Let's Build A 1 Ton Crew Cab 4x4

[NastyBuzzard]

Eventually maybe. I got to finalize the concept and make a couple to try out and make sure they are just right. Then I'll send some out for a reduced price for others to try it out. Eventually though I plan to have a full 2wd to 4wd conversion kit that is hopefully about 70% bolt on.

[NastyBuzzard]

Originally Posted by NastyBuzzard

I noticed my core support mount is a little funky and cocked... I need to fix that. Is it straight and flush with the frame like the pic above? I don't have any pictures of actual crew cab 4x4 81-87 mounting position. Edit. I found these pics from diesel rats thread.. Yeah I need to fix mine.

How he did it:



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How mine looks... Yeah I gotta fix that. I did model up those core support mounts so I can make me a new set if I need to, be more boxed like the b52 mounts on the first pic but I don't see that as a problem.



Another weekend with not a lot of progress...

I did score this hydr. SM465 bellhousing for $80 though! I see them sell for bookoos on ebay. I will hang on to it, I thought about modifying the NV4500 to accept this bellhousing but not sure yet.



I did build my new hitch though!! Fits perfect, needs welding finished up and paint.



I also started tinkering around with how the seats mount and all.. I really need to find an upholstery guy, I do not like the red.



I need to get the bed back off once more and finish drilling holes and clearance it for the fuel tank. Hopefully soon I can finally mount the gas tank for good. Finally found my spools of fuel line so I can finish up the plumbing for the fuel.



Hopefully I can finish up the 2x4to4x4 xmember this weekend and start getting some parts made up.

Oh yeah, I have been kind of searching for a banks or ats turbo setup for 6.2 in a square, I may go that route if I can find a set cheap enough. I am not sure which is better, stock 6.5 turbo or the banks/ats setup.

[bealaddison]

Did you end up going with crossover steering? If not, I would recommend it. You have most of the parts already...just swap a 2wd sector shaf tinto your 4x4 box and use the drop pitman arm you already have. Very nice upgrade for a lifted truck like this.

[NastyBuzzard]

No cross over for this truck. It should drive and handle just fine with the stock style steering setup, especially since this is for the highway. I currently have no reason to believe that xover is better for highway driving and I want to keep my sway bar. However, who knows what may happen down the road.

I am getting some parts prototyped for the crossmember! To keep costs down it is a no rush deal but shouldn't be too much longer. Hopefully this week. I am also kind of stuck until I can get the bed back off, been to scared to do it alone considering last time I went at it alone I ended up dropping it and wrecking a perfectly good long bed on my 87... Which I tried to crank up and move to the shop this weekend to start looking at putting the H3 brakes on the 1 ton and the damn fuel pump has died...

I did get a new welding cart which is worlds above what the old home made one was!!!



Waiting on my big spool adapter to come in for the welder and I may need to buy a new lead as well.

I have been working on my 04 crew cab... It scared the **** out of my on Tuesday. When I pulled into the driveway I heard knocking!!



After more investigation though it seems the bearings in the water pump died. So I yanked it Friday, parts should arrive for it today.

[daddyjeep]

I'm liking that HF welding cart. I modified a HF tool cart for my welding cart.

[IMG][/IMG]

[NastyBuzzard]

I am loving it. It was on sale and worth it. It has a lot of storage and shockingly fits my commercial sized bottle. So easy to roll around and what not vs before. I always dreaded moving it now I just grab the handle and go.

Later I think I am going to swap casters out for larger ones so I can roll it outside on the gravel though.

I dig what you did for sure! I am all for whatever works.

[bealaddison]

Originally Posted by NastyBuzzard

No cross over for this truck. It should drive and handle just fine with the stock style steering setup, especially since this is for the highway. I currently have no reason to believe that xover is better for highway driving and I want to keep my sway bar. However, who knows what may happen down the road.

I am getting some parts prototyped for the crossmember! To keep costs down it is a no rush deal but shouldn't be too much longer. Hopefully this week. I am also kind of stuck until I can get the bed back off, been to scared to do it alone considering last time I went at it alone I ended up dropping it and wrecking a perfectly good long bed on my 87... Which I tried to crank up and move to the shop this weekend to start looking at putting the H3 brakes on the 1 ton and the damn fuel pump has died...

I did get a new welding cart which is worlds above what the old home made one was!!!



Waiting on my big spool adapter to come in for the welder and I may need to buy a new lead as well.

I have been working on my 04 crew cab... It scared the **** out of my on Tuesday. When I pulled into the driveway I heard knocking!!



After more investigation though it seems the bearings in the water pump died. So I yanked it Friday, parts should arrive for it today.

Speaking from experience, the swaybar is not necessary. I removed mine from my '87 Suburban and have not noticed any ill effects in on-road performance. Also...with the 6in lift, you will experience loss of motion and wandering with the stock style steering. I ran with stock style steering for years and recently converted to crossover when I swapped in my dana 60. Wish I had done it years ago. Not saying stock style steering won't work...but crossover is just that much nicer.

[NastyBuzzard]

Yeah but the swaybar really comes in handy when towing. Which is partly what I'm building this truck for, hence the diesel. It should be hauling gooseneck trailers with heavy equipment down the interstate. Also be able to tow a real good size camper. That is why I'm sticking with stock steering.

Xover shines off-road and around town but long distance hauls, interstate driving and towing it sucks not having a sway bar. I speak from experience on that. If I was to do xover it would be with radius arm or 4 link style setup.

[bealaddison]

Fair enough. Keep up the great thread!

[NastyBuzzard]

Trying! I have fingers crossed that I will receive some prototype parts to tinker with sometime this week!

[NastyBuzzard]

Seems to fit with no drilling! I have some revisions to make to make it better though!

[DieselRat]

dayumm! you liked my crossmember, yours is absolutely sweet!

and just saw you posted my pics, I made sure the top of my front cab mount/spring hanger was level with the top of the frame as thats how the true 4x4 frame was. For future note, I make a mark with a chisel at the center of the bushing hole on the stock mount, then just found center on the 4x4 mount and lined it up, drilled the holes. Fit perfectly when I put the front clip back on.

How are you going to mount up a front sway bar? I plan to add mine back in, possibly with the 4x4 sway, using the 2x4 brackets which look like they drop down a little, and of course the holes should still be there to mount them up since its the 2x4 frame.

[NastyBuzzard]

It's getting there! This was just first run of parts with some oversized holes to make sure I got the holes lined up and all. Gonna make a few changes and make a final one sometime soon. I'm glad you like it!

As far as sway bar, since mine is lifted I'm going to make some spacer type mounts (similar to diy4x or ord ones that has the pin so you can easily remove the sway bar) to raise the mounting point of the sway bar about 2" so it will be more level and in line with the frame like it should be, I was also considering trying to use the 2wd mounts. We shall see.

[DieselRat]

Yea exactly what I meant. With the lift I have just holding it in place its def not parallel to the frame anymore. I didn't get rid of my 2wd xmember piece and noticed the mounts for that drop down a good 1 1/2" or so. I may yank them off and see what I can come up with this weekend.

Cool thing with mine was it actually had a rear sway on it as well. I put the mounts under the U bolts in the back but same deal, it needs to be lowered some to work. For now I'm not too worried about the rear, would be nice in the front as I can feel it shimmy when I hit bumps.

[NastyBuzzard]

I just want it for when I'm towing. A rear sway bar too huh? Hmm I may have to look into that.

[NastyBuzzard]

This was my first time removing hubs and what not from a dana 60, more specifically the 1 ton version. It took me a good while to figure out how the calipers came off seeing how they are pinned and not bolted as usual.

I took some measurements to start to try and develop some mounting brackets for the H3 calipers.



How do I "check" the king pins? It doesn't feel loose in any direction per say.



I also needed to get the bed off and couldn't get anyone to come help...Finally had to go get my cherry picker and try and remove it by myself. It wasn't easy. Worst part is I put the truck on jack stands up front in a bad spot leaving hardly any room to work at the rear. I got it, a lot of luck was involved though.

As you can see I had to add some weight for it to balance decently.



Shes naked again! Hopefully I can get to drilling all those extra holes and start swapping to grade 8 hardware for the stuff I have mounted in the rear!

I also have to move the fuel door on the bed and paint the bottom of it and fenderwheels with the chassis saver paint I did on the rest of the fame/cab.

[silverbear]

I am liking the progress you are making. I really like the detail in that cross member. Showing a little love for the TA on the crew cab...nice.

[NastyBuzzard]

Thank you. Hopefully once I get all these designs nailed down it will be a lot easier to swap one over to 4x4 if the need ever arises.

The bird is actually supposed to be my little "Nastybuzzard" emblem. It is just so small on the crossmember it is hard to flesh out any details so I can see how you would think that about the TA.

[NastyBuzzard]

Anyone know MCMLXIX from this thread about Dana 60 Brake Upgrades?

http://67-72chevytrucks.com/vboard/s...d.php?t=463042

I am trying to reach out for more information. Oh how I would love to run dodge 14.125" OD rotors up front on my dana 60 with dodges dual piston calipers. I know they will fit with me running the 17" dodge wheels...

[porpaintt]

Hey Nasty,my 90 1 ton crew/w a 6.2 has a 375 behind it not a 400.
375s are not electric kick downs.
I also have a 6.5 long block,that is new.

[NastyBuzzard]

375? That is interesting for sure, 400s aren't electric either they are vacuum. I am jealous of the 6.5 long block for sure. I really wish I could get my hands on a banks turbo setup or ats designed for 6.2

[porpaintt]

Nasty,I think if you look up the 400 on the internet you will find it is a electric kick down,the 375 is a glorified 350 with a cable kick down and a vacuum modulator,and the 475 is a heavy duty 400,with a cable kick down,and a vacuum modulator.
The switch for the 400 is a slider on the gas pedal bracket.
The 375 and the 475 are usually marked on the tail shaft housing.

Nice work you guys are doing.
By the way if anyone is interested in the 6.5 it can be bought for $500.00 bucks.
The heads are worth that,because they will work on a 6,2 also,and the 90 (c30) truck with the 6.2 (with 112,000 on it can be had for $1900.00,with the flatbed.
I have no need for them anymore.

[NastyBuzzard]

Good information! I didn't know that. I don't really deal much in non OD transmissions though.

I wish I could get the 6.5 off your hands but Ohio is quite a ways away otherwise I would pick it up for sure.

[mcmlxix]

Originally Posted by y5mgisi

I lied. Not cheap.

Rightgear.com

I was looking into a brake swap for a cheap 70's era 14bff drum rear. I ended up with a 2005 GMC AAM full float rear with twin piston calipers and integral e-brake...and factory posi - 4.11 gears from a junkyard... $400.... Bolted under my K5 with a set of $30 spring perches.

Also, I ended up with a spare set of AAM rear brakes from a another axle that had a bent housing.

[NastyBuzzard]

Yes! I have seen that and that is the plan for the most part. I want to keep my 14BFF, it has 4.10 gears to match the front and is in excellent condition. I plan to develop something similar or just use a kit like that if it is truly available. I just can't stand using the front calipers on the rear or the el dorado calipers that don't half ass work and you have to set every time you change pads.

Right now I am still struggling to figure something out for the front, I don't plan on putting it back together with stock brakes but I hate having it stuck on jack stands!