Let's Build A 1 Ton Crew Cab 4x4

[NastyBuzzard]

Noted! I will definitely look into band clamps. I really hate using those ubolt style clamps. They never come apart easily. My truck is 1ton with lift so should have clearance but still.

Man that engine bay looks awesome!! I don't think I will be using the banks sidewinder intake box thing though, the one on top of the intake. I found a thread where someone used the 6.5 good intake that flows a lot better and adapter it to the turbo tube. He said it lowered his EGTs a lot as well as boost in fuel economy and power.

Details on the duramax style filter stuff?

I will be running the 89-91 setup as well. I really need to get a 6.2 radiator still and figure out where I am going to put oil cooler.

[83GMCK2500]

What are you referring to as the good 6.5 intake? Just an F-VIN one without the EGR in the center? If that is the case that is what my dad's 6.2 has, swapped the lower for a non-egr and then bolted the Banks hat on top. I know the 6.5 one is a bit different in bolting and egr position, just curious if that's what you're referring to.

One thing I will say, getting Banks' filter box intake to line up with the factory 89-91 core support intake piece is a nightmare. I wish I had some pics, but I do not and the truck is across the state from me. If you check out this post: Post #24 there you'll see the differences on the intake piece between the vertical stack headlight core support vs. the 89-91 one. The later one is higher and at an angle...good Lord it was a PITA to mate up to the 6.2 filter box. Heated that piece up with a heat gun and reshaped it a little. Bought some universal bends and pieces that reminded me of ricer intake parts from Amazon and put something together that sealed.

Reminds me...the CDR valve, probably want to look into venting that thing to atmo or installing a catch can. Engine is still pretty tight on that 6.2 I showed but man that CDR just drools oil.

EDIT: In regards to the exhaust clearance, it was between the pipe and oil pan or the pipe and the crossmember that is near front of engine. The way those manifolds mount it puts the crossover at the front of the engine.

[NastyBuzzard]

Not just the lower F vin intake but the 6.5 upper as well. Here is a thread where the guy describes it as being a lot more beneficial for the banks setup even lowering EGTs.

http://www.dieselplace.com/forum/63-...-manifold.html

I will check out the post, sucks I have to look forward to that pain...

CDR, I am just learning of this. I mean, one guy stated he lost a gallon of oil between changes. I definitely don't want that. What to do? What is the norm?

Oh, I see what you are saying. I hope the crossover clears my fancy xmember I made or I will have to make my own anyway.

EDIT: So are you saying I need that plastic piece from the 89-91 supports?

[83GMCK2500]

Gotcha, the full open plenum and open lower.

Good info on CDR catch can and/or removal in this thread, there is a provent product that some people replace them with. http://www.thetruckstop.us/forum/thr...n-maybe.43709/ There is some mention in that thread of a CDR for turbo engine being different than n/a...I'm not sure on that, might take more research. Might be why my Dad was coating his intake with oil.

I mentioned lift pump and relay harness earlier, here was a thread about the fuel system in general for the 6.5: http://www.thetruckstop.us/forum/thr...shooting.6872/

EDIT: I was thinking, that '96 block might last longer if you paint it Alpine Green.

[NastyBuzzard]

Ok, I am checking those links out now. So were you saying I needed that plastic piece that bolts to the 89-91 core support?

Edit: Ok, I read up on CDR. 6.5 used to have on with its stock turbo, I will be using banks turbo that I assume isn't setup for that. What do? Just do a catch can or actually try and implement the CDR some way. I am used to using catch cans on LS motors bc of how much oil ends up in the intake.

In this thread, http://www.thedieselpageforums.com/t...ad.php?t=28732, he says the banks instructions said to run the line back to stock air filter box, which I am supposed to be getting. IDK

[NastyBuzzard]

Seller supplied me some final pics of parts before they are boxed to be shipped out.

I am waiting to see part # for this IP to see if 6.2 mech IP or 6.5 mech IP.



Banks air intake.



Mechanical Pump & adapter (which I don't think I will be using.)



Banks CDR valve So that problem may be solved! It connects to the air intake.



Spot for EGT sensor which he doesn't have so I will need to get one of those.



He also sent a crap ton more pics and videos of all that is getting sent but don't want to bore anybody.

I basically went through the banks install manual and anything I didn't see I asked him and he was able to procure almost all of it so that is awesome.

If anyone thinks of something may be missing let me know.

I need to procure a 6.2 radiator and possibly a duramax fan or electric fan setup.

Plan is to order the 93 EP158 lift pump. Still not sure what filter setup I am going to run.

I also need to find part number for the air filter for the banks.

[NastyBuzzard]

From what I can see and what other people have said, it looks like it is a 6.2 injection pump that has been rebuilt.





It got boxed and shipped yesterday!







Tracking says to arrive the 21st.

Now I need to get the guy rebuilding the turbo to finish up and ship. Apparently he got sent the wrong bearings for the rebuild, the wait is killing me.

Also my parts for REV 002 of my conversion xmember are showing up.

[83GMCK2500]

Very cool, I'm sure that's an exciting crate for you. The tube on the fuel pump plate is the oil return from the turbo, might need it unless you're going a different route.

[NastyBuzzard]

I already have that tube in that spot on the 6.5 engine.

It is exciting, I just wish the right parts would come in for the banks turbo so that can get shipped out as well!

Kinda bummed I am switching it up from doing the electric IP but this saves me a lot of other hassles that would have followed it. Very nice I don't have to modify the AC box.

[NastyBuzzard]

Well Rev 002 is in. Still got to weld in my gussets but I can't wait to try it out!

[daddyjeep]

Rev 2 is looking good.

[NastyBuzzard]

Rev 2 went in pretty well.




Except the vendor I had make them bent one of the bends at the wrong measurement but that's an easy fix once I can have power ran back to the welder.



I did see this twin turbo 6.5 square body on facebook over the weekend. Thing was bad ass.



Also doing some prep for engine install.





Also the Dana 60 is all but back together!! New bearings/seals all the way through. Nice and tight.





Test fitted wheels to see if I still needed spacers and check wheel stud length. Seems like I do not need spacers anymore and studs are nice and long.. Now just to see if I can use the 610-303 studs instead, they are rear 14bolt dually studs and are a tad longer and a good bit cheaper. Also no drilling required to install, I think.

Also, I can't see these clearing 16" wheels.





Also had to clearance the bolt.



Sad news too, my shipment for turbo stuff is delayed to 12/27 which is a day I can't come pick it up so... Going to have to figure that out. Also, the damn turbo still isn't finished being rebuilt! Waiting on bearings.

[mcmlxix]

I forget what you're doing for wheels but look into some Dodge takeoff wheels. I think 17s will clear but really close. I had some Hummer H2 wheels on mine and the caliper was very very close to the inside of the rim.

[83GMCK2500]

Any updates? You're moving down my list of subscribed threads, can't have that.

[NastyBuzzard]

Originally Posted by mcmlxix

I forget what you're doing for wheels but look into some Dodge takeoff wheels. I think 17s will clear but really close. I had some Hummer H2 wheels on mine and the caliper was very very close to the inside of the rim.

I will be running 3rd gen (I think) cummins wheels. The 17" 5 star ones. I posted pics of them earlier in the thread. I don't see how it would ever clear 16" wheels.

Originally Posted by 83GMCK2500

Any updates? You're moving down my list of subscribed threads, can't have that.

Oh no!!!! I am sorry. I have been very busy, all around. Family, Work, Shop, Truck and so on!

I do have a few pictures though.

My grandpa gave me this 1.5 ton electric heater so I wired it up. I am thinking if I was fully insulated and all it would be enough but as is I think I need at the least a 2 ton.



I did get the PS all finished up as far as the hub/bearings/seals install goes. Passenger side is almost done. I was thinking I could get away with using the dually studs 610-194 studs from dually but once I installed them they have too much play and could easily push out. So I need to drill out the other hub for the 610-303 studs.



I even went to put on the brakes and be done with that side and of course damn caliper bracket had a frozen pin in it. I had it assembled and it was all crooked and I was like holy ****, this isn't going to work. Then I noticed the frozen pin. I reached for the other bracket to use and then remembered I never got another one. So I had to order all that up. Waiting on new pins to arrive tomorrow for install.

My turbo/mechanical injection swap stuff arrived!! Got lots of cleaning to do.



Checked for clearance one final time to make sure I won't need damn spacers. Looks Good!



Gotta clean up and paint the hydroboost unit from the 83 donor. Came with my turbo/mech ip parts.



Installed my engine xmember Yes I need new motor mounts.



Started installing the 83 6.2 wiring harness w/ the 91 front end light wiring harness. The 6.2 harness looks totally different than what I am used to. Actually I have never even messed with a square harness that wasn't TBI.



I also gotta decide which instrument panel to use.. The tach one I made is for electric speedo.



Also the best part is, I wired up the heater and all my receptacles. I finally have more than 1 outlet! I have like 14!!! It is so exciting haha. Still have to wire 220 for my welder though and a few more things.



I also got me a pedestal mount for my bench grinder finally as well and hooked it all up.

Had a good Christmas, hope you all did too!

Happy new year as well!!

Hopefully I will have more updates after the weekend. I have lots I am working on for sure.

Still struggling with getting the rebuilt banks turbo to me. He can't find one bushing/bearing from anyone apparently. They keep sending him the same one that won't fit.

[daddyjeep]

That's quite the update. You have been busy.

[NastyBuzzard]

These brakes are huge. I love this conversion.



These are the wheels I will be running for now.



Started tinkering with the bed!











Of course right at the end we heard a pop and a dent formed.. I need an inflatable dent remover or something its ok for now.

Hopefully to get the door welded all in tomorrow.

Also, not sure If I have shared this yet but my friend is building us a plasma table! We should be making some parts in a few months!

[NastyBuzzard]

Its time!











Now I need to get the fuel pipe cover from a k5 or suburban.. I also ran out of flapper wheels to finish cleaning up the door section.

I gotta get the bed outside and cleaned underneath and wheel wells so I can paint it with the same stuff I painted chassis and under cab. I will probably rhino line or some brand the actual bed. Gotta install my gooseneck hitch too.

[COS399]

Nice work..

[jdb_us1]

nice progress! What will you use to cover the fill pipe in the bed? I remember seeing factory beds that had that notch and cover, cant remember for the life of me what where or when though.

[NastyBuzzard]

The plan is to use a k5 bolt on cover.... If I can ever find one for cheap... I know LMC has what I need for around $50 or so plus shipping but I am not sure it is going to work yet so I want a used one I wouldn't feel bad about modifying if necessary.

[NastyBuzzard]

Got the drivers side buttoned up. Damn pin is stuck in the caliper bracket so can't put brakes on yet. Have to get it out or buy another expensive ass bracket.



I did pull the tbi harness out and now to put the 83 diesel one in.

[NastyBuzzard]

Ok. Since the 83 harness doesn't have connectors for intermediate wipers, I will be using the 88. So it is going back in. What changes to it do I need to make for the diesel?

I really need some diesel wiring harness info. I have never even been through a carbed wiring harness on one of these trucks. Always had TBI trucks.

For instance, I know this harness is for the diesel bezel where the two lights are for glow plugs and water in fuel but where does it connect into the cab harness?



Also, what the hell is this red box?



I did build my cluster last night. Went from 3 clusters robbing parts to make one. I still NEED to track down a decent mechanical speedo with a working trip meter, this one is so loose it doesn't do jack. Also a wire harness for the tach would be nice





Also, I have been hella curious if the motor is going to bolt right in or if it was going to be a fight like before. I am not sure if you remember but I never got this engine to bolt in all the way when I had the 4x4 xmember in. It was about 1/8" off to one side and I could never get it to align. Well after a little bit of trying, voila. She bolted right in perfectly!







I also removed the ds door because it was just all in my way. Plus it needs replacing anyways. Funny thing I found was the door pins. Someone apparently tried to replace them but got the wrong stuff. They are barely all the way through and still up at least an inch above them instead of being flush.



Also, what is the cheapest but still decent quality dynamat like material? I want to order some and try it out. I have never used any before and want some decent sound deadener on this rig!

[NastyBuzzard]

I did discover the red box is for the cruise control. Interesting.

[83GMCK2500]

It's coming together, slowly but surely.

As for the harness and whatnot, have you checked out that big post of hatzie's where he's got most of the factory service manuals posted? Might be able to find something in there.