Let's Build A 1 Ton Crew Cab 4x4

[NastyBuzzard]

Originally Posted by daddyjeep

I know that you are already done with the shackle on the rear of the springs, but maybe you should just revisit that instead of building the big drop brackets for the front. I have seen shackle hangers frenched into the frame before on LCG Jeeps so there is no reason you couldn't come up with something to fit your needs. Just food for thought.

What do you mean? What I am doing to the front is to fix the caster angle and shackle angle problem I have. It is what you have to do unless you plan on cutting tubes loose and rotating the hog head and welding them back. As far as I know anyways.

This is what another person did to fix the problem. He had bought the B-52 mounts and then come to find out his angles were all wrong so he dropped it down 3" to get his caster at 8deg which is what it is factory.

[NastyBuzzard]

Here is the mockup. I still have to weld it together. Doing this puts my spring pad at almost dead 0deg, which will put my caster angle back around 8 deg like it is supposed to be.



Now to get it all welded together, both sides installed and axle back under it.

I am so ready to be finished with chassis/suspension!

[COS399]

Looks good.

[NastyBuzzard]

Originally Posted by NastyBuzzard

I noticed my core support mount is a little funky and cocked... I need to fix that. Is it straight and flush with the frame like the pic above? I don't have any pictures of actual crew cab 4x4 81-87 mounting position. Edit. I found these pics from diesel rats thread.. Yeah I need to fix mine.

How he did it:



[/

How mine looks... Yeah I gotta fix that. I did model up those core support mounts so I can make me a new set if I need to, be more boxed like the b52 mounts on the first pic but I don't see that as a problem.



Another weekend with not a lot of progress...

I did score this hydr. SM465 bellhousing for $80 though! I see them sell for bookoos on ebay. I will hang on to it, I thought about modifying the NV4500 to accept this bellhousing but not sure yet.



I did build my new hitch though!! Fits perfect, needs welding finished up and paint.



I also started tinkering around with how the seats mount and all.. I really need to find an upholstery guy, I do not like the red.



I need to get the bed back off once more and finish drilling holes and clearance it for the fuel tank. Hopefully soon I can finally mount the gas tank for good. Finally found my spools of fuel line so I can finish up the plumbing for the fuel.



Hopefully I can finish up the 2x4to4x4 xmember this weekend and start getting some parts made up.

Oh yeah, I have been kind of searching for a banks or ats turbo setup for 6.2 in a square, I may go that route if I can find a set cheap enough. I am not sure which is better, stock 6.5 turbo or the banks/ats setup.

[bealaddison]

Did you end up going with crossover steering? If not, I would recommend it. You have most of the parts already...just swap a 2wd sector shaf tinto your 4x4 box and use the drop pitman arm you already have. Very nice upgrade for a lifted truck like this.

[NastyBuzzard]

No cross over for this truck. It should drive and handle just fine with the stock style steering setup, especially since this is for the highway. I currently have no reason to believe that xover is better for highway driving and I want to keep my sway bar. However, who knows what may happen down the road.

I am getting some parts prototyped for the crossmember! To keep costs down it is a no rush deal but shouldn't be too much longer. Hopefully this week. I am also kind of stuck until I can get the bed back off, been to scared to do it alone considering last time I went at it alone I ended up dropping it and wrecking a perfectly good long bed on my 87... Which I tried to crank up and move to the shop this weekend to start looking at putting the H3 brakes on the 1 ton and the damn fuel pump has died...

I did get a new welding cart which is worlds above what the old home made one was!!!



Waiting on my big spool adapter to come in for the welder and I may need to buy a new lead as well.

I have been working on my 04 crew cab... It scared the **** out of my on Tuesday. When I pulled into the driveway I heard knocking!!



After more investigation though it seems the bearings in the water pump died. So I yanked it Friday, parts should arrive for it today.

[daddyjeep]

My thought was....since you were worried about the additional height, I thought raising the rear of the spring would be better than lowering the front.

[NastyBuzzard]

Thanks COS!

Yeah I got what you meant about the rear of the spring. I just didn't want to have to cut the frame back there. I'm trying to do it like anyone else could. Plus my welding skills are limited so I'd have to get my friend to come over to weld in some extra support after it was notched out.

Got the drop downs welded up. A little cleanup work and they'll be ready to bolt on!

[NastyBuzzard]

Got her back on all fours!!



Front pinion is no longer pointing down!



It was time to come outside so I can wash and clean the frame and underside of the cab, firewall and floor inside the cab. I am going to paint them with summits chassis shield.

Any taller and she wouldn't have cleared.



Working on cleaning the frame. As well as cleaning up the shop while the truck is out.

It looks way to tall in this pic. To me is seems huge, I can't imagine another 2" of lift from 35" tires. I am thinking I will assemble as is and if its too tall after the fact then I will get some 2-2.5" lift springs for the front.



Here is a comparison from the old springs.



Few more shots to show the size.



Going to fix the gap when I get some grade 8 hardware and have to switch hardware back out. Right now all I had was some 5/16 bolts to put it all together.



Shackle angle is looking a hell of a lot better. Once the full weight is on it, it should be where it is supposed to be.

[68Timber]

Looking good. The diesel weight might bring it down to a more desirable height.

[NastyBuzzard]

Yeah I am thinking so. With it and the front clip should bring it down a good bit, and the springs are new so they should settle some. So we will see. That is why I am in no rush to just buy a new set of 2" lift springs. Then again, 35" tires will lift it another 2" so that will put it back close to where it is already.

Don't get me wrong I love lifted trucks, but I wanted this to be a driver and hauler. More so than just a jacked up truck. I don't even plan on running mud terrains.

[daddyjeep]

The shop looks much better. I wish I could clean mine up. I have three cars to finish and get out of there before I can really get mine organized...darn kids.

The paint came out real nice too.

Brake and fuel lined should be pretty straight forward. One thing I found with mine was that the rear brake line was 1/4" from the proportioning valve to the rear axle and then split into 3/16".

[NastyBuzzard]

Originally Posted by daddyjeep

The shop looks much better. I wish I could clean mine up. I have three cars to finish and get out of there before I can really get mine organized...darn kids.

The paint came out real nice too.

Brake and fuel lined should be pretty straight forward. One thing I found with mine was that the rear brake line was 1/4" from the proportioning valve to the rear axle and then split into 3/16".

Thank you! Still has a long way to go! I have another 2 storage sheds that I need to fill up once I clean them up a bit. So a lot of stuff will be moving out.

I have the brake lines on the axle, they go up to the line that used to go to the load valve that used to be on the truck. The one that was supposed to increase braking in rear depending on load. I heard they didn't work worth a crap anyway so I chunked it.

I just don't want to use the cheap autozone type lines bc I have tried in the past and they either split all to hell when I flared them or rusted so dang fast.

I want some good fuel line that will last the test of time as well but not stainless, that **** is so hard to flare. I could use hose I guess? Diesel is low pressure, I am used to LS stuff that is like 60 psi.

[daddyjeep]

Napa sells that NiCop (Nickel/Copper)stuff that is supposed to be pretty good stuff. I haven't tried it yet myself, but it might be something to look in to.

[NastyBuzzard]

I see they sell it on Amazon as well so that may be the route I go. That and stainless fittings. I just need to know sizes.

[daddyjeep]

Hopefully someone can help with fitting sizes. I have a bunch of fittings laying around so I just found some that fit. I use brake line to build the chassis for our R/C Rock crawlers and since I like to use straight pieces I get spare fittings.

[NastyBuzzard]

Only assorted stainless fitting set I have seen so far was on summit and it was $140 for a box of them. Granted, it had a lot of fittings in it but I only really need 10 or so. I have to keep cost in mind but another good thing about stainless fittings is they don't round off so dang easy.

[NastyBuzzard]

Finished painting the rear drums and installed the fuel tank.




Then I realized I will have to probably drop the tank again to swap out for grade 8 hdw on the drop perches.

I will also be needing to fix my sway bar mounting for the lift. I don't like just the drop brackets. I am leaning more so towards the one that shift the pivot angle up. I don't need ones that are detachable either. I found the ones zone offroad sells but just seems like $60 shipped is high for what these items are.

What other products are out there? I may just look into making my own.

[NastyBuzzard]

I couldn't help it any longer. I had to put the bed on to see how it will look. My palms are bruised real nice from having to move it myself but its on! Front holes lined up perfect. As you can see I have a bit of a rake.







I had to drop down the tank to get the bed on. The bed was kind of smooshing it with how I had to get it on there by myself. I still plan to move the fuel door to the rear of the bed around same spot as a blazer or suburban. Now I can mark the extra holes I need to drill as well as rear bumper and hitch mock up.

[MTCK]

Nice work! You've been knocking this project out lately. Your rake isn't that bad I don't think. Maybe an inch or two. Remember to measure to the body crease, not the top of fender opening, because the front fender opening is taller.

[NastyBuzzard]

I am trying to get it back together! Slowly pecking away at it is what it feels like. I will measure the body crease. It should be around 1.5" or so difference but then again I still lack the weight up front. I will work on leveling it out when all the weight is on it.

Trying to see about rear bumper and hitch and other holes to mount bed and such now.



Also finally replaced that bent steering link, and working on getting other steering components on.

[Deer_hunter_088]

subscribed!!

[NastyBuzzard]

As much as I want this big tough bumper on the back. It just isn't looking right or as good as I'd hoped. This bumper is off my 87 V1500 longbed that I ls swapped.

May end up with the sport style or blazer, unsure.





Also... I wanted to use the tow hitch off the k30 crew cab.. Tried clearancing it for the drop down perches and all, I'd have to go back and fix it where it would be strong again but it's close to where it would be mounted and once again... It just doesn't look right hanging so low from the bumper. So I may use the k5 blazer hitch that is laying on the floor instead so it will tuck up closer to the bumper.




Also may be swapping out the 4x4 stock xmembers from the engine area. I'm going to try and modify this diy4x one for the engine then the other xmember I swapped back out for the 2wd one. I'll just have to find a good strong way to mount the sway bar back bc I want to use it.





I also cleaned the crap off the stock tbi fuel lines. I may be able to use them and just make whatever else I need. Just have to replace the filter for diesel filter and put lift pump in line somewhere.

I'm also going to clean off all the other oem brake lines I have so I can use them and just make ends for what's missing.

[daddyjeep]

Cool, it's looking like a truck now.

[jott_06]

On my suburban I kept the front 2wd crossmember in tact and built mounts for the sway bar off of it. I will try to get some pictures because I dont think I took any during the build.