Let's Build A 1 Ton Crew Cab 4x4

[Flatpat]

I put High Country wheels on one of mine. Looked pretty good need 8x6.5 to 8x180 I used 1.5" all the way around but on a 4x4 I'd probably go 2.5" in the rear.

imag

[NastyBuzzard]

Those look amazing!! & Damn I am jealous of your yard! Those new model wheels fit the crew cab just fine. I really like my dodge 17s but I would love to step it up to 20" wheels or so but nothing too fancy. However, all $ right now has to go into getting it driveable.

[obijuan]

studs are nice to have for the ubolt plate instead of bolts because you get full thread engagement into the housing. for the knuckles, i wouldnt use anything but studs.

[mcmlxix]

wheel stud list from Dorman with all the specs
list
https://static.dormanproducts.com/do...Attributes.pdf

pictures and part numbers

http://www.billavista.com/tech/pdf_i...%20Catalog.pdf

[NastyBuzzard]

Very good info thank you.

[mcmlxix]

Originally Posted by NastyBuzzard

Very good info thank you.

Yeah. I made the mistake of reading the Pirate4x4 site and upgrading to 5/8 wheel studs in front.. OVERKILL for me and the level of abuse the Blazer will see. If I redo the front hubs I'll get some metric 14mm studs to match the late model rear end....

[NastyBuzzard]

Yeah I saw that and I agree 5/8 studs are insane overkill but I understand the mistakes of reading Pirate4x4 lol. All those beefy upgrades look tempting but I am not doing what most of them do to their vehicles.

Any reason you can see why we couldn't use the 610-194.1 wheel stud (drw 14bolt stud) instead of the 610-303 studs? The 194.1s wouldn't require drilling.

[NastyBuzzard]

I had a bolt break off in the PS knuckle. I tried to drill it and use an easy out but long story short I screwed up and drilled at an angle and it may be screwed up. Anyone have a spare PS knuckle I can buy? This blows.



I spent all day Saturday though finally wiring up a breaker box inside the shop as well as running wire for my lights, finally!! Those LEDs have been mounted for a year now and never been cut off. No more string lights, finally I can walk in and flip a switch for lights. I am working on doing outlets now.

From this.



To this.

[83GMCK2500]

That knuckle may yet be saveable. Not sure where your skills begin/end but I'd bet a competent person/shop could weld a nut to that broken piece and get it out, or set it up in a mill and get it out. Would probably have to put a stud in that hole, but I don't think that's an issue. If not, maybe hit up the big offroad forums like Pirate and find someone who upgraded to Dedenbear/Reid knuckles and has the stockers for sale.

NICE lighting. Always makes such a difference, being able to see what you're working on.

[obijuan]

I've got dodge and Chevrolet knuckles for sale as pairs if you decide to replace em

[NastyBuzzard]

I think the lighting makes a world of difference! Now if I can get some more outlets! So tired of all the drop cords.

I think it is salvageable too. I am going to try and weld and pull it out. We have a mill at work too I can try but we will have to see. I was just hoping to find another knuckle quick and cheap but no dice.

[mcmlxix]

I heli-coiled one of the holes on one of my knuckles... but the bolt came out ok...

Maybe just upgrade to some Reid Racing knuckles... only $600 for a pair....

[NastyBuzzard]

Yeah I wish! Can't do that during this initial build up. I am working on fixing that knuckle. I am rewiring my shop right now so trying to get my buddy to weld nut on so we can try and get it out of there.

However, I did have a guy contact me yesterday about selling me a full banks turbo setup w/injection pump (& lines), throttle cable, down pipe, exhaust manifolds, crossover pipe, intake, fuel filter housing, fuel pump and plate with oil return for the turbo, oil feed line, air filter housing, intake tube, wiring harness and instrument panel for about $1000 shipped.

Seems like a good deal.

Trying to figure out what else I would need if I was to buy it.

[NastyBuzzard]

Pics of the banks setup he has. Also is coming with extra battery trey as well and hydroboost.















His friend tore down the banks turbo for a rebuild yesterday. Still waiting a few parts but has it back together for the most part.

[COS399]

I had a 90 suburban with a 6.2 and the Banks Sidewinder turbo set up. I bought it with it already set up but in my opinion it wasn't worth the money they spent putting it on. Just my two cents.

[NastyBuzzard]

I'm not getting it for the power really. I mean I will be running 6.5 turbo for now regardless if it is banks or stock GM turbo. From what I see though the banks turbo should make more power than the stock GM turbo just won't spoil up as fast.

So that's my options unless a Cummins falls in my lap or better yet a duramax!

Still though, it should have the power indeed for a driver and hauler. That's all I need for the time being. That plus dependability and good fuel economy.

I definitely agree it isn't worth the list price but I'll be getting it and a lot more for about $1,000 shipped.

[Matt72blaze]

Hey Mr. Nastybuzzard,

I read through your build. I'm doing a 2wd to 4wd also but I'm way behind you. Any chance you'd share or sell the drawing for your awesome looking engine crossmember?

Thanks!
Matt

[83GMCK2500]

Originally Posted by NastyBuzzard

Pics of the banks setup he has. Also is coming with extra battery trey as well and hydroboost.

Revisiting this picture...I would suggest ditching those awful u-bolt clamps on the crossover and getting a set of the nice band clamps. There is VERY little clearance around those two and I scratched the crap out of the back of my hands on them. I know summit/jegs has them, I think http://www.mandrelbends.com/ was cheaper though.

I've got a couple pics from when I was working on my dad's truck, doing an 89-91 core support swap, if you wanted an assembled pic, what to look forward to. Note, Duramax style filter on the firewall.

[NastyBuzzard]

Awesome that there is some interest about the crossmember. I am currently on REV 002, have to make sure it all fits perfect. I will be selling the first run cheap to weed out any issues.

We are currently working on building plasma table to start making parts, so pretty much everything you've seen that I have made in this build will be available.

The end goal is an entire 4x4 conversion kit that I sell as a paperweight.

[NastyBuzzard]

Seller provided a video of the last time his diesel was running showing proof IP is in good shape and what not. Said the video was taken right before he started to strip it down.



Latest pic on the turbo rebuild.



I started to tear into my 6.5 a bit to begin preparations.



IP is off.



Also finally got started on putting the DANA 60 back together.







Was able to fix the knuckle, just need to run a tap through.

[83GMCK2500]

Originally Posted by NastyBuzzard

Was able to fix the knuckle, just need to run a tap through.

Love it when a plan comes together.

Remind me, please, I don't recall all the engine specs/plans. The Banks kit is obv. (is that ceracote on the snail? looks good!) are you going with a DB2 (stock or modified?), what block is that, heads? Other than the Banks, any upgrades?

[NastyBuzzard]

Nice to see interest!!! Yes it is ceracote, the builder is only charging $500 for the rebuild an the seller has agreed to pay half of the cost.

So far just stock DB2 IP, 506 (****ty block... ....) but it is what I have, stock 96 6.5 heads as far as I know.

So far no real upgrades besides exhaust and I will be running the good 6.5 intake. I plan to do more down the road including building an engine on the side. For now with all the $ I am putting into this thing I am just praying this engine will fire up and run at least until after I get the truck painted.

Any cheap upgrades to do before I put it all back together?

[83GMCK2500]

If you're using the filter that mounts to the intake I'd say an o-ring kit and larger fittings in the 6.5 FFM: http://walkingjdesigns.myshopify.com...feed-the-beast

Forum write-up on 6.5 FFM upgrades: http://www.thetruckstop.us/forum/thr...uel-to-ip.572/

You can actually upgrade to the nice big Donaldson filter and mount that the Duramaxes use, my Dad put one on his '87 V1500 w/6.2 + Banks. If you're not familiar with it, the filter has a water-in-fuel sensor on the bottom that will wire into the squarebody circuit. Bonus features include a priming button on the filter mount.

6.5 glowplug harness is prone to wearing out over time, not saying you need to buy this, you or someone you may know might have the sparky skillz to make one yourself: http://ptwiringsolutions.com/t/glow-plus-harnesses

If I remember correctly the factory 6.5 fuel system includes a lift pump which is a good unit and often added to 6.2s. Alternatively there are some nice relay kits with Walbro pumps here: http://leroydiesel.com/product-category/fuel-delivery/ <---really, all of that guy's stuff is pretty nice with quite a bit of research put into it. I follow that TTS forum that I linked above and that's where I found his stuff.

[NastyBuzzard]

Thank you! I'm starved for good 6.2/6.5 info! I am supposed to be getting entire wiring harness from the 6.2 donor including glow plug controller and the diesel instrument cluster.

I wasn't sure what lift pump I was gonna run but was thinking of running the 93 6.5 lift pump andnwiring it up some how.

So should I ditch the 6.2 fuel filter setup?

[deejaaa1]

TTS has a lot of good info on the 6.5 and still a few good members left.