Re: Let's Build A 1 Ton Crew Cab 4x4
 

Good progress!

Re: Let's Build A 1 Ton Crew Cab 4x4
 

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

Re: Let's Build A 1 Ton Crew Cab 4x4
 

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

Re: Let's Build A 1 Ton Crew Cab 4x4
 

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.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

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.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

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.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

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.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

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

http://i1223.photobucket.com/albums/...psulcnb78n.jpg

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.

http://i1223.photobucket.com/albums/...ps3xlahcab.jpg

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

http://i1223.photobucket.com/albums/...ps5dfmdybv.jpg

Started stripping down the Dana 60 as well.

http://i1223.photobucket.com/albums/...psjbiwjxat.jpg

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!

Re: Let's Build A 1 Ton Crew Cab 4x4
 

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

Re: Let's Build A 1 Ton Crew Cab 4x4
 

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.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

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.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

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.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

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.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

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.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

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.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Here is a link to the u bolt stuff.

http://offroaddesign.com/catalog/u-bolts.htm

Re: Let's Build A 1 Ton Crew Cab 4x4
 

And a link to the valuable 4x4 swap thread. The first post has a ton of info with links to the specific parts of the thread he talks about.

http://ck5.com/forums/threads/89-r35...-found.303347/

Re: Let's Build A 1 Ton Crew Cab 4x4
 

And here is a link to the whole she bang worth of front spring hangers for about $100 on eBay.

http://pages.ebay.com/motors/link/?n...225880&alt=web

That link doesn't seem to work... But all I typed in on eBay was "chevy front spring hangers" and it was in the top 3 results.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Thank you for all of that! Wow! Someone has done some research! This is why I love this site.

About the spring hangars. I am seeing that LMC sells them for $30 each? Am I mistaken? Or is it missing the other parts? http://www.lmctruck.com/icatalog/cc/full.aspx?Page=17

I have the shackles from the 4x4 that are in good usable shape. As well as the actual mount that has the bushing in it from the rear. I just have to measure out where to drill those holes in the frame.

Yeah the long bent piece is just a tie rod or whatever, I think that there are different types with one being hollow even. Idk, just have to find it.

I also kept the engine kmember from the 4x4 donor as well as the front xmember from the 4x4 that I will have to install as well I think.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I don't see anything on the lmc page that looks like the spring hangers. Here is the eBay link that should work.

http://m.ebay.com/itm/Front-Leaf-Spr...880?nav=SEARCH

Re: Let's Build A 1 Ton Crew Cab 4x4
 

You are correct it just list it as the core support 4x4.

Yeah that link worked but I need the 81-87 style since I will be using the 91 style core support. Correct? I found one of those on ebay from same seller. I may just go ahead and pull the trigger.

Were those U bolts you sent, stock size? I just need to find longer ones. I see they have the stud instead of the big ass bolt the dana 60 normally has.

Next is just leaf spring bushings.

Now if you could find me a cheap 32 spline 208/241 I would owe you a beer.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I THINK the front spring hangers and body mounts are the same for all the years 73-91. And the u bolt page says they are good for just about anything. Thin or thick Springs. I assume they mean that are taller than stock but still threaded low enough to work with stock Springs. I'll find you the bushings real quick.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

This should be the ones you need.

http://m.summitracing.com/parts/ens-3-2112g

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I think I am gonna go with rubber on this truck unless it is just that much cheaper to use poly. What do you think? I know they're a lot of disagreements about which is better.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

As far as I know, there is no rubber option for aftermarket Springs.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Yes, you may be correct! I forgot about that aspect!

I ordered front hangers today and rebuild kit for my t56. Tomorrow I'll get bushings and u bolts and start locating everything else.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I have read through most of this, great information!! I just wish I could find a swap where people don't go crazy with x over steering and big lifts and tires. A lot of the complication he seemed to have because he was lifting it so much.

I do plan to utilize x over but not as complicated. I will just have the 4" lift springs up front and run 35s, nothing ever bigger.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

The biggest not worthy complication is the frame area where the rear shackle hanger goes. It doesn't have the proper clearance for the shackle there. So you have to either mount the hanger too low and end up with a weird caster angle, mount the shackle low and make the front spring hangers lower to compensate, or modify the frame to mount the shackle hanger up higher like a factory 4x4.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

So you are talking about the rear hanger of the front leaf springs right? I see where he showed the frame on the 2wd doesn't curve up at a sharp of an angle like the 4x4 frame did.

Should I cut it and weld it back so it does have that angle? I have seen a lot of other 4x4 swaps in the past and it seems no one else addresses that issue.

I am no wheeler or climber or anything and I don't even play in the mud anymore but I do want my angles to be as correct as possible and not cause issues with driveability.

Also, so far the plan is to shorten the frame Saturday morning so if there is any other welding I need to do I need to have planned to have it done that day.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

My plan on my upcoming 4x4 swap is to cut the frame and re shape it for clearance. You'll have to fact check me but as I understand it, the issue only comes to light on the c20 crew cabs since they have the taller one ton frame. Something like a suburban on the other hand wouldn't have the taller frame issue.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Yes, that seems to be correct. In this case I do have the tall 3/4 ton frame. It seems I may do the same as far as reshaping it to be more like the 4x4 frame. However, another option I have considered is making longer rear shackles for the front with several holes in them. That way when I have the full weight on the front end I could move the spring in different holes to find the angle that I need then just cut off what isn't necessary.

To do that though I would have to have it all back together. So I guess time will tell.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I thought of something similar. I thought of just putting it too low in the frame and then just running degree shims between the axle and Springs to correct the caster angle. But like you, I wouldn't know what shims I would need until it was all together.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

We will figure it out I am sure. I just don't think I need to jump the gun on cutting the frame just yet.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

I was worried about the rear suspension being 3" shorter and started on a hunt for rear hangers from a 4x4. Then I remembered I already had a set from a previous purchase so I went out and dug them up. Looks like I will need to swap them out.

2wd rear spring hangers vs 4x4 rear spring hangers.

http://i1223.photobucket.com/albums/...psynoyfs9h.jpg

I also measured my lift springs for bushing sizes.

http://i1223.photobucket.com/albums/...psi5i6eaoo.jpg

http://i1223.photobucket.com/albums/...psekekvmjl.jpg

I also got some bad news from machine shop about my tbi heads. One is fixed and ready to go but the other head "was the worst wore out head he has ever seen" and supposedly isn't worth fixing. So I have to find another head to get reworked, which I don't have. Damn head is useless as a boat anchor until you need one.

Also may have found another diesel engine that I could buy. I guess we will see how that pans out.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

For my swap I plan on just running a block in the rear. Since I'm going to run stock front Springs. Then a 3" block in the rear should make it level with the front.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Yeah that would be nice. Unfortunately, the front springs from the dana 60 donor were completely toast. Only set of springs I had lying around were the 4" lift springs so... On they go.

I am not about to do a 7" block in the rear and I damn sure don't want it to be squatting!

So I went to the machine shop about my heads. One head was done and already had 3 oversize exhaust valves put in previously. They decked it, cleaned it and checked for cracks and put it back together. My other head was toast, they showed me the valves had sooo much play it was ridiculous. Luckily for them, they had a 193 head handy that was in great shape and would only cost me $200! At least for the $200 it will be completely assembled, checked and decked.

So total cost for getting heads done is going to be $250. Not bad but originally I was going to be having them done for a bit shy of $100.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Good enough! And yes, I would not run any taller than a 4" block!

Re: Let's Build A 1 Ton Crew Cab 4x4
 

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

Re: Let's Build A 1 Ton Crew Cab 4x4
 

The 2wd hangers are 3" shorter than the 4x4 hangars. So with all stock springs the rear would sit 3" shorter than the front. Since I am using 4" lift springs up front it may sit 7" shorter in the rear than in the front.

Re: Let's Build A 1 Ton Crew Cab 4x4
 

Nice project you have going on here! As far as I know, all the crew cabs had the heavier 1 ton type frame because they only made 2 frames for crew cabs. A 2wd one, and a 4wd one. On my 76 on the rear suspension, I installed 4x4 spring hangers in the front, and did a shackle flip in the back. No block at all and it was cheap. I may have used the 2wd rear hanger too but I'd have to double check on that.