Let's Build A 1 Ton Crew Cab 4x4

[NastyBuzzard]

Yeah I wish! Can't do that during this initial build up. I am working on fixing that knuckle. I am rewiring my shop right now so trying to get my buddy to weld nut on so we can try and get it out of there.

However, I did have a guy contact me yesterday about selling me a full banks turbo setup w/injection pump (& lines), throttle cable, down pipe, exhaust manifolds, crossover pipe, intake, fuel filter housing, fuel pump and plate with oil return for the turbo, oil feed line, air filter housing, intake tube, wiring harness and instrument panel for about $1000 shipped.

Seems like a good deal.

Trying to figure out what else I would need if I was to buy it.

[NastyBuzzard]

Pics of the banks setup he has. Also is coming with extra battery trey as well and hydroboost.















His friend tore down the banks turbo for a rebuild yesterday. Still waiting a few parts but has it back together for the most part.

[COS399]

I had a 90 suburban with a 6.2 and the Banks Sidewinder turbo set up. I bought it with it already set up but in my opinion it wasn't worth the money they spent putting it on. Just my two cents.

[NastyBuzzard]

I'm not getting it for the power really. I mean I will be running 6.5 turbo for now regardless if it is banks or stock GM turbo. From what I see though the banks turbo should make more power than the stock GM turbo just won't spoil up as fast.

So that's my options unless a Cummins falls in my lap or better yet a duramax!

Still though, it should have the power indeed for a driver and hauler. That's all I need for the time being. That plus dependability and good fuel economy.

I definitely agree it isn't worth the list price but I'll be getting it and a lot more for about $1,000 shipped.

[Matt72blaze]

Hey Mr. Nastybuzzard,

I read through your build. I'm doing a 2wd to 4wd also but I'm way behind you. Any chance you'd share or sell the drawing for your awesome looking engine crossmember?

Thanks!
Matt

[NastyBuzzard]

Awesome that there is some interest about the crossmember. I am currently on REV 002, have to make sure it all fits perfect. I will be selling the first run cheap to weed out any issues.

We are currently working on building plasma table to start making parts, so pretty much everything you've seen that I have made in this build will be available.

The end goal is an entire 4x4 conversion kit that I sell as a paperweight.

[NastyBuzzard]

Seller provided a video of the last time his diesel was running showing proof IP is in good shape and what not. Said the video was taken right before he started to strip it down.



Latest pic on the turbo rebuild.



I started to tear into my 6.5 a bit to begin preparations.



IP is off.



Also finally got started on putting the DANA 60 back together.







Was able to fix the knuckle, just need to run a tap through.

[83GMCK2500]

Originally Posted by NastyBuzzard

Was able to fix the knuckle, just need to run a tap through.

Love it when a plan comes together.

Remind me, please, I don't recall all the engine specs/plans. The Banks kit is obv. (is that ceracote on the snail? looks good!) are you going with a DB2 (stock or modified?), what block is that, heads? Other than the Banks, any upgrades?

[NastyBuzzard]

Nice to see interest!!! Yes it is ceracote, the builder is only charging $500 for the rebuild an the seller has agreed to pay half of the cost.

So far just stock DB2 IP, 506 (****ty block... ....) but it is what I have, stock 96 6.5 heads as far as I know.

So far no real upgrades besides exhaust and I will be running the good 6.5 intake. I plan to do more down the road including building an engine on the side. For now with all the $ I am putting into this thing I am just praying this engine will fire up and run at least until after I get the truck painted.

Any cheap upgrades to do before I put it all back together?

[83GMCK2500]

If you're using the filter that mounts to the intake I'd say an o-ring kit and larger fittings in the 6.5 FFM: http://walkingjdesigns.myshopify.com...feed-the-beast

Forum write-up on 6.5 FFM upgrades: http://www.thetruckstop.us/forum/thr...uel-to-ip.572/

You can actually upgrade to the nice big Donaldson filter and mount that the Duramaxes use, my Dad put one on his '87 V1500 w/6.2 + Banks. If you're not familiar with it, the filter has a water-in-fuel sensor on the bottom that will wire into the squarebody circuit. Bonus features include a priming button on the filter mount.

6.5 glowplug harness is prone to wearing out over time, not saying you need to buy this, you or someone you may know might have the sparky skillz to make one yourself: http://ptwiringsolutions.com/t/glow-plus-harnesses

If I remember correctly the factory 6.5 fuel system includes a lift pump which is a good unit and often added to 6.2s. Alternatively there are some nice relay kits with Walbro pumps here: http://leroydiesel.com/product-category/fuel-delivery/ <---really, all of that guy's stuff is pretty nice with quite a bit of research put into it. I follow that TTS forum that I linked above and that's where I found his stuff.

[NastyBuzzard]

Thank you! I'm starved for good 6.2/6.5 info! I am supposed to be getting entire wiring harness from the 6.2 donor including glow plug controller and the diesel instrument cluster.

I wasn't sure what lift pump I was gonna run but was thinking of running the 93 6.5 lift pump andnwiring it up some how.

So should I ditch the 6.2 fuel filter setup?

[deejaaa1]

TTS has a lot of good info on the 6.5 and still a few good members left.

[83GMCK2500]

Originally Posted by NastyBuzzard

Pics of the banks setup he has. Also is coming with extra battery trey as well and hydroboost.

Revisiting this picture...I would suggest ditching those awful u-bolt clamps on the crossover and getting a set of the nice band clamps. There is VERY little clearance around those two and I scratched the crap out of the back of my hands on them. I know summit/jegs has them, I think http://www.mandrelbends.com/ was cheaper though.

I've got a couple pics from when I was working on my dad's truck, doing an 89-91 core support swap, if you wanted an assembled pic, what to look forward to. Note, Duramax style filter on the firewall.

[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.