Re: 86 Silverado K20 12V CUMMINS Build
 

So "CHEV RED" I'm not sold on yet. I really wish I went with a darker red. I guess I got caught up with the name of the paint. Any how I painted the color over the POR15 "primer" coat as per the instructions the next day. There is a 24hour window for 2nd or recoats.

http://i1284.photobucket.com/albums/...psa6fcf2a8.jpg

I still have to paint the injection lines and I want to change the valve covers. There is too much red. I think aluminum.

http://i1284.photobucket.com/albums/...ps1d97e4ad.jpg


The manifold and turbo came out awesome. That is some good paint. It is not suppose to burn off until after 1400' It will darken after 300+' for 20min of running.

http://i1284.photobucket.com/albums/...ps32f5b598.jpg

Next I installed the engine adapter, flywheel,clutch, etc and cleaned up, locktight and torqued down for final assembly. ( until I upgrade to a 4500, 5600, G56 when I blow this one up! )

http://i1284.photobucket.com/albums/...ps2b91832b.jpg

http://i1284.photobucket.com/albums/...psc055be6b.jpg

http://i1284.photobucket.com/albums/...ps7213b9ad.jpg

http://i1284.photobucket.com/albums/...psb106aeb1.jpg

So I still got lots to do but, this brings me almost up to date. I have to go buy some more metal to finish my engine mount supports and build a xmember. Pull all the rear suspension and paint. My goal is to get all that done, then get the fuel tank done with all new lines and lift pump. I can't wait to fire this thing up in it's new home ! :chevy:

Re: 86 Silverado K20 12V CUMMINS Build
 

This week I got the rear springs and mounts etc. all pulled and cleaned up and painted. Starting getting most of that put back together. Today I picked up some metal at the Barrie Metal Superstore and this weekend hopefully will get my engine xmember built and installed. It is finally at a point in the build when things start coming together. I just wish there was more time to spend on it. ( and money hehe ) I post some more pictures after the progress.

Re: 86 Silverado K20 12V CUMMINS Build
 

Awesome build thread :metal:

Looking good so far, going to be sweet when its done.

Subbed

Re: 86 Silverado K20 12V CUMMINS Build
 

Been really hot and also a busy week! I did manage to get my engine xmember all cut up, mocked up and now it is ready for finish welding. Hopefully get it all completed this weekend. I have been taken lots of pictures but only have one to share for now until I get them uploaded.
http://i1284.photobucket.com/albums/...psf34ecb22.jpg
Hopefully have much more to share this weekend!

Re: 86 Silverado K20 12V CUMMINS Build
 

Thanks. I really enjoy reading threads with lots of pics. I wanted to make sure I had lots to share in return.
I can't wait for it to be done but, trying hard not to rush it.

Re: 86 Silverado K20 12V CUMMINS Build
 

So I picked up some more metal at the super store.

http://i1284.photobucket.com/albums/...ps3d27a7ab.jpg
3/16" 3"angle, flat and 2X3 tube.

Started out with the angle on the bottom side of the frame. Now this setup is going to be somewhat different from others I have seen. I wanted more support than just being bolted, or welded on the inside of the frame.

http://i1284.photobucket.com/albums/...ps217cf2cb.jpg

http://i1284.photobucket.com/albums/...psef7a1520.jpg

http://i1284.photobucket.com/albums/...ps841b503b.jpg

I figure if the frame is sandwiched between the engine mounts and the removable xmember, it should be pretty strong.
So before I pulled the engine the last time, I made a cardboard template to give me the distance between the frame rails, oil pan, and front axle. I started off with the 2X3 tube 36" long. I made a center mark and measured off the template. I was going to use the saw at work but, I went ahead and did it by hand.

http://i1284.photobucket.com/albums/...psa8f4cd2d.jpg

Cut out the notches and then bent it up to fit my template. I then used a strap to hold it as it had some spring to it so I could tack weld it.

http://i1284.photobucket.com/albums/...ps83607f5f.jpg

http://i1284.photobucket.com/albums/...psa842be6e.jpg

4 tack welds held it firmly enough for the next part of the process.

http://i1284.photobucket.com/albums/...psd046f900.jpg

Re: 86 Silverado K20 12V CUMMINS Build
 

I also cut the tops off so they would be flush with the angle iron already temporary bolted to the frame. I used my floor jack and a block of wood to hold it up into position.

http://i1284.photobucket.com/albums/...psf67fa040.jpg

http://i1284.photobucket.com/albums/...psa588822f.jpg

http://i1284.photobucket.com/albums/...ps1555945f.jpg

Tack welded that into place after several checks with a tape measure. Then drilled all my holes. There will be 20, Grade 8, 3/8" 1 1/4" bolts holding the engine mounts and xmember onto the frame. ( 10 per side ) Pulled it off for final welding.

http://i1284.photobucket.com/albums/...ps8a25819d.jpg

http://i1284.photobucket.com/albums/...ps3ba8573b.jpg

Re: 86 Silverado K20 12V CUMMINS Build
 

I also got the front OE xmember trimming completed and painted to clear the front balancer. I completely finish welded the xmember and set it into the frame and took a couple pics tonight. Now I just have to prep it for paint, pick up my bolt order at Bolts +, and install it.

http://i1284.photobucket.com/albums/...ps2c2e4186.jpg

http://i1284.photobucket.com/albums/...psc520680b.jpg

I know, I am not the best welder, but they are good welds. haha

http://i1284.photobucket.com/albums/...psebf05aef.jpg

http://i1284.photobucket.com/albums/...psd576bacc.jpg

Hopefully this heat will let up so I can get more done this week. The garage is 40' right now, can't even hardly breath out there! :devil:

Re: 86 Silverado K20 12V CUMMINS Build
 

Pretty cool build :metal: I am a big fan of the Cummins swaps.
Reading through yours makes me want to get restarted on mine.

Re: 86 Silverado K20 12V CUMMINS Build
 

Engine crossmember looks good, didn't happen to make an extra one? I need to fab up one myself.

Re: 86 Silverado K20 12V CUMMINS Build
 

Ya I agree. Reading all the great threads helps get motivated.

haha, no I didn't make an extra one. But really it was fairly simple.

Re: 86 Silverado K20 12V CUMMINS Build
 

Nice work on your engine cross member! That's how I decided to do the one in my 76. We'll be getting our loaner engine back in a few weeks and then it's going in the 76. Keep up the great work!

Re: 86 Silverado K20 12V CUMMINS Build
 

Thanks for the feedback on the xmember.
I hope you are able to start working on your 76 again. I really enjoyed following your thread on that one.

Hopefully this heat wave crap will let up and I can get more work done in the garage. I really can't wait to get this truck into a roller and get the engine fired up!

Re: 86 Silverado K20 12V CUMMINS Build
 

x2 Too hot to do much, so I have been hunting down parts

Re: 86 Silverado K20 12V CUMMINS Build
 

Looks like the weather has cooled down some for this weekend. Hopefully means more work down on all our trucks!
I picked up some Grade 8 hardware at bolts plus for my engine cross member.

http://i1284.photobucket.com/albums/...ps9770422e.jpg

http://i1284.photobucket.com/albums/...psc21eb624.jpg

http://i1284.photobucket.com/albums/...psc7cf6e62.jpg

Question for you all, I have allot of new hardware to buy for this project obviously. Is this a reasonable price I paid or is there some better place to pick up large orders?

Re: 86 Silverado K20 12V CUMMINS Build
 

Have you tried Brafasco ? Im not sure how the prices campare

Re: 86 Silverado K20 12V CUMMINS Build
 

I get them at tractor supply for about $3.00 a pound. Grade 5 for $2.30 a pound.

Re: 86 Silverado K20 12V CUMMINS Build
 

thats a good lookin helper youve got there!!

Re: 86 Silverado K20 12V CUMMINS Build
 

Usually I go into a local tractor supply store and buy about $40-$50 worth and when it gets low, I go back. :lol: Hardware isn't cheap when you're going grade 8 and get 10lbs or more at a time.

Re: 86 Silverado K20 12V CUMMINS Build
 

Thanks everyone for the reply's on the bolts. I have bought some hardware at TSC stores and they didn't sell grade 8 by the pound. Only in special individual bags. That was how I bought the new 9/16 bolts for my new springs. Very expensive. They do sell grade 5 by the pound though. I'll keep looking around here, but for now the Bolts plus+ place was alright.

Re: 86 Silverado K20 12V CUMMINS Build
 

So now that I got my pictures up-loaded, time for an update from the past several days! I got a good 2 coats of POR15 on my new engine cross member after sanding it all down with a 60 grit flap disk.

http://i1284.photobucket.com/albums/...ps10db2eb6.jpg

http://i1284.photobucket.com/albums/...ps02e3d346.jpg

http://i1284.photobucket.com/albums/...ps8eccd23d.jpg

http://i1284.photobucket.com/albums/...psfdfc8904.jpg

http://i1284.photobucket.com/albums/...ps2ff1edad.jpg

I think it turned out alright. Next time I would rather use a good saw and angle finder to make perfect cuts. The seams and welds would look better, even though it is under the truck you can see it real good behind the tire in the wheel well.

Re: 86 Silverado K20 12V CUMMINS Build
 

So tonight I got the cross member all bolted in place with the 20 new grade 8 bolts. Used some blue thread locker and torque wrenched them down. This thing is super solid now!

http://i1284.photobucket.com/albums/...pse2161106.jpg

I also bolted the front springs onto the frame for the final time.
NOTE: The stock spring shackles are temporary. I will make a new set at least 1" longer and will be 1/2" wider and made out of 3/8" material. I may wait until I see the ride height before I do though.
So next I started to install the front Axel.

http://i1284.photobucket.com/albums/...ps386ce264.jpg

I use the engine hoist for just about everything.

http://i1284.photobucket.com/albums/...ps61d6ff31.jpg

Just have to keep fishing it into place by unhooking and hooking back up again.

http://i1284.photobucket.com/albums/...ps699bd36b.jpg

http://i1284.photobucket.com/albums/...pse66a81dd.jpg

Then just lift it up into place. Line up one side first then the other.

http://i1284.photobucket.com/albums/...ps2569a586.jpg

http://i1284.photobucket.com/albums/...ps68d83f75.jpg

Then just draw it up tight against both pins.

http://i1284.photobucket.com/albums/...ps2ccca9c8.jpg

I pulled it up tight until the frame started to lift off the saw horse at the front. Then started bolting on the new U bolts.

http://i1284.photobucket.com/albums/...ps982b64eb.jpg

I lined it up best I could and just did about half torque for now until I get all the weight on the springs. Then I installed a second nut to make the spot to cut off the excess bolts as they are too long for me.

http://i1284.photobucket.com/albums/...ps6e7f7ead.jpg

http://i1284.photobucket.com/albums/...psaaab4d2f.jpg

All 8 cut off and sanded down.

http://i1284.photobucket.com/albums/...ps46507105.jpg

Now just a few pics of the cross member and front Axel installed for I hope the last time!

http://i1284.photobucket.com/albums/...pseda1a259.jpg

http://i1284.photobucket.com/albums/...psb076aebe.jpg

http://i1284.photobucket.com/albums/...ps9279152a.jpg

http://i1284.photobucket.com/albums/...ps076bb4bc.jpg

Now I can install the engine for the last time, get the hubs, brakes and tires on and I have myself a roller real soon. ( I hope ) Can't wait to fire this thing up!!

Re: 86 Silverado K20 12V CUMMINS Build
 

It looks really nice!

Re: 86 Silverado K20 12V CUMMINS Build
 

Now I am starting to get excited!:lol:

Re: 86 Silverado K20 12V CUMMINS Build
 

well, it sure is a lot prettier than mine is at this point.

Re: 86 Silverado K20 12V CUMMINS Build
 

Haha, Thanks Guys! It's slowly coming together. Just keep plugging away at alittle at a time.

Re: 86 Silverado K20 12V CUMMINS Build
 

Wow, time for an update....
I got the rear 14 bolt put together just enough to get the wheels back on it. I need to turn the drums but have decided to hold off because they will just rust up. I'll do it after this winter when the project will be closer to finished.

http://i1284.photobucket.com/albums/...ps5a3179af.jpg

Just need to seal the axle shafts and diff cover, then fill. Oh ya and run the new lines.

http://i1284.photobucket.com/albums/...ps7986842d.jpg

Re: 86 Silverado K20 12V CUMMINS Build
 

Then I installed the engine for the last time ( I hope ) into the frame. Checked final clearance to the front balancer and oil pan to crossmembers. I think they turned out alright for my first time !:lol:

http://i1284.photobucket.com/albums/...ps64a66fda.jpg

http://i1284.photobucket.com/albums/...ps1389e66b.jpg

http://i1284.photobucket.com/albums/...psfb55642d.jpg

Re: 86 Silverado K20 12V CUMMINS Build
 

I also got the injection lines painted up as well as the oem fuel filter canister.

http://i1284.photobucket.com/albums/...psc4f411a6.jpg

http://i1284.photobucket.com/albums/...ps22ff7067.jpg

http://i1284.photobucket.com/albums/...psfb7798c4.jpg

The next few weeks I hope to have it on 4 wheels and fuel system finished, pickup all the filters and oil etc. then fire this thing up for the first time in almost a year.

Re: 86 Silverado K20 12V CUMMINS Build
 

Looking good man! I don't see one and I don't remember if you said anything about one, but do you plan on installing a steering box brace on the frame? If not, I'd really consider it as these frames love to crack there and the added weight with the big tires will really progress that wek spot. On your fuel filter housing, those are a nice piece but really suck to replace the filter in a dodge. :lol:

Re: 86 Silverado K20 12V CUMMINS Build
 

Thanks for the compliment. I too think it is starting to look good. It is nice to get most of the dirty work finished and start putting things back together and start taking shape. I know about and have thought about the steering brace several times. I checked this area when I bought it and when I removed the box and there is no signs of any stress or cracking as of yet. This truck was run kinda hard with 35's for awhile off-road before I got it. I might just leave it be and call it a test to see how it does. This project has been a learning curve for all the pro's and con's for when I build the next one. This one might just be a training project :lol:
As for the filter housing, I like them better than the older spin on's. I had no problem changing on the Dodge. Should be just about the same in the Chev. Might not be there long as I might "upgrade" the hole low pressure side.

Re: 86 Silverado K20 12V CUMMINS Build
 

I would get the steering brace. It's only a half ton frame and a ton of them get cracked just driving around the steets. The extra weight of the drive train is going to add a little more stress to the steering. I would get one and install it and you won't have to worry about it. If it does crack your going to have to drill the ends of the cracks, grind the cracks out some and then weld it all back up grind it smooth and have to install a brace anyway.
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Re: 86 Silverado K20 12V CUMMINS Build
 

Well time for an update. Been longer than I thought. Between having some summer holidays the first week of August and building us a 10X10 "Garden Shed" there hasn't been as much time on the truck as I would like. Nothing fancy, just some extra space to clear up much needed space in the main Garage!
http://i1284.photobucket.com/albums/...psab793c1f.jpg

Still needs a bit of trim work and paint in the next few weeks, but turned out good.

Re: 86 Silverado K20 12V CUMMINS Build
 

Been shopping on Kijiji as I always do. Got a line on several things and found a brand new front tint windshield. Going to go get that one this week. Also I found this, kijiji.ca/c-cars-vehicles-auto-parts-tires-transmission-drive-train-77-chev-dana-60-front-axle. with 4.10's. I wish I was ready to start stocking parts for my next project, but have to pass on this. Just thought I'd share.

Re: 86 Silverado K20 12V CUMMINS Build
 

So the truck is now rolling on it's own 4 wheels. 4 brand new ball joints and new high lift steering arm installed.
http://i1284.photobucket.com/albums/...ps6c4b5ebd.jpg
Just stuck the old rims and hubs/breaks on for now until I get it closer to finished. Pushed it outside to "Bake" in the sun and take a few pics outside.

http://i1284.photobucket.com/albums/...ps56ec8b4b.jpg

http://i1284.photobucket.com/albums/...psd656cb3a.jpg

http://i1284.photobucket.com/albums/...ps01f01ef6.jpg

It is getting closer. Next will be fuel tank and plumbing then repair and install cab mounts.

Re: 86 Silverado K20 12V CUMMINS Build
 

Got a bit done today. Fuel tank, supports all cleaned up and mounted with a 2" lift to match the Body lift.
http://i1284.photobucket.com/albums/...ps9fb94a20.jpg

http://i1284.photobucket.com/albums/...ps6f05b0c2.jpg

http://i1284.photobucket.com/albums/...psc2b75d22.jpg

One step closer!

Re: 86 Silverado K20 12V CUMMINS Build
 

Well got only a small amount done to the truck this last week. Very Hot and Very WET.
Sending unit cleaned up in the glass bead cabinet and some fresh por15 to finish it off. I also modified the pickup tube to sit just about the bottom of the tank after I removed the filter/sock.
http://i1284.photobucket.com/albums/...psf25a89b7.jpg

http://i1284.photobucket.com/albums/...ps152179e8.jpg

http://i1284.photobucket.com/albums/...ps9ac6f6fb.jpg

I think it will work just fine. Just need to get some good lines, fittings and clamps.

Re: 86 Silverado K20 12V CUMMINS Build
 

So since I can't do anymore on the fuel side until I go shopping, I decided to work on the air side for the time being. Started by pulling out the core support.

http://i1284.photobucket.com/albums/...psf8ebcbf7.jpg

The support is in rough shape but I figure why cut up a good one? I can weld up the cracks and reinforce it better than new!
Then semi cleaned the inter cooler and taped up some cardboard to protect it during the mockup process.

http://i1284.photobucket.com/albums/...ps2c722502.jpg

I will be using the dodge rad for ease of use and buying easy replacement parts like hoses etc. I have to buy a new rad, this one is toast. I will just use this one for hacking up the rad support and mockup.

http://i1284.photobucket.com/albums/...ps5488fa1f.jpg

Now I plan on keeping the Mech. fan. I want to run this truck with as little electrics as I can. Also, I ran without a fan for several years and just installed it when needed. Takes 2 min. with the top of the shroud cut off as seen on the picture. If I cannot make it fit, ie: fan-rad clearance, I will go electric. For 95% driving this engine needs no cooling fan unless pulling and in traffic based on my previous 5 or 6 years experience pulling our 8000lb 26' trailer.

http://i1284.photobucket.com/albums/...ps9587771f.jpg

Hopefully more work and updates on the truck after this long weekend!

Re: 86 Silverado K20 12V CUMMINS Build
 

Nice job!, your truck is coming along really nice!

Re: 86 Silverado K20 12V CUMMINS Build
 

Wow, long time no update. 2 months really?
Anyhow here we go. The rad support was in really bad shape. Aftermarket thin cheap tin crap. I went nuts with the cut off wheel and ended up with this,

http://i1284.photobucket.com/albums/...psf9d797eb.jpg

Then ended up with this, a big old hole with a bunch of new metal tacked in place.

http://i1284.photobucket.com/albums/...ps8a0c7448.jpg

http://i1284.photobucket.com/albums/...psf40332b4.jpg

I used part of the dodge support and the holders for the IC. Little cutting, welding and the IC and Rad fit like a glove. I then decided I needed to test fit the entire cab and front end. So I did. First time Cab was back on the frame since I pulled the plug on the old 350 and pulled the trigger on parting the dodge.

http://i1284.photobucket.com/albums/...ps21735868.jpg

I got a 1 inch body lift in there right now and I got the fenders/hood fitting, and open-close good as before, maybe better.
The IC and rad fit perfect behind the rad support, so there will be no issues with the grill or lights etc.

http://i1284.photobucket.com/albums/...ps9666d15a.jpg

Just enough room for electric fans. Mech fan just touches the rad so I tossed it out back in the pile. Didn't really want it anyway.

http://i1284.photobucket.com/albums/...ps2584ef90.jpg
http://i1284.photobucket.com/albums/...ps67a2fde2.jpg

Tons of room between the firewall and the block/head and the modded 2nd gen exhaust pipe.

http://i1284.photobucket.com/albums/...psca270bb8.jpg
http://i1284.photobucket.com/albums/...psfdb6c6ec.jpg
http://i1284.photobucket.com/albums/...psc9aa5403.jpg

What I really notice is that I think I have the engine sitting really low compared to others I have seen. I hope that works out to be better in the end because I am not moving it. haha

http://i1284.photobucket.com/albums/...psb996aaed.jpg

So then I ripped the front end all apart again and finished welding the core support and gave it a good coat of POR15.

http://i1284.photobucket.com/albums/...ps7732270b.jpg

Also got the IC cleaned up and put a fresh coat of paint on it as well.

http://i1284.photobucket.com/albums/...psab535fcf.jpg

Little bit closer.......:metal: