1978 Chevy Crew Cab Ultimate Offroad Build

[Chevy1TonFun]

Finally found the truck I've been looking for my next project. I picked up this fully loaded 1978 K30 Silverado dually: 467BBC, 400, 203, D60, D70HD. Its going to be a slow build, unless I sell my 72' then it will pick up. I'll list up the do to list soon. For now here are some pics! FYI: Lots of parts will be for sale.

[andrewmp6]

Are you sure its a 203 not a 205 ?

[Chevy1TonFun]

Yes, it has the HUGE 203 in it.

[Chevy1TonFun]

Ok so here is the to do list:

-Shorten frame to short bed length
-Build custom bed or find a short bed (which ever ends up to be less $$)
-Strip interior to install full cage and custom dash and center console
-Relocate radiator and battery to behind cab
-Install fuel cell
-Remove and replace all new wiring
-Swap D70HD for 14bolt with 5.13 gears and spool or locker
-Build build D60 with 5.13 and spool
-203/205 double case setup
-Swap in my 486 BBC race motor
-Trans has already been rebuilt
-Custom suspension 12" suspension
-Run 44" Boggers on 16" Steel wheels with beadlocks
-Lots more that will be figured out along the way

I'd love to run a 4 link, but its just not in the budget for now.
The idea is to build this truck to be competitive and win at Top Truck Challenge in 2020. Ultimately I'd like a all around family offroad truck that is dominate in the CA mud, good on medium trails (not a big rockcrawler guy), and fun in the sand.

I welcome input and wisdom. I do have my mind set on a few things, but if you provide good facts or make a good point then I am always open to changing plans. I can't wait to get started!!!

[ryanroo]

Originally Posted by Chevy1TonFun

Ok so here is the to do list:

-Shorten frame to short bed length
-Build custom bed or find a short bed (which ever ends up to be less $$)
-Strip interior to install full cage and custom dash and center console
-Relocate radiator and battery to behind cab
-Install fuel cell
-Remove and replace all new wiring
-Swap D70HD for 14bolt with 5.13 gears and spool or locker
-Build build D60 with 5.13 and spool
-203/205 double case setup
-Swap in my 486 BBC race motor
-Trans has already been rebuilt
-Custom suspension 12" suspension
-Run 44" Boggers on 16" Steel wheels with beadlocks
-Lots more that will be figured out along the way

I'd love to run a 4 link, but its just not in the budget for now.
The idea is to build this truck to be competitive and win at Top Truck Challenge in 2020. Ultimately I'd like a all around family offroad truck that is dominate in the CA mud, good on medium trails (not a big rockcrawler guy), and fun in the sand.

I welcome input and wisdom. I do have my mind set on a few things, but if you provide good facts or make a good point then I am always open to changing plans. I can't wait to get started!!!

sweet old chev!

i am curious about the suspension. when you say custom 12" what does that mean?

[Chevy1TonFun]

The suspension is going to be 6" lift springs (52" front/63" rear) and I'm going to fab brackets that relocate the spring mounts and shackle mounts to give me the remaining 6" of lift.

[andrewmp6]

On the bead locks have you looked at http://www.trailworthyfab.com/-200-1...l-Special.html They can be cheap depending how you get them made,Its a 16.5 rim but you get a dual beadlock vs the single sided most others are.And you can get a 42.5 bogger for the 16.5 rim.

[Chevy1TonFun]

Originally Posted by andrewmp6

On the bead locks have you looked at http://www.trailworthyfab.com/-200-1...l-Special.html They can be cheap depending how you get them made,Its a 16.5 rim but you get a dual beadlock vs the single sided most others are.And you can get a 42.5 bogger for the 16.5 rim.

Yeah I just found that site. Thanks they looking really nice. I'm try to figure out if that will work since we are going to be running 44" boggers.

[Chevy1TonFun]

Ok so after spending some time at pismo, ca playing on the dunes and looking at some linked trucks, I'm trying to figure it out money wise. So I need recommendations for coil overs and reviews. I have the links, joints and brackets figured out.

[andrewmp6]

Have you seen http://offroaddesign.com/catalog/Fro...Conversion.htm i know its not the cheapest way but its designed for your truck and will give you less trail and error of fitting everything.

[Chevy1TonFun]

After having to watch my new truck sit for 4 months, I have finally found the time to start working on it. I have it all torn down and the parts are starting to gather. I am going to be working on the mounting for the new springs. For now here are the pics of what she looks like now.

[Chevy1TonFun]

Quick update: Was able to work on the truck yesterday. I extended the front of the frame and started to fab the new spring hanger mount. While getting everything lined up we found that the frame was bent. So we had to pull the porta-power out and fix the frame. Everything is square and lining up now. I am still working on filling all the holes in the frame since we are boxing the frame. I'll go out and take some pictures later today.

[bilfman]

Looks great , I will definitely follow your thread. My next go over of my dually will be a major off road transformation as well.

[DWilbur]

Check out Ruff Stuff for the 4 link they have kits that could save you money if you have some fab skills.

[Chevy1TonFun]

So after really looking at my budget, I can't afford to go with a link setup. I am going with a 6" lift 56" front springs and 6" lift 63" springs in the rear. As the parts are piling up in the garage, I am taking a week off from work next week to hopefully get all or most of the frame and suspension work done. I have also decided to move the complete drivetrain in my 72 mud truck into this truck. I will pulling the 72 a part this weekend to pull the 468 stroker BBC, built 400, and divorced 205. I am going to order 5.38 gears with spool in the rear and still trying to figure out the front for the D60. I will post pictures are the end of the week so give you all idea of what we are really doing. I bought a set of new 44" boggers. Ouch that hurt, but worth every penny. Can't wait for next week!

[DWilbur]

I see you will be cutting fenders to fit the 44" boggers with 6" lift. Building up a truck is not cheep. I'm around $40,000.00 on my 1971 crew cab.

[ryanroo]

Boggers! Yes! I've all but decided for sure that the jeep gets boggers for it's next version(coming sometime after my Chevy...)

I don't keep track of my 'investment'. Too scary.

Looking forward to some pics!

[Chevy1TonFun]

Originally Posted by DWilbur

I see you will be cutting fenders to fit the 44" boggers with 6" lift. Building up a truck is not cheep. I'm around $40,000.00 on my 1971 crew cab.

Actually I will be about 15" of lift in the front and 13" in the rear. Since I am using rear springs in the front it adds an extra 2" in lift. I built a 4" drop spring hanger for the front and relocated the shackle mounts to the bottom of the frame giving me my 15". As for the rear, 63" rear 6" + 2" because I'm going with a shackle flip with gives me another 4" plus a 7" shackle giving me another inch or two. Total 13-14" lift. We might play with the location of the spring hanger if need be. I am hoping for minimal trimming of the fenders. I am going with bed sides only so I am willing to trim those a lot more the. The fenders.
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[DWilbur]

Originally Posted by Chevy1TonFun

Actually I will be about 15" of lift in the front and 13" in the rear. Since I am using rear springs in the front it adds an extra 2" in lift. I built a 4" drop spring hanger for the front and relocated the shackle mounts to the bottom of the frame giving me my 15". As for the rear, 63" rear 6" + 2" because I'm going with a shackle flip with gives me another 4" plus a 7" shackle giving me another inch or two. Total 13-14" lift. We might play with the location of the spring hanger if need be. I am hoping for minimal trimming of the fenders. I am going with bed sides only so I am willing to trim those a lot more the. The fenders.
Posted via Mobile Device

Got it. should be cool truck.

[Chevy1TonFun]

Took this last week off to work on the build. My buddy joined me to help out. We extended the frame in the front to accept the longer front springs.



We wanted to build off the frame in order to keep the spring height lower to keep our ride and articulation good. So I added a 4" square tube to mount the spring hanger to.



We cut the back of the old frame off. We added 2x6x.250 wall steel to replace the frame. This allowed us to shorten the frame and didn't have to box it.




I bought DIY4X's Shackle Flip kit for the rear suspension. With 6" springs and shackle flip, this will get me around 10". I went down to see Stan and Mark at Early Classic Enterprises to pick up a used set of 1972 Rear spring hangers to give me an extra 3" of rear lift.





To get to the 15" lift mark, we decided to move the shackle hanger to under the frame. We still need to fab the phish(?) plate, but we need to make sure the suspension sits right before all finish welds are accomplished.



We have most of the frame boxing complete. I bought half go DIY4X 1 Ton boxing kit. It is a great kit, but each frame is a little different. So we have some gaps at the front of the frame that my buddy is going to work.



I bought a none welded DIY4X's 67-72 Chevy engine crossmember so I could build one to fit the 73+ frame. Built a simple, but strong trans crossmember. After a day and half of mocking up and welding, I was so excited to put the cab on that I forgot to take a picture of the transfer case crossmember. So I have to get that one to you all later.



Now for the picture you all have been waiting for.... The cab and over all height of the truck sitting on 44' Boggers. Holy crap this thing is taller than I expected!!!! Just for reference... I stand at 5'8".






After much thought, I have decided to run with just bedsides. It keeps the truck lighter and easier to clean after playing in the mud.



Overall I am so excited and can't wait to finished this truck even more now. We have a little adjusting to do with the suspension to level the truck out. I am very happy for the mock and fit test fit with all the heavy parts.

[tommys72]

Yep, I wanna see more

[Chevy1TonFun]

Been finding time here and there to work on the truck. Its starting to take shape and look like a truck again. The list in getting smaller but so are my funds. I am trying to save up for gears and lockers. Here is what I have accomplished since my last post.



Moved the front axle back a little bit and got the doors back on the cab



Finished up the rear frame section.







Mounted the Radiator and battery tray



Mounted the Fuel Cell





Once we got the bedsides aligned with the cab we trimmed for our race cut.

[74CustomK20]

Updates!?

[19silverado77]

This thing is wicked I would daily it.

[Chevy1TonFun]

Finished building all the new brackets to mount the front clip. I have a few ideas on the grille but that will be one of the last tasks. I'm dying to drive this thing.





Now that all the body parts are mocked up, we completed all finial welds EVERYWHERE!


After two days and 11lb spool of wire, we finished all the welding and got the frame all painted. Started driving in to get brake, fuel and trans cooler lines and electrical ran down the frame.


Replaced a leaky rear main seal and the pan gasket, installed my new high volume water pump and get the rest of the motor all cleaned up. Was super excited to find someone locally selling the headers I was looking for a great price! Need to go get them coated. Still doing some research on what the best coating for mud will be.



I am working on getting the cab all cleaned up and the cage built. I hope to have the cage built my the end of the year. I am having to switch to working on putting my 1972 Chevy truck back together to sell for funds to finish this truck. So progress is going to stop until I'm finished with it.