87 Chevy Crew Cab 4x4 Converion/Cummins swap

[DieselRat]

Well if I get my motor set in and everything lines up like planned, if you sent me a set of mounts I would gladly make ya up a set! I just don't have a spare set of mounts to use. You should jump on craigslist and find yourself a simple welder and just start burning metal! Best way to learn with a little help from friends. At bare minimum you can tack pieces together then take them to someone else to weld them tight for you.

[NastyBuzzard]

Originally Posted by DieselRat

Well if I get my motor set in and everything lines up like planned, if you sent me a set of mounts I would gladly make ya up a set! I just don't have a spare set of mounts to use. You should jump on craigslist and find yourself a simple welder and just start burning metal! Best way to learn with a little help from friends. At bare minimum you can tack pieces together then take them to someone else to weld them tight for you.

Funny story! I actually have a stick welder, a 120 mig welder and an actual good welding setup with bottles and all. I have used the little welder to tack stuff up and take it to someone others I don't use b/c I don't have 220 outlet yet.

I have 1 out of 2 of the 1500/2500 engine mounts!

[DieselRat]

Got some updates. Working on it non stop, was HOPING to be able to take this on a trip in about a month, well see how that goes HA

Got the motor hoisted up and in to make sure that everything lined up as far as the engine mounts go, and it all looks like its going to be good!

2nd I scored some pedals, column and trans tunnel from a fellow member.

Even cooler than that I ended up finding the holy grail transfer case I've been searching for forever, 29 spline NP205!

SO heres a picture of that guy after i got it all degreased and ready for inspection/paint.



And after having to take apart half of the lower dash, I got the pedals in.



I had read that there were dimples in the firewall to located the 'feet' that supported the clutch side, and also created the mounting point for the clutch master, and sure as crap they were there.



and heres the location on the outside for those studs. I'm guessing now I'll probably end up having to take it all back out to modify it for the dodge setup, but well see.

[NastyBuzzard]

Awesome progress! Those pedals are a pain aren't they? I am jealous you found the dimples.. I could not.

[DieselRat]

Pedals was a 2 evening adventure. I got it 90% buttoned up last night. Not sure what I'm gonna do tonight!

[DieselRat]

Anyone know what this plug goes to? Its under the dash near the gas pedal. Its 2 prong, I can't see where it plugged into.

[NastyBuzzard]

Cruise control or brake switch one I do believe.

[DieselRat]

Had a couple days away, and bought a new car in the past couple weeks of no activity here, BUT I am making good progress.

First up I sold the 54 GMC in my sig and had been looking for a muscle car of sorts. Ended up getting a 72 Duster 340. Not my first color choice but we can change that!



Now back to the project. I got the engine sat in last week and realized it was a little crooked (thats what I get for doing this conversion blind) so I yanked it back out and welded a plate to the passenger side engine stand and that brought it up to level.



Pretty pleased so far with positioning being that I was just measuring off the 4x4 frame as far as mount position and all. Gives me good valve cover to firewall clearance, and should leave me plenty of room for the stock mechanical fan in the front.

Picked up some fuel hardline to re-route my lines, but first I need to figure out how I am hoisting the 250lb trans in by myself! The fuel lines are going to have to come across at the Xmember to hit the ports on the driverside of the engine.

Also started to dissect my wiring to figure out what is what. Pretty basic for the Cummins, just need to get some different senders for oil/water as well as some reducer fittings. I'm at the point where this could all come together quickly once I get the ball rolling. Goal is to have the trans in and be able to start it up with the key by the end of the weekend. Well see how that goes!

[DieselRat]

Just like my other build thread...:::crickets::: Guess I need more useless banter instead of progress???

anyways, moving along as always..Got the floor cut out for the 4x4 bolt in piece, also to help aid in hoisting up the NV4500



couple hours later with a little help from the wife



and the cover sitting there for now

[DieselRat]

Dont have a picture of it but I ended up re using the stock 2wd trans crossmember. Added a plate to the top of it and drilled a few holes and bolted it all into place. Engine and trans are finally supported on their own in the chassis.

Started to sort through some wiring, decided I'd rather have my electrical guru buddy come help me with that, so I went ahead and got the front clip mounted back up so I'd have a place to sit the batteries and all

Heres a together pic with my little 2 year old in front. Shes gonna be my future helper, shes always laying on me while I'm on the creeper under the truck



and a side shot which gives sort of the whole feel of where this thing is going.



hoping to at least get the electrical 'hot' tonight, then to get the NP205 on and fluids filled up and fire her off. Didn't quite meet my goal of running by the weekend, but enough progress that I am happy with where I am at.

[NastyBuzzard]

Looks like great progress to me!! I have had my 6.5TD and NV4500 in for mockup but looks like you are getting really close to firing it up.

[daddyjeep]

Little helpers are always good. Those small hands are good to get into tight areas.

As far as the crickets go...we are still following, maybe not commenting a bunch, but following none the less.

[DieselRat]

Originally Posted by daddyjeep

Little helpers are always good. Those small hands are good to get into tight areas.

As far as the crickets go...we are still following, maybe not commenting a bunch, but following none the less.

I know I know, I guess its partly my fault in that I rarely ask for much help, not saying I know much of anything about anything, I just research stuff to death then go get my hands dirty, Keeps the chit chat out of my threads I suppose! I browsed your whole thread as well and your truck is looking great!

I'm at the point now where i need to slow down and focus on finished one thing up instead of bits and pieces of all at once. Get myself overwhelmed when I do that!

on a side note I like your style with the jeep and tow rig mentality. I USED to wheel, before I had kids and got myself into doing dumb things like putting a cummins in a chevy lol, but one day soon I plan to get back into that. My current DD is a YJ, with a little lift etc. Used to wheel rausch and reading anthracite a lot those a few years back. Sorta miss it!

[daddyjeep]

I'm the same way myself. There is so much information out there that I feel I'm taking a shortcut if I ask a question.

I have been preaching that thought process to one of my boys with his car project. Focus on one task, get it done, then move on to the next. He was jumping all over the place and getting nothing done.

[COS399]

Thanks for the updates and as stated previously, we are still following along.

[Greenlee]

Nice work! This truck will be a beast.

[DieselRat]

Well last night was a big success of simplicity really. A little key info for others who are in my swap about powering your fuse box etc. If you are using a chevy alternator that will plug into the factory harness, once your batteries are connected your golden. Since I am going to be using an external reg on the first gen alt (like i said because its new and it fits and its just simpler right now) I didn't have any power wires hooked to the alt and had no power. On the chevy harness you have an orange wire and a brown wire. The brown is a key hot which I assume is the exciter wire for the alt. The orange wire needs to see 12V or you get no power fed back to the fuse panel and there fore have nothing. SO I was hooking up a red wire that originally went to the starter main post that I had assumed was grabbing power and bringing power to the main power distribution block, well when I hooked it up I had nothing. I put the ORANGE wire from the dist to the junction block, and everything came to life!

Maybe everyone already knows that, but I searched EVERYWHERE to find that info in black and white to no avail. So there it is for the future searchers.


On a side note, the wire to power the fuel shutoff solenoid will come from the PINK wire that originally went to the distributor. That is also a key hot.

That previously mentioned red wire (larger dia wire) that went to the starter, will go directly to the battery to give power to the junction block.

The trigger wire is the same as the factory chevy I believe is a purple wire that goes to the small post on the starter.

I will update this list with the rest as I narrow them down, but basically it leaves oil pressure and water.

[COS399]

My 88 was wired with an external Dodge regulator and the surging of the lights every time the regulator kicked in and out drove me nuts. I installed an internal regulator and problem solved. I have the part number in my thread if your interested.

[DieselRat]

Good to know, did you add the internal to the dodge alternator or just change to an internally regulated alt?

[COS399]

Originally Posted by DieselRat

Good to know, did you add the internal to the dodge alternator or just change to an internally regulated alt?

I used the Dodge 1st Gen alternator. The box is marked as being made by "TRANSPO" and the part number is "IN8315." Below the part number it reads "V R INSERT NIP/CHR." I am assuming it means, voltage regulator insert Nipondenso and Chrysler.???

[DieselRat]

Thanks for that I will definitely look into that!

So I got a lot of my old wiring loomed up and tucked to the firewall. Had to modify the battery holder bracket on the drivers side as it was a little tall and I didn't want my post to be so close to the hood. Finished welding that up last night so today I plan to get the battery in there and finish up the headlight harness and put the washer bottle etc back on the fender. Got all my wiring DONE on the truck short of starting it because I dont have my TC bolted on or fluid in the trans yet. If all planets align once the fuel system is bled it SHOULD run. Basically now I am down to front brakes, rear ebrake cables, steering (undecided against factory push pull or a crossover setup) and at least a rear driveshaft for now and it should be mobile.

Heading away to the mountains for a week for some fishing and hanging with the family. Original plan was to have the truck done to take it on the first voyage, and I almost made that happen, so I am satisfied with my progress nonetheless.

[DieselRat]

Haven't taken any pictures to share but still making progress. Got my wiring all sorted out and loomed up, everything is hooked up except for oil and water. Hit the local junkyard and pulled a 4wd steering box, decided against the crossover steering for now. Got all new steering links and arms.

Last night got the transfer case bolted in, which was easy and hard at the same time. 150lbs isnt easy to muscle around laying on your back. And now that brings up a new problem, which is going to be where the heck the exhaust is gonna go. Almost need body lift to get a pipe down over the xfer case. So for now I am stumped on that one. Hoping to get fluid in it and a downpipe attached and try to fire it up for the first time. Gonna finish up my steering lines and new ends tonight and I think I am finally onto the 'short list' of things to do.

[COS399]

Yep, not much room in there. I think i was able to put a 3" pipe in there and then bumped it up after the transfer case. Good Luck.

[DieselRat]

After looking at it again in the daytime I think I'll be able to squeeze a 3" in there above the TC. Only issue will be is that my fuel line runs along that frame rail since I only had a passenger side tank. So I may just have to put a shield along that part.

[COS399]

Originally Posted by DieselRat

After looking at it again in the daytime I think I'll be able to squeeze a 3" in there above the TC. Only issue will be is that my fuel line runs along that frame rail since I only had a passenger side tank. So I may just have to put a shield along that part.

I forgot to mention that I ran new lines down the left side before doing the exhaust.