Let's Build A 1 Ton Crew Cab 4x4

[NastyBuzzard]

Finally something worth posting! The bed is off!



Now I need to decide the best way to shorten the frame. Then I will be fixing a head gasket and swapping the Dana 60 under the front.

[NastyBuzzard]

I got it in the shop. Which was kind of a feat considering how nasty my driveway is.. I had to improvise with some 2x6's and what not but it is in.

PS fuel tank is off, DS is on its way. Hoods off and I am starting to take the front radiator core support off. I plan to swap in the 89-91 style while I am doing the front end swap and fixing the head gasket. I currently have a 89-91 Chevy grill but need a GMC one and maybe the wiring harness or at least pigtails.




Now I need to find the exact information on shortening the frame. I think it is 6" back from rear cab mount then 14" with the "Z" cut. Then a few inches off the rear of the frame.

Also need to decide if I am going dual 16 gal tanks or the k5 tank.

This is why I didn't get to make much progress..









I hate this ****tily done addition..

[deejaaa1]

starting on post 156, this is what scotts62 did:
http://67-72chevytrucks.com/vboard/s...=369443&page=7
might be an alternate instead of cut/weld.

[lgvl]

Not to get off topic but i couldn't help but notice the pitch of your roof. It's hard to tell from the pics but thats an awfully low pitch for shingles. 2.5" of rise per 12" of run is the minimum for shingles. It looks like you did a good job of installing the new shingles but wind and rain might find their way under them. Just my 2 cents.

BTW, the truck looks great, i'd love to convert my C30 some day.

Originally Posted by NastyBuzzard

I got it in the shop. Which was kind of a feat considering how nasty my driveway is.. I had to improvise with some 2x6's and what not but it is in.

PS fuel tank is off, DS is on its way. Hoods off and I am starting to take the front radiator core support off. I plan to swap in the 89-91 style while I am doing the front end swap and fixing the head gasket. I currently have a 89-91 Chevy grill but need a GMC one and maybe the wiring harness or at least pigtails.




Now I need to find the exact information on shortening the frame. I think it is 6" back from rear cab mount then 14" with the "Z" cut. Then a few inches off the rear of the frame.

Also need to decide if I am going dual 16 gal tanks or the k5 tank.

This is why I didn't get to make much progress..









I hate this ****tily done addition..

[deejaaa1]

later in the thread i asked him. he did end up cut/weld but said it rode good.

[NastyBuzzard]

So today I found some stuff of interest on craigslist. I never ever thought I would find a NV4500 for "cheap" but it is possible I just did. It is out of a 94 3500 chevy from behind a 6.5 TD. He wants $500 for it and $700 for the running 6.5 TD. They have like 120k miles. Before I spend the money which I really shouldn't do...

What options do I have for transfer case that would be cheap? I know the trans is hydraulic so what would I need for that? Also I guess I would need to find clutch pedal assembly somewhere. Any info I need before progressing?

[MTCK]

Search for DirtyLarry's NV4500 swap thread. Very comprehensive.

[deejaaa1]

that IS a good deal. need the clutch pedal switch also.

[NastyBuzzard]

I started to strip down the crew cab some to prepare for the work I have to do to swap to 4x4. Also it will make it easier to fix the head gasket.



Then I found one of the valve spring cup pieces that sit on top of the spring between it and the rocker had broken. I will need to fix that. I don't think any pieces made it into the engine, they were all sitting right beside the spring. Head has to come off anyways.



Next was to get my 4x4 components off the 78 4x4 crew frame. Time was limited so I just had to go borrow my dads cutting torch which ended up costing me $200 b/c he was out of acetylene and o2... It got the job done though.



Here is what is left.



Also while I was doing that I had my buddy trying to fix my driveway to the shop somewhat.



So stoked about the NV4500!! The 6.5TD fell through, not because of me but because the sellers boss sold it the night before and didn't even tell him.



I like this shot 2016 the year for manual swaps.



Hopefully I can get some more work done in the coming weekend. I need to get the th400 pulled and sold.

[y5mgisi]

Good progress!

[NastyBuzzard]

Thanks. It sucks the diesel fell through. I was ready to yank out all the tbi stuff and put it up for sale...

Now I guess I will get the NV4500 behind that 350TBI once I put a new head gasket on it and wait for my diesel.

I need to find:
The right clutch/brake pedals.
What bellhousing that will work that isn't expensive.
What xmember I need to work
A 32 spline NP208 or NP241...
Dana 60 locking hubs

[slotard]

I wonder if it's possible to run triple tanks (duals plus Blazer), might be nice in a truck that size.

[NastyBuzzard]

That would be a lot of damn fuel! My buddy has a 40 gal tank in his K5 blazer. I think it was from a diesel suburban maybe. This truck had 2-20gallons, but since I will be shortening it I will have to go to dual 16 gallons or just the standard K5 blazer tank.

Supposedly with the diesel I should be getting 20MPG so I don't think all that is necessary for this build. Although I may do an auxiliary tank beneath the tool box just in case.

[deejaaa1]

i carried a freightliner 100 gallon aluminum tank in the bed of the 96 for years. when fuel creeped up i took it out. i could go 3 weeks between fill ups.

[NastyBuzzard]

That is nice! At some point though the extra weight you are hauling negatively effects the MPG you could be getting so there is that.

[deejaaa1]

Originally Posted by NastyBuzzard

That is nice! At some point though the extra weight you are hauling negatively effects the MPG you could be getting so there is that.

true. i had removed the heavy bumpers so it was compared to only putting in half the fuel weight. i still plan to put in a 50 bed tank and install a short bed by moving spring perches.

[NastyBuzzard]

So I made a little bit of progress over the weekend. In total about 6 hours worth of work. A few on Friday and then some last night.

I need to sell the TH400



This 350TBI is in good shape & will have to do for a bit until I can find a good running 6.5 TD or rebuild the one I am picking up soon. Found out not only was the headgasket on the DS leaking at the rear but the passenger side had blowby as well across cylinder 4 & 6. I will be taking the heads to be checked. They were rebuilt heads, they had the heat sensors on them. Engine looks like a remanned one, rear main seal was even leak free.



I got the front hangars off the 2wd frame and started working on the sway bar and the front xmember.. Getting there.



Started stripping down the Dana 60 as well.



I need to order some parts.

Mainly the parts needed to attach dana 60 to front end & longer U bolts for my 4" lift springs.

Still need to find some Dana 60 locking hubs. I am trying to avoid getting real spendy on this build. As well as clutch pedals for hydraulic clutch and hydroboost brakes. Then I need to find a reasonably priced 32 spline transfer case!

[y5mgisi]

Maybe you can find a good used set of hubs on eBay? What all do you need to attach the 60 to the frame?

[NastyBuzzard]

Originally Posted by y5mgisi

Maybe you can find a good used set of hubs on eBay? What all do you need to attach the 60 to the frame?

I am hoping. I have been searching but they just are not cheap at all apparently.

Just to be able to attach it to the frame I need the front spring hangars. I was able to save the rear spring mount at the 2 links, they were fine. Need all new bushings though and new bolts. I need longer U bolts for the 4" lift springs I have as well. The original front springs were trash, ds was cracked then broken at the end and the ps side wasn't in the best shape either. I ended up using the torch on them anyways.

Then I need to fix the bent link, new tie rod ends, x over steering and on and on.

Most important part right now is to mount the actual thing to the frame. I need to get measurements of where to drill and everything. I can have the 2wd stuff off really quickly.

I am searching LMC right now. The front hangars off my 4x4 donor were rusted super thin.

[y5mgisi]

You should be able to find a set of front hangers on eBay. Or, you can always get the super awesome B52 front hanger kit from diy4x4.com. They are awesome and cheap. Bushings can be found for cheap. You can look them up on summit or Napa or whatever. Just look up front spring bushings for something like the k30 and it should ask if it has factory or aftermarket front Springs. It's been my experience that virtually all the aftermarket front Springs use the same bushings so that should be easy. As for u bolts, off road design sells them for $10 a piece. So those aren't too bad either.

[y5mgisi]

Oh Yea, and the bent link you are talking about. Is that the steering link? Cause that whole big long driver side link is what they call a tie rod end, so of you get a new left tie rod end, you will be good to go there. If your looking for shackles (which I think you are calling links) off road design and diy4x4 both sell some nice thick ones. If you're looking for original, back to eBay.

[y5mgisi]

Have you read mrk5s thread on ck5 about the 4x4 swap? It had some good need to know info. Mostly in regards to mounting the spring and shackle hangers. I'll find a link.

[NastyBuzzard]

Originally Posted by y5mgisi

You should be able to find a set of front hangers on eBay. Or, you can always get the super awesome B52 front hanger kit from diy4x4.com. They are awesome and cheap. Bushings can be found for cheap. You can look them up on summit or Napa or whatever. Just look up front spring bushings for something like the k30 and it should ask if it has factory or aftermarket front Springs. It's been my experience that virtually all the aftermarket front Springs use the same bushings so that should be easy. As for u bolts, off road design sells them for $10 a piece. So those aren't too bad either.

IDK if B52 kit is cheap.. I think its almost $200 shipped? I don't ever think I will do the B52 swap anyways. It is very doubtful but who knows.

I will check ebay for spring hangars again, maybe I wasn't searching the right thing before.

I should only need 3 of the u bolts, correct? I need to make sure right diameter and length though. Then I need 2 of those longer bolts for the passenger spring.

I want to get some stuff ordered this weekend.

If I had it my way it would have the front under it and be shortened this weekend.

[y5mgisi]

Have you checked out the off road design website? I think they have a description of the u bolts and the bolt bolts on there. I guess $200 isn't exactly cheap. And I knew you weren't going to do the 52 inch Springs but they can also be used with stock length Springs by using the further back holes.

[slotard]

I don't see why you have to swap out hangers, where is the significant difference?