Project: 1972 502 HO 4x4 Suburban

[k5kev]

Well I actually started this project a couple years ago, but I thought I'd go ahead and start a project thread for it. I'll get you all up to speed where it is now and then start posting as I make more progress.

Started out with a 1972 3/4 ton 2wd Suburban. This is what it looked like just before I drove it to the body shop. I stripped it down about as far as I could and still be able to legally drive it down to the shop.






Instead of converting the 2wd chassis to 4wd, I bought a 4x4 truck frame and started building a 4x4 suburban chassis from there. This is the way to go when coverting to 4x4, especially since I was pulling the body off anyway. I put on 4" Tuff Country springs, a Dana 60 front, and a 14 bolt detroit locked rear.



More to follow........

[1956cameo]

Looks like an awesome project. Glad you got a good foundation to begin with. Definately keep us posted on this build. Not enough blazer and suburban builds on here for my taste.

Also I noticed all of the patch panels in the back of the suburban. Your project doesnt seem rusty; it really needs all of those panels replaced?

[thirdstreettito]

Nice project!

[k5kev]

Originally Posted by 1956cameo

Looks like an awesome project. Glad you got a good foundation to begin with. Definately keep us posted on this build. Not enough blazer and suburban builds on here for my taste.

Also I noticed all of the patch panels in the back of the suburban. Your project doesnt seem rusty; it really needs all of those panels replaced?

Yep, those are the patch panels I knew I needed before sandblasting it. It needed the normal 72 Chevy stuff: rockers, floors, front pillar, and kick panel patches,..... on both pass and driver side. Otherwise the rest of the body looked great.

As you'll see later I ended up needing even more patch panels after sandblasting!

[k5kev]

So then I drove the Burb to the body shop, were the pulled the body off the frame and took the front end off and apart.

Also had them build a tube steel dolly so the could move the body around and trailer it down to the sand blaster.

Here is the 2wd rolling chassis I've since parted out and/or scrapped.

[k5kev]

I'll continue on with the body,....

So the body went of to the sandblaster, and here is what she looked like when she came back,...along with some self-etching primer.

Firewall and interior looked pretty good, except the rockers and floors of course!





Passenger side looked awesome.



Roof looked real good.




And last but not least the drivers side was a mess!



By the way those are new door skins on both doors.

[1956cameo]

Don't you hate it when you find more body damage after the paint comes off? Still; from what I can see that is a great looking project suburban. Can't wait to see more progress of it. Quick question, when you took the upper chrome moulding off of the suburban. How did you get it off of the upper tailgate hatch. I cant see where it bolts in. Was it a glue on piece? Thanks.

[k5kev]

Originally Posted by 1956cameo

Don't you hate it when you find more body damage after the paint comes off? Still; from what I can see that is a great looking project suburban. Can't wait to see more progress of it. Quick question, when you took the upper chrome moulding off of the suburban. How did you get it off of the upper tailgate hatch. I cant see where it bolts in. Was it a glue on piece? Thanks.

If I'm remembering correctly all the upper molding on mine, including the hatch, was just pressed in. No glue anywhere. I just pulled off the molding, which I didn't worry about saving since I wasn't going to re-use it. Most of the time the molding clips snapped off and just left a little pin in the body which I pulled out with some needle nose pliers.

[k5kev]

Next, my paint & body guy prepped and painted the roof. I used the original white color, PPG 2185 White.



Then he shot the bottom with undercoating. I used the existing plywood floor. I thought it was in okay shape and I didn't want to invest the extra time and money to put in new wood. Hopefully that works out for me in the long run.





Before we dropped the body on the chassis he shot the firewall with some paint. The blue paint is PPG 19220 Riviera Blue, from 1996 Porsche.

[Hart_Rod]

Burbs rock!!!!!

[k5kev]

A few more pics of the Burb at this point of the project:

[ChaseDale3and8]

Great looking project! I really like that shade of blue on these trucks! ...Joe

[k5kev]

So now for the difficult body work. Here is the damage again on the driver's side,....pretty nasty. You may also see some of the layout lines for the patch panels. We are attempting to "Frankenstien" this side together with 4 patch panels. A long bed lower front quarter, a shortbed bedside, a lower rear Suburban quarter, and a Suburban tail light section.

[k5kev]

We wanted to get the body bolted to the frame before we started cutting sheet metal. Probably a good idea just so the body doesn't twist up or loose its shape. If we tried cutting it up on the dolly who knows what may have happened. So with the body bolted up he started cutting:

[k5kev]

Before I could get back to the body shop my guy already had the bedside patched welded up. I think it turned out pretty good.

[k5kev]

Then he buttoned up the lower rear quarter and tail light section:








and that's where its at right now. I dropped this thing off at the body shop a year ago. Its been a slow go, but hopefully six more months and I get it back with all the paint done. We'll see

[MrBeast]

Cool build, I am subscribed.

[k5kev]

Okay, so now you're up to date on the body. Let me go back and get up to speed on the frame/chassis.

I wanted to make this a 4x4, and at first I was looking into converting the 2wd frame to 4x4. I was having a hard time finding the leaf spring hangers, and I figured out from this site that the wheelbase and frame from a longbed truck is basically the same as a suburban. I found a 4x4 longbed frame locally for $300, and bought it. It was already sandblasted and powdercoated. This I think turned out to be one of the decisions I made. Way less work than converting a 2wd chassis, plus I wasn't going to use any of the stock 2wd drive train stuff anyway.

As soon as I got the truck frame I hung some 4" Tuff Country front springs and 6" rear springs. Also picked up a 14 bolt rear 4:10, put in a detroit locker and disc brake conversion. And bolted up a Dana 60 front, open w/ 4:10's.

I lost the pics I had of the frame, springs, and axles only, so your getting a peak at some of the other upgrades I made.

[k5kev]

So in order to make this Burb a little special I decided to go with a GM crate motor,...502 HO, 450hp and 550 torque. I also moved the engine forward an 1-1/4" to be sure the valve covers and HEI distributer clear the firewall. I used the stock 4x4 engine crossmember and small block motor mounts, but in order to do so I had to ditch the 6 qt. oil pan that comes on the motor (and doesn't clear the crossmember), and install GMPP's 4 qt. oil pan which they recommend for corvettes, chevelles, and other custom applications........So far so good.





I also picked up a used turbo 400/np205 combo. Had the t400 rebuilt, and re-sealed and gasketed the 205. I moved the transmission/TC crossmember back an 1-1/2". The 1-1/2" for the trans and the 1-1/4" for the motor add up to the 2-3/4" in extra length of a turbo 400 versus a turbo 350, which was originally in the 4x4 frame.

[k5kev]

The next chassis project I tackled was extending the truck frame and making it a suburban frame. I picked up a pair of rear frame horns from a board member. I spliced em in, filled in the oval truck body mount holes, re-holed sawed a round suburban position #6 body mount hole, and then added about 8 inches of plate to box the frame in that area and add strength.





I also bought a Valley Industries hitch for a "67-72 Carryall" and bolted it up. I really like the way this hitch bolted up, although I had to make a modification to it to make it work the way I wanted. I bolted the two side brackets thru some of the existing rivet holes. In doing so the brackets were about 1/2" away from tow bar on each side. I just made pair of 1/2" spacer plates, drilled 4 holes in em and slid them in and bolted everything up. I think it turned out nice.

[MrBeast]

Just a thought, but have you test fit your fuel tank yet?

Also you might consider having your body man install the gas door out of a 88-98 pickup, it will look way cleaner.

[msgross]

cool build..

[k5kev]

Originally Posted by MrBeast

Just a thought, but have you test fit your fuel tank yet?

Also you might consider having your body man install the gas door out of a 88-98 pickup, it will look way cleaner.

Since you mentioned gas tank let me share what I did. I know the stock gas tank capacity isn't going to cut it with a 502.

I decided to try and install a Northwest Metal Products 37 gallon tank for a 69-72 Blazer. As you can probably guess from my screen name I've got a K5 Blazer too, and its also a 72. I figured since the truck and suburban frames are close to the same, the Blazer should be too, and I didn't see why a "Blazer" tank wouldn't fit. As it turns out it does fit. I'll confess its slightly off center between the frame rails, and I sorta ditched the directions provided and figured out how to mount it myself. I don't know if this was due to it going into a Suburban, or just manufacturing variances from Northwest Metal Products. Again I think it turned out allright.

[LEEVON]

Better fill that puppy up while gas prices are low Love the build!

[nuke1]

looking real nice and clean, job well done so far, what rims and tires do you plan on running?