Let's Build A 1 Ton Crew Cab 4x4

[NastyBuzzard]

Originally Posted by Honest Bob

Awesome work! I just finished reading through the entire thread.

I've been trying to research how to 4x4 swap a 2wd 1 ton and so much of the information out there is wrong or does not take into account the differences between the 1/2, 3/4 and 1 ton frames. Thanks for taking the time to document everything you've done its been an immense help.

Thank you!!!!!

You are absolutely correct about all the misinformation. I am so glad to help anyone through this. This kit I installed on my truck has now been installed on quite a few other trucks now to help them convert their 1 tons and crew cabs to 4wd!

[NastyBuzzard]

Trying to see all what I have for this build and figure up what is left to buy. Also noticed I have noticed I some how ended up with 2 boost gauges... I kind of would either like to find a RPM gauge that matches the 2 banks gauges or I guess find a pyrometer and RPM gauge to match the ISSPRO one.

[NastyBuzzard]

Finally got one of our aftermarket skid plates made for my truck! I really like this thing.

Also, wanted to show off my partners 4-linked & bag swap. Its really coming together.

[daddyjeep]

You are correct... That 4 link set up is looking good. The fancy link bars aren't for me, but I can appreciate the work involved. I can't wait to link and bag mine. That will be a fun project.

[NastyBuzzard]

Glad you like it! Yeah the link bars are mostly just for show and since we have a plasma table we wanted to cut them out and make them look cool.

[daddyjeep]

Originally Posted by NastyBuzzard

Glad you like it! Yeah the link bars are mostly just for show and since we have a plasma table we wanted to cut them out and make them look cool.

It makes sense to showcase the kind of work you can do. Regular boring round tube links aren't going to get much attention. A lot of people won't notice the link brackets and stuff, but those bars will get their attention and draw them in.

[NastyBuzzard]

A few photo updates. I finally had to go snatch back all my parts from my painter. 3 years it spent in paint jail with nearly no progress. I am getting back on track now. The photo with primer is how it is sitting at the moment.

[daddyjeep]

Glad to see you back at it

[lunatic1968]

Nice ride! sorry to hear about your stint in Paint Prison . So whats the plan?

[NastyBuzzard]

I have found someone else to paint it. We are making decent progress. It will be all black with several coats of clear so I can maintain the finish for several years with paint correction and coating.

So far sticking with the 6.5 diesel with the banks turbo setup and NV4500. I have a spare LB7 duramax I am about to start rebuilding that may end up in it if I can find a way to mate it to the NV4500 or find a good enough deal on a ZF6.

I'm also currently building a new house so I'll have to prioritize it at the moment.

[WilliamFd55]

I remember this beast. Good to see you are back at it!

[NastyBuzzard]

One thing I noticed from the side view was that my silver tank stuck out like a sore thumb but also I realized that I did not have it mounted flat at all.

So I dropped it, took the mount out and a friend of mine came over and we devised a way to rework the factory suburban bracket to fit in my frame and mount it level. I also had to paint it black so maybe it would stick out less.

I also had an issue with my new tailgate and new hardware. I finally realized the issue when comparing it with the factory mount. Once I ground it down I was able to fit the new tailgate properly. Glad I am doing this now bc I rubbed some paint off the first go round.

I also am test fitting the bumper. I'm having to modify the end of my frame some more as well as chop up my new factory style brackets. I am still missing the inner DS bracket though because they are on back order so I cant finish the bumper modification. If anyone has one let me know a price please. Also, anyone ever modify the bumper to get rid of the round carriage bolt heads?

[daddyjeep]

I have seen guys just weld the carriage bolts to the bumper and grind off the head, but haven't done so myself.

[NastyBuzzard]

I got the newly modified front tank mounting bracket installed. I'm waiting on the tank insulation to arrive before reinstalling it.

I even played around and put the fuel door on. I'm really liking how it turned out.

Next I started working on the tailgate band. I originally wasn't planning to run one so I ordered a new tailgate without holes. Now I am considering whether to double side tape it or add the holes. Luckily someone on a Facebook group was nice enough to go measure their gate and give me dimensions.

I took it apart to fix the dents and weld the holes. It will be blacked out with the rest of the truck.

I also saw a picture of these very interesting door panels but no one knew who made them. Anyone seen these in a thread before?

[NastyBuzzard]

I'm in love with these LS-Fab billet anodized door handles.

[evan]

Thanks for pointing out the tailgate hardware issue. I'll keep an eye out for that.

Those billet handles look sweet. If you can afford 4 I should be able to afford 2, right...

[NastyBuzzard]

My painter is back in town and we are back at it. Spent a little time last night working through what the previous person did to fix the bed where it was dropped on the corner. Come to find out it was bondo city and didn't even need to be. I also found he reworked my original patch for the fuel door and did what I think to be a worse job. Just glad we are addressing it now.

Also, after a month or so my flush mount rear glass arrived! Now to store it somewhere safe until it is time to install.

[daddyjeep]

yikes.... that was a lot of bondo

[NastyBuzzard]

I built us a new house, sold the old one, then I built a new shop, sourced factory 4wd v30 frame and my body is still in paint jail. How the cycle continues!

[Wide Open]

Congrats!
Are you making the 4WD conversion pieces?

[NastyBuzzard]

I haven’t started back up because I’ve noticed several places make the parts now. I lack incentive to get back to making parts currently.

I was able to paint my factory V30 frame last weekend as well as the fish plates welded in since I shortened it.

Planning to swap axles under it for my birthday.

Any good options for new brake lines and fuel lines for a shortened crew cab? It will still be rocking the 6.5 diesel/NV4500/NP208 combo. Not sure if I’ll keep the disc brake converted rearend or swap to the spar AAM 11.5 I have that will need to be swapped to 4.10 gears.

[NastyBuzzard]

Anyone remember who used to sell a fixture for lifting front axles? It was made to go onto the tube around the pumpkin so you could lift from the center. I've searched with no luck.

I feel like it was offered by ORD or DIY4X. It was a fabricated item for the offset front pumpkin.