Let's Build A 1 Ton Crew Cab 4x4

[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.

[NastyBuzzard]

Yeah I just lack the time to get out to the shop and work on it. When I do I have so much to do, kind of gets overwhelming sometimes. I don't want to just throw it together but then again I want it to run! I need to hear it run to fill my motivation back up.

Pretty much I am only getting a few hours maybe on Saturday and Sunday to go mess with it.

I did find wiring diagrams here:

http://www.dieselplace.com/forum/63-...ml#post7049009

Crap ton of information! Now to decipher it all to make a bastard setup using 88 fuse block and interior harness and 83 engine harness.

I really wish I could paint the door jams and finish painting interior of the cab so I can install this stuff for maybe the last time instead of knowing I will have to pull it all out again.


Also looking for cheapest alternative to dynamat.

[daddyjeep]

Originally Posted by NastyBuzzard

Yeah I just lack the time to get out to the shop and work on it. When I do I have so much to do, kind of gets overwhelming sometimes. I don't want to just throw it together but then again I want it to run! I need to hear it run to fill my motivation back up.

Pretty much I am only getting a few hours maybe on Saturday and Sunday to go mess with it.

I really wish I could paint the door jams and finish painting interior of the cab so I can install this stuff for maybe the last time instead of knowing I will have to pull it all out again.


Also looking for cheapest alternative to dynamat.

This sounds all too familiar. I am also just trying to get mine to the point of functioning and then will tear it apart again to finish things right.

I have read a couple posts mentioning a foil backed insulation from Lowes or Home Depot that I am going to check out.

[NastyBuzzard]

Yeah peel and seal is what it is called. I used something very similar when I redid the roof on my addition. It was called storm guard but still basically the same. It is a tar backed roll that has some adhesive on it. It worked great on my roof but smelled like tar and is designed to attach to a flat surface such as a roof and maybe not ceiling of your ride. So I have heard stories of it falling down when applied to ceiling.

Anyways, I believe it could work for sure on the floor and what not but the tar smell is what gets me. It may go away or not be prominent in colder climates but I live in the south so my fear is when it heats up to 100+ and add our humidity, it could stink pretty bad.

So I don't think I am going to use that stuff, just looking for the best alternative to dynamat at good price. So far Fatmat is looking like the best deal 100 sq ft w/ roller & tape for $150.

[daddyjeep]

I was looking around on the net a bit and came across this stuff. It seems to be pretty good stuff and the price is right.

http://www.lobucrod.com/index.html

[NastyBuzzard]

I found that... It isn't like any of the other stuff. It is actually like the insulation I used for the roof of my shop. It is a material filled with tiny bubbles. I am choosing not to use it because you have to use spray glue adhesive to make it stick. So for the price, the Fat mat is a better deal b/c of the adhesive backing it already has.

That's like my opinion though.

[NastyBuzzard]

So I guess I got lucky again. This vacuum pump was included in the parts I bought. It has an engine speed sensor on it I can use for the tach. My buddy tells my I could have just used the crank sensor for the 6.5 but this could work too.



Only problem is I can't find a plug for it in the 83 harness and I am sure I will have to do more than just plug it up to get a tach signal.

[83GMCK2500]

Originally Posted by NastyBuzzard

So I guess I got lucky again. This vacuum pump was included in the parts I bought. It has an engine speed sensor on it I can use for the tach. My buddy tells my I could have just used the crank sensor for the 6.5 but this could work too.



Only problem is I can't find a plug for it in the 83 harness and I am sure I will have to do more than just plug it up to get a tach signal.

That vac pump may be from a late late 6.2 out of a GMT-400 or even a 6.5. Never was diesel + tach in squarebody. I got an alternator with an R-terminal on it for my dad's '87 to get a tach signal.

[NastyBuzzard]

It was definitely in 6.2 squarebody from my research. Just most say was only in California trucks. Seems like a sought after piece to be able to run 4L80E.

http://www.dieselplace.com/forum/63-...sor-6-2-a.html

GM PN for it is 7849303, but is discontinued. So is the A1-Cardone reman as well.

Since I couldn't replace it I may run the tach from the crank sensor instead on the 6.5 since I am running mechanical IP. Not 100% sure yet.

[NastyBuzzard]

Few picture updates.

Starter bolt was broke off in block... Luckily it wasn't too much of a pain to remove.



Stamping on pistons?



Working on the TA a bit as well as spending time at my buddies shop helping build up the plasma table, for our future ventures.





The 6.5 is finally coming back together... Parts are trickling in. Oil pan and valve covers on using RTV.



Next weekend is my sons 3rd birthday so I doubt I will get much time to be in the shop.

[NastyBuzzard]

Saw a guy had a banks setup for sale but also had the gauges... Now I want a set of the banks gauges to complete my setup. Doubt I will find them though, he doesn't want to separate.



Here is the swing I built. I built it by myself on a rainy ass Saturday. Still got to go back to add the sandbox and slide.



This is what I am having to do to clear the top caliper bracket mount bolt for the brake swap on the drivers side. Not sure if I want to go this route or find a stud.

[83GMCK2500]

Originally Posted by NastyBuzzard

Saw a guy had a banks setup for sale but also had the gauges... Now I want a set of the banks gauges to complete my setup. Doubt I will find them though, he doesn't want to separate.

Call Banks. Last year my dad picked up a low mile 1987 V10 SWB with a 6.2/700R4 and with a couple phone calls he was able to have them piece together an entire turbo kit for it of NOS parts.

[NastyBuzzard]

Turbo finally arrived. Rebuilt like new!