75 Dually build

[75Dually]

Originally Posted by COS399

Looking good. My 88 still has the chevy 454 heavy duty radiator in it and the second gen intercooler. I can PM you some pictures if you want to look at it. I had Ken, at Autoworld, install it about 14 years ago. He did have to cut the two tubes, rotate them 180 degrees and weld them back together to make it work. Keep us posted and hope to see it in person next time I pass through Lubbock.

Yeah man post a pic of it! I would like to see it.

[75Dually]

The transmission mount is done and in the vehicle!!!

Now on to the motor mounts. I knew I had to get the trans mount finished and the trans located perfectly in the middle of the frame before I started to mock up the motor mounts. So after the trans mount was installed I got out my lasers and levels and got the engine all centered and leveled. I then made a card board template and used it to cut out all the plate this evening.

Tomorrow (or sometime this weekend) I will get the mounts all tacked in, double and triple check all my measurements, and then finish weld everything.

I really like these fun parts of the build process. My list is getting shorter and shorter! Yeah right!!

Stay tuned!

[75Dually]

Started on the engine mounts this evening. Rough cut the supports out last night, and tonight I drilled the through holes for the mounting bolt. What you see here is just a very rough mock up. Tomorrow I will weld it all up and put in a cross brace between the two supports. I will also cut the main mounting plate to the correct size too. Then all that's left is to clean it all up and make it pretty!

Stay tuned!

[75Dually]

The Cummins motor mounts are done!

Man I am so glad those are done and now even painted. Time to yank the engine out and get everything bolted up and paint the engine. Then it is back in for the final time (I hope!).

Now I can move on to getting the intercooler/radiator package figured out.

Stay tuned!

[aboesec10]

nice work man!

[75Dually]

I know you're probably tired of seeing engine photos, but it is now sitting fully on the new mounts. For a DIY guy like myself this is a major milestone! Oh yeah and it's perfectly level, and right on the centerline!!

Can't ask for more than that!

Stay tuned!

[Palf70Step]

Very nice. Just a couple hoses and you're ready to go.

[75Dually]

Originally Posted by Palf70Step

Very nice. Just a couple hoses and you're ready to go.

Exactly!

...and a turbo, radiator, electric fans, fuel lines (both supply and return), power steering lines, drive shaft shortening, York, York mount, AC compressor notch cut out, AC compressor, throttle cable, transmission cables, transmission cooling lines, transmission electrical, transmission shifter, run new exhaust, rewire engine bay, heater hoses, mount intercooler, intercooler tubing....

LOL!!! Yeah just a couple of hoses!!! (this made my day!)

Ug! Death by 1000 cuts!!

[75Dually]

There are always important parts to any build. This pulley is one of them. In many ways it was a show stopper if I could not find one. For those of you who do not know this is the pulley you attach in place of the stock alternator pulley and it allows you to run a York pump and the stock serpentine drive belt.

You will see some more photos coming up as I build the mount for the York and the pulley system to drive it. Stay tuned for that.

If I was unable to find this part I would of had to use electric Viair's or something similar. Not that I don't like them but if you have ever had a York pump verses the old electric pumps you would never go back to the electrics. They just take too long and you really need a lot of juice to run them too. So for me that was a no go. However I will run an electric pump as an emergency backup.

I highly recommend you check out the guys at C U Offroad. They now own the old Kibly Enterprises company. They will have what you need if you want to run something similar to my setup. Their website is: https://www.cuoffroad.com/ and the pulley's are under the Air Boss product line.

I hope this helps you out if you plan on doing this in the future!

Stay tuned!

[aggie91]

you left off something on you list of stuff that needs to be done.

The insides of the front fenders really need to be painted. Maybe a satin black to make it easy on you...

[daddyjeep]

I have a feeling he left about a dozen little things off his list.

[75Dually]

Originally Posted by aggie91

you left off something on you list of stuff that needs to be done.

The insides of the front fenders really need to be painted. Maybe a satin black to make it easy on you...

I need inner fences too... Add one more to the list!

Originally Posted by daddyjeep

I have a feeling he left about a dozen little things off his list.

Try 2 or 3 dozen... Again death by 1000 cuts!

[COS399]

Sorry it has taken a few days but here are the pics of my intercooler and radiator set up in my 88. He may have had to resize the lower radiator hose. As you can tell the intercooler is inverted and the inlet and outlet come through the air holes punched into the radiator core support. It's hard to see but the inlet and outlet tubes were cut where they are chocked down and welded back 180 degrees from their original position so that you can clear the radiator. Hope this helps.

[75Dually]

Originally Posted by COS399

Sorry it has taken a few days but here are the pics of my intercooler and radiator set up in my 88. He may have had to resize the lower radiator hose. As you can tell the intercooler is inverted and the inlet and outlet come through the air holes punched into the radiator core support. It's hard to see but the inlet and outlet tubes were cut where they are chocked down and welded back 180 degrees from their original position so that you can clear the radiator. Hope this helps.

Thanks so much for the pictures!

A couple of questions: 1. What intercooler did you use? 2. What radiator did you use?

Thanks again!

[COS399]

A couple of questions: 1. What intercooler did you use? 2. What radiator did you use?

The intercooler is from the 1994-2000ish models but there seems to be a small variation in the height so verify that it will fit in your core support first.

The radiator is the four core that I bought back in 1996 and it was the same size that it replaced.

Keep up the good work and keep us posted.

[3757chevy]

That's true, 1 thing always leads to another.

[COS399]

A couple of questions: 1. What intercooler did you use? 2. What radiator did you use?

The intercooler is from a 1994-2000ish. For some reason there is a height difference between this models so you need to verify the height to ensure it fits in you core support.

The radiator is the factory four core radiator.

Hope this answers your question.

[75Dually]

Intercoolers are cool! The gen 1 unit from the donor fits perfectly under the grille. Still need to make the top mount, but that's for another day.

I also got the Dodge radiator fit tonight too. I have started the mock up on the electric fans. I just need to make the additional shrouds and make the mounts. Sounds like a 10 minute job right! Oh I wish....

Stay tuned!

[75Dually]

Today was a parts running day, mostly... Actually this is more about how this hobby is having good friends help you with your projects, and meeting new friends along the way. Some of my best friends are "car" or "truck" guys. They just get it, and they seem to go out of their way to help people who have the same passion.

Here is how today went. I started out the day going into the shop and pulling the transmission fittings off the trans so I could make hard lines. I went to Napa and saw my buddy Scott (he is a legend!) and we went back into the warehouse and found a reel of 3/8" hard line. I asked Scott how I was going to make this hard line into a straight line? Well the roller straightener, duh! We go further back into the warehouse where the tool benches are for hydraulics, and he hands me the roller straightener, and says bring it back when I finished. They rarely use it but just Wow! (see below pic of tubing and tool) So while I'm checking out I ask Scott who he knows that has used 4" exhaust tubing (yeah I'm a cheap DIY guy and don't like buying overpriced kits) He gives me a name and a number for a guy just north of town.

Enter Benny and his amazing truck bone yard. Now before I tell you about Benny, I did make a stop before this at a friends shop where he had a 4" straight pipe DEF delete kit he wanted rid of. (pic below). I got it for next to nothing, and he was happy it went out of his junk pile, score! Now back to Benny. I called Benny and asked him if he had any 4" mufflers for sale, yes sir he said come out to the yard and I could poke around and see what he had. Now for those of you who like junk yards, and especially old truck bone yards this was a cool place. However his place is not clean and neat like most of the salvage yards today, nope this was an old school yard, less the junk yard dog though... Benny and I found the perfect specimen and he and his hired hand pulled it for me. Benny BTW is around 85 or slightly older, they will never make guys like him ever again. The cool thing is we sat on the tail gate and swapped stories for quite a while, and I made a new friend. When a junk yard guy from around here says you are welcome anytime and to come back soon, you have made a great bud.

Now why am I including this in my blog? Because this is the best hobby I know. Not only do you get to use cool tools and make cool stuff, but you get to meet folks that make this land great. I don't get why some guys get all wrapped up in shows to the point that they forget to keep it fun. Your only going to get a plastic trophy that is going to collect dust somewhere in your shop or garage. Guys like Benny and Scott are what keep me going. They are the cool part of this hobby. Like Ronnie on C10 talk says "The trucks are cool, but the people are cooler!" Remember to go help a friend out this weekend. You will never regret the time spent hanging out and making cool stuff.

Stay tuned!

[daddyjeep]

Well said sir. I went the other way myself over the weekend. Instead of hanging out with an old school car guy, I helped a kid work through some issues on his truck.

[Dieselwrencher]

Nice scores on the parts! Nice to hear ya made a new pal especially one with good parts. Does he have any old heavy trucks he will sell? (I need another project like I need another hole in my head)

[75Dually]

Originally Posted by Dieselwrencher

Nice scores on the parts! Nice to hear ya made a new pal especially one with good parts. Does he have any old heavy trucks he will sell? (I need another project like I need another hole in my head)

If you got another project and I was to blame then both of us would be in deep trouble! LOL!

[75Dually]

I have been really busy on the truck lately. I have pulled the engine back out and been prepping it for paint and all the dozens of other items that still need to be done, but I am making progress.

For instance today I got the throttle cable assembly out of the donor and have it ready to go into the truck. I have all the power steering from the truck ready to be bolted up to the Cummins. I now have the 4" down pipe mounted and ready for the muffler to be bolted up. The transmission and the torque converter are finally bolted correctly to the engine. etc... Yup this and about 100 other small items I have been checking off my list. Oh yeah and I got the new injectors installed last night along with the return line.

So the part you see below is one of 3 new transmission cooler mounts I made today. I have decided that I am going to run 2 coolers, the first unit will have a thermostatically controlled fan, and the second unit is an older cooler I have had for a long time and decided that it will be out in open flowing air. Just a bit of insurance to keep this beast as cool as possible. The mount is actually upside down in the pic (the paint was not 100% dry yet). The short portion of the mount will be bolted to the frame, and the long part will have the cooler mounted to it underneath the truck close to the transmission. I will be running steel hard lines from the trans to both of the coolers. I will run the line first into the cooler with the fan, and then into cooler #2, then back into the trans. I will post some pics once I get everything finalized.

Stay tuned!

[75Dually]

So I went back out to the shop tonight to mock up the transmission coolers. The bench by the way is a prized possession of mine. My son built it in wood shop in high school. He and his buddies built a couple of them but I got his first one. OK back to the coolers... The coolers are just laid flat on the bench but under the car they will be angled so as to get the most air movement possible. I will run some small supports between the fan cooled unit to the middle support once I find the right angle to mount them. I will also make some ducting for the large unit, but again I will have to see how it all fits first and will also need to keep it out of possible damage.

If your more confused now, well just hold on and hopefully the pics of it under the truck will do it justice.

Stay tuned!

[75Dually]

The twin fans for the radiator are done! Now just to mount it tomorrow and I can check this off my list! The sheet metal after it was painted was then pop riveted and then the back side glued together, that should make it a very solid assembly.

Stay tuned!