68 GMC to a 2003 Tahoe chassis

[Dieselwrencher]

Looking good. Do you have any plans to cut the cab floor to lower the cab down over the frame or are you just planning on dropping the suspension to get it lower?

[75Dually]

Originally Posted by Dieselwrencher

Looking good. Do you have any plans to cut the cab floor to lower the cab down over the frame or are you just planning on dropping the suspension to get it lower?

This will primarly be a suspension drop. If I don't have to cut the cab I won't.

[75Dually]

Today I got some work done on the core support. My best friend was over and helped me work through most of the issues. He was a big help! We got the Tahoe core support all torn down and the front end cleaned up a bit.

What we discussed was possibly using the old 68 radiator and getting it fitted with a big block core and adding the necessary outlets to run all the LS stuff, but seeing the budget is tight (Thanks Santa!) right now I'm going to try and use the stock Tahoe radiator. BTW the 68 radiator has the exact outlets and in the correct location as the LS radiator. Thought that was cool! In the long run I will use the 68 radiator because it really cleans up everything under hood.

I went back out to the shop tonight after dinner and got the 68 core support sitting in there with the radiator, the AC, and the trans cooler just loosely sitting in their respective spots. I will have to fab up some mounts for each of them.

LST is now 61 days 11 hours 29 minutes 30 seconds away! I've got to hurry up and get this thing put together!

Stay tuned!

[thetucks]

Its starting to take shape now.

[75Dually]

Originally Posted by thetucks

Its starting to take shape now.

I was talking about your ride today to my best friend. I was telling him about all the firewall work you did and the other stuff you did on your ride. Going to steal all the ideas I can!

[thetucks]

Originally Posted by 75Dually

I was talking about your ride today to my best friend. I was telling him about all the firewall work you did and the other stuff you did on your ride. Going to steal all the ideas I can!

you are more than welcome. honestly if I do it again I dont think I will use the stock tahoe airbox. Thats why I had to mold in the tahoe firewall to the truck. Its a major pain in the you know what. On the plus side ive got a 1972 chevy truck with dual heat and air...

[75Dually]

Today was a layed back day. I did get the cab all squared on the frame and then started to mark and drill the location for the rear cab mounts. No pictures just yet, I mean they are just holes in the floor... The interesting part is going to be the new rear frame mounts that will meet up with the existing Tahoe body mounts. I think I have found a decent way to make the rear cab mounts. I hope to have some pics in the next couple of days.

Merry Christmas everyone! Be safe and let's make 2018 one of the best years ever!!

[Dieselwrencher]

Nice work on it! 58 or so days means you're going to be busting your hump on it!

[75Dually]

Originally Posted by Dieselwrencher

Nice work on it! 58 or so days means you're going to be busting your hump on it!

Yeah tell me about it! I told myself that all it has to do is roll up on the trailer so it can go to LST. I still have to finish the mounts for the cab, bed, the core support, front and rear bumpers, etc... Oh yeah and hopefully I can get to some of the suspension mods. I actually like having a deadline because it helps motivate me to get out there, concentrate, and get done what needs to get done. I use to do this for all the years we did the Power Tour. Man we built some fun stuff that went the distance. Spent a lot of sleepless nights right before we left too.

Git-r-done!

[75Dually]

I started on the rear body mounts this evening. This is the main portion that will be welded to the truck floor pan. It will have a couple of additional supports added before it is all said and done. All the up's and downs you see in this part match the profile of the floor pan. The tubing you see here is 2 1/2" with 1/8" wall.

Lots of getting up and down, card board, tape, and tons of measurements!

I should have a couple more pics once it gets final mounted and welded in.

This will all make sense once you see it in place and welded in.

Stay tuned!

[75Dually]

Today was a good day in the shop. I've been working on the rear end on the dually, now I have to change out the bearings, but at least the ring and pinion are in super shape.

On to the 68! I needed to drop the front core support and that meant that I had to cut the front sub frame. So I got all the little bits out of the way and cut at an angle the front sub frame. That way I could lower it however much I needed. I did cut the front Tahoe bumper mounts off so I can make way for the front frame horns off the 68 frame. That way I can mount the bumper without any hassle. I do have to wait to weld it back up until I get the cab mounting all finalized.

I did not take a picture of it but I cut the 2 Tahoe body mounts off that were on the front sub frame. I need to move them back about 4 inches and use them for the core support mounts. Again I have to wait until the cab is finalized before I can weld these mounts back up, but that should not be to long from now.

Stay tuned!

[79azc10]

This is going to be nice

[aggie91]

Nice job Chris. I thought I was already following along, but I guess I was not.

I'm all set up for LST, and plan on brining you an item that's in my shop!

[75Dually]

Originally Posted by 79azc10

This is going to be nice

I certainly hope so! Thanks for following along!

Originally Posted by aggie91

Nice job Chris. I thought I was already following along, but I guess I was not.

I'm all set up for LST, and plan on brining you an item that's in my shop!

It is going to be like a second Christmas! I'm looking forward to next month!! Thanks again for storing and picking that up for me again... I still owe you dinner!

[75Dually]

Tonight was about starting to clean up the firewall. I really need to remove the cab again on the 68, but the dually is in the way, and that won't be moving until I repair the diff. I got a lot of the lose wires, the choke cable, the old speedo cable, and a lot of odds and ends removed. I also got the heater assembly taken out too. I took an old circular wire brush in a drill and got a lot of the material removed. I was then going to use a flapper disc to remove the rest of the sealant that was left on the firewall (pic below), but I had enough dust tonight from all that and decided to call it a night.

One thing that I would like those guys reading this who have never done a project of this size to understand is that there are a million nasty jobs that those 30 minute shows never tell you about. The gunk that just won't come off the firewall with anything but an old wood chisel (true story, had to use an old wood chisel tonight to remove that old hard sealant between the blower box and the firewall. That stuff was flexible 25 years ago, and now was as hard as a rock!). I don't want to scare anyone off, but just make sure you don't lose heart when you have to get all those not so fun jobs done. I've seen a lot of guys, even pros, drop a project because it stopped being fun about forever ago. Keep that final vision in your mind, go get a rendering done of the final result, or bring over your buddy's to help keep you motivated. The first time you get to fire it up and go around the block is an over the moon feeling that you will never forget. Ok that is unless it pukes on the way home, but that is a different story....

Stay tuned!

[75Dually]

Just a short side note, tonight while I was working on the truck I wanted to take out the old door seals. Oh boy! At some time in it's history someone had glued the weather strips with what should only be described aggravation glue!! Every inch of these crusty, nasty, old dirty strips had this mega glue. What should have taken 10 minutes max, went on for over an hour. I mean really... Dude!

They are now off and ready to be cleaned up and the new seals installed in the near future. Man is nothing ever easy... This is my hobby, but man there are days!!

Stay tuned!

[Dieselwrencher]

I've had a few of those seals too. It sure is a PITA!

[75Dually]

Originally Posted by Dieselwrencher

I've had a few of those seals too. It sure is a PITA!

Word!

[Advanced Design]

Another cool build! I never realized a Tahoe chassis could work...tagging along for the rest.

[75Dually]

Originally Posted by Advanced Design

Another cool build! I never realized a Tahoe chassis could work...tagging along for the rest.

I've seen these done with the 4WD Tahoe chassis, some of them are really cool, but I have yet to see one finished that is 2WD. So lot's to learn, and lots of problems to solve. At least my wife knows where I hang out! The shop!!

[67Monster]

You keeping the ABS system or bypassing?

[75Dually]

Originally Posted by 67Monster

You keeping the ABS system or bypassing?

Keeping the ABS if at all possible.

[67Monster]

What major problems have you had to overcome so far? or can see will be a problem before you're finished?

[75Dually]

Originally Posted by 67Monster

What major problems have you had to overcome so far? or can see will be a problem before you're finished?

My 1st problem to overcome is the cab to frame mounting. What I want is the cab as low as possible on the frame without interfering with the components on the frame. For now that's my major hurdle. I'm sure there will be lots more but that's why I did this project was to find the hurdles and overcome them. I hope you like this project I know I do!

Stay tuned!

[67Monster]

Originally Posted by 75Dually

I hope you like this project I know I do!

Stay tuned!

Working on the same thing right now. 2003 Tahoe Z71, putting 68 C10 on it. 2006 LQ4 4l80e swap doing AWD. Most of my Tahoe was already butchered up, by people parting it out. I'd have to go back and get all new wiring harnesses for the ABS and other Tahoe perks. I was curious because I think I'll be bypassing my ABS system. I also purchased a set of coil over conversion mounts from atomicfabandperformance.com. Will be eliminating all of the torsion bar mess, especially since some of it has been unbolted, cut, etc. when they pulled everything out of it.

Thanks for the info. I am staying tuned.