-71

Hey man, I see your crew cab on Craigslist forsale???

Great platform for a killer rig. I hope all is well.

Yeah, I just bought a new Polaris RZR, and with my son in private school, a new baby, and my wife only working 4 hours a day, money is tight and I'm worried I will never finish the truck. I put it on there to free up some cash but if it doesn't sell I'll just keep working on it slowly and hopefully finish it soon. If I do sell it I plan to get another one 1 day and start all over. Next time I will start with one in better shape, this truck needs EVERYTHING replaced!

[91V3500]

Ok I didn't sell the truck, which is good because I really didn't want to sell it anyway. I have been inspired to finish it so I ordered a new dash from Summit Racing ($189 versus $340 at LMC Truck), all new flame red seatbelts from seatbeltsplus.com, took my door panels to the upholstry shop to get covered in red like the rest of the interior, and started sanding it down to get ready for paint. I decided to paint it solid white just for the good looks, simplicity, and ease of maintenance. I think the color is GM Summit White. I plan to blow the truck all apart for paint and hopefully will have some color on it by next weekend.

Also attached a pic of my 5 year old sun helping me wash the wheels just to show how massive this setup is

[bohmankid]

Nice I'm glad you kept it. Hope to hear more updates

[1968vetL-71]

Cool, glad too hear!! Never go wrong with white! It's the new "resale red" ! Lol

[91V3500]

While sanding I managed to find enough rust in the rockers to the point they need replacing, so I ordered new rockers from LMC Truck and started cutting the old ones out. This sucks and I didn't want to be in this position but it is what it is. There was absolutely no dirt in the rockers, it was the salt that ate them up. I've never installed patch panels before but luckily I have a Millermatic and Youtube so the fun begins.

I also overhauled the cooling system with a new radiator, new hoses, thermostat, a 12" electric cooling fan and a 18" electric fan. I don't want to ever worry about this engine overheating. Also nothing cool but replaced the battery and all the belts. Also ordered new window seals, outer door handles, interior light, and cargo light all from LMC truck.

[Greenlee]

Slow and steady wins the race. Can't wait to see it with some paint!

[nekkidhillbilly]

kept it longbed.....i love you for this