Mike's 60 Suburban build

[piratexpress1369a]

now i understand its fuel injected ..i was blinded lol

[mikesacs]

Originally Posted by piratexpress1369a

now i understand its fuel injected ..i was blinded lol

Yes, diesel fuel injected.

When starting this project I wanted to get more than the typical 13ish MPG that I knew that I could build with a SBC. I wanted a burb that I wouldn't not drive because MPG sucked. I needed the power similar to a SBC, but am old enought to know I don't need a truck that can pull a track hoe through Colorado (or think I can). I read into low cubic inch SBC with turbo's and EFI and then looked at turbo 4 cyl diesels (4btswap.com) in either cummins or isuzu. I finally settled on the 6.2 with a Banks turbo with a 89 or newer block and 1 dot Riccardo combustion chambers and a 700r4.

The 6.2 was GMs answer to the 70's oil price problem. They made a fuel efficient diesel starting in 82. The sticker highway MPG was 23 MPG for a 1/2 ton truck. It got a bad rap because the early blocks were prone to crack at the main bearing web. GM reinforced that starting in 89. It also is often compared to other diesels which are built for power like the Cummins. The 6.2 was never ment to tow a 8,000 lbs motor home. Not a fair comparison. Just like the Cummins was never ment to get 23 MPG sticker. It was designed to compete with the small block chevy and nearly double the MPG of a small block chevy. GM dealers started offering Banks Turbo's installed on the 6.2 as a dealer option and GM even adopted the Banks in 93 (I think) for factory trucks. My research for a high MPG engine that could move this burb well and tow 4 to 5,000 lbs occasionally is why I chose this engine.

I know my burb is heavier than the 1/2 ton truck and probably has poorer aerodynamics, but my goal is to still get MPG in the low 20's.

[piratexpress1369a]

Originally Posted by mikesacs

Yes, diesel fuel injected.

When starting this project I wanted to get more than the typical 13ish MPG that I knew that I could build with a SBC. I wanted a burb that I wouldn't not drive because MPG sucked. I needed the power similar to a SBC, but am old enought to know I don't need a truck that can pull a track hoe through Colorado (or think I can). I read into low cubic inch SBC with turbo's and EFI and then looked at turbo 4 cyl diesels (4btswap.com) in either cummins or isuzu. I finally settled on the 6.2 with a Banks turbo with a 89 or newer block and 1 dot Riccardo combustion chambers and a 700r4.

The 6.2 was GMs answer to the 70's oil price problem. They made a fuel efficient diesel starting in 82. The sticker highway MPG was 23 MPG for a 1/2 ton truck. It got a bad rap because the early blocks were prone to crack at the main bearing web. GM reinforced that starting in 89. It also is often compared to other diesels which are built for power like the Cummins. The 6.2 was never ment to tow a 8,000 lbs motor home. Not a fair comparison. Just like the Cummins was never ment to get 23 MPG sticker. It was designed to compete with the small block chevy and nearly double the MPG of a small block chevy. GM dealers started offering Banks Turbo's installed on the 6.2 as a dealer option and GM even adopted the Banks in 93 (I think) for factory trucks. My research for a high MPG engine that could move this burb well and tow 4 to 5,000 lbs occasionally is why I chose this engine.

I know my burb is heavier than the 1/2 ton truck and probably has poorer aerodynamics, but my goal is to still get MPG in the low 20's.

cool .i would like to get a diesel also for my panel.

[piratexpress1369a]

looks good ..have you fired it up yet?

[mikesacs]

Originally Posted by piratexpress1369a

looks good ..have you fired it up yet?

I'm lacking radiator and fluids to start it. The radiator has oil cooler and trans cooler inside. I also have bumper, hood, flexplate cover, and some misc. I might get to work on it in the evenings this week to have it running by the weekend. Can't wait to hear it run!

[mikesacs]

Radiator and fans are mounted. Started on the oil cooler hoses. It's the first time I've used real braided hose. Aeroquip is the product. The ends are a bolt together reusable compression fit. High quality stuff.

[gostranger]

i cant wait untill it is fired up could you do a vidieo!! so we could hear it!!??
by the way nice job on the build!!

[mikesacs]

Originally Posted by gostranger

i cant wait untill it is fired up could you do a vidieo!! so we could hear it!!??
by the way nice job on the build!!

Thanks, I'll try a video. I haven't tried to post one of those yet. I wonder if it loads just like a picture.

[gostranger]

i am not sure how to load vidieos i think you have to post them on youtube then link themto here but i would love to hear that motor when it gets running i think it will be awsome!

[piratexpress1369a]

how loud is it in the cab when its running

[mikesacs]

It's quieter in the cab than my 62 p/u with a small block 400. I think it also quieter than the old 6cyl with turbo mufflers that came out of the suburban. Right now I don't even have a firewall pad. I'll add the firewall pad and something under the rubber floor mat in the future. I do have a dB meter that I could take some readings on to have a real comparison between a few vehicles. You can definitely have a conversation with the passenger. It seems like the diesels avoid some of the noise due to the lower rpm that they run.

[mikesacs]

Ordered some 3.73 ring and pinion gears. Need to change the existing 4.11s. A note came with the US Gears that said they are noisy. Didn't know that when I ordered them. I'll return those gears and either get OEM or Yukon gears, whichever is quieter. If I can find that out. I plan on doing my first reared in a few weeks.

I just got my B&M torque convertor lockup working. I had to replace the brake light switch with a Honda switch that had 4 connections, a normally open and a normally closed. One was needed for the brake light circuit (NO) and the other was needed to disengage the lockup (NC). Works great now, crappy instructions.
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[mikesacs]

Removed the cover on my 14 bolt rear differential. Can anyone tell me if this is a posi or an open carrier? From what I can tell, they both look similar on the 14 bolt. It's not obvious like other rear ends.

[mikesacs]

My carrier turned out to be an open one. I ordered an Eaton posi, 3.73 ring and pinion, and bearing kit all from thegearshop.net. Returned the noisy gears. Been driving it a lot lately and really like it. Can't wait to get the rear end changed to the 3.73 for some highway driving.

I need to do something with the front leaf springs. They are the stock 2 leaf and bent below flat about an inch. I did add about 200 pounds to the front with this engine. I found some 1400 lb springs (200 over stock) that show a 1 1/8" arch. Does that mean my front end will be 2 1/8" taller than it is now? The truck is 2 1/2 lower in the front than the rear currently.

[Zane M]

Great build.

[mikesacs]

Spent Saturday working on the rear end. Changed the ring and pinion from 4.10 to 3.73. This put the diesel RPMs where they should be. It took about 6 hours of work and this was my first one. It is a 14 bolt 10.5" full floating axle. I replaced the open carrier with a Eaton posi unit. Drove it for 170 miles so far without any noise or problems. The backlash ended up being .007 after about 4 times changing the pinion shims and the pinion preload is at 35 inch pounds. I've heard that the 14 bolt is one of the easiest to set up.

My front is a Dana 44 8.5" with 4wd hubs, brakes, and axle u-joints to deal with that I didn't on the rear. I think that will be a two day job. I'll tackle that job in a month or so, before 4x4 season.

[mikesacs]

Been doing some driving and mileage calculations. These are all based on about one tank of fuel each and the engine and rear end are not broke in yet.
16 mpg when the rear end was 4.10 with mixed driving
18 mpg mixed driving with the new 3.73 rear end
19 mpg at 70 to 75 mph interstate
20 mpg at 60 mph highway

They should get slightly better as the parts break in and I keep fixing things. Overall I'm happy with the milage.
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[mikesacs]

Finally picked up an original bumper for the suburban. The one it came with looked awful. Spent about 2 hours on the press trying to get some of the dents and bends out of it. Built a trailer hitch that fit between the frame rails.

[Bigffjoe]

Nice and clean, looks Great!

[piratexpress1369a]

nice work getting the dents out

[mikesacs]

Removed the seats and economy heater box. Painted the floor and firewall with POR-15 and then installed the Fat Mat. I have jute padding and a new firewall pad next. After that I install the new A/C evaporator and heater under the dash. The new floor mat will be last.

[piratexpress1369a]

the por-15 easy to work with ..brushed or spray

[Bigffjoe]

That looks like nice floor cover, what did you put down and where did you get it?

[mikesacs]

Originally Posted by Bigffjoe

That looks like nice floor cover, what did you put down and where did you get it?

I brushed on the POR-15 then applied Fatmat Rattle Trap. That's the reflective stuff. Then a 1/2" layer of jute padding then the floor mat. I found the mat on another thread http://67-72chevytrucks.com/vboard/s...d.php?t=529854
From www.stockinteriors.com
It didn't lay as well at the upper hump as the guys in the thread have. I'm hoping that it will lay better when summer rolls around.

You can also see the new vents for the A/C unit in the photos.

[jmack91z28]

This is a great build. Where is the rest of it?

Any update on how the 6.2 is holding up? Fuel mileage reports?