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

I will have to check through your build thread then! More work I can avoid the better!

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

I remembered your build thread as soon as I got to the front page. I have looked through it several times. Unfortunately for me though, you didn't document the 4x4 swap in there. It just went from 2wd to 4x4 to REALLY high.. I have found threads in the past that document the swap pretty well but I cannot seem to find them again or find a crew cab 2wd-4x4 swap that documents it well.

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

Just wanted to show the differences from 2WD frame and 4x4 frame at the spot where the rear hanger for front spring would go.

1988 crew cab 2wd frame

http://i1223.photobucket.com/albums/...psvnppw9jo.jpg

1979 4x4 crew cab

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

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

Interesting isn't it?

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

That's for sure. It seems the 2wd is thicker through this area.

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

Here is some more information!

Those who shorten 1500's have it easy! All that nice straight frame to play with.

Here is a comparison.

http://i1223.photobucket.com/albums/...psl1wskv8s.jpg

When I was going to cut I had to go through several times before I decided how I wanted to do it.

I had to keep in mind it was going to be welded back together with a stick welder.

So the only thing I had that would show up was one of my kids white crayons. Don't hate, it worked.

http://i1223.photobucket.com/albums/...psvsa8chqd.jpg

http://i1223.photobucket.com/albums/...pss7fqiiod.jpg

http://i1223.photobucket.com/albums/...psqxu6jutu.jpg

http://i1223.photobucket.com/albums/...psboxc6w9q.jpg

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

http://i1223.photobucket.com/albums/...psi2jbvziv.jpg

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

This was an amazing feeling!

http://i1223.photobucket.com/albums/...psagi5nugg.jpg

http://i1223.photobucket.com/albums/...psl9ji0fin.jpg

It was sad to have to pull the bed back off bc I still had to swap rear hangers, do fuel tanks and so on. It gave me the motivation to go back out from 11PM to 1:30 AM to get the front out.

http://i1223.photobucket.com/albums/...psdty3zcyu.jpg

http://i1223.photobucket.com/albums/...psbq2pvejl.jpg

This was a heavy bastard to drag out from the shop.

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

The dana 60 wasn't to easy to drag back to the front of the shop either...

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

Got the rear axel dropped to replace hangers.

http://i1223.photobucket.com/albums/...ps2pu9cy45.jpg

I did find out that my 350 TBI has been rebuilt. .030 it looks like.

http://i1223.photobucket.com/albums/...psyq96lcy1.jpg

Wind was crazy, it tried to rip tin off my building.

http://i1223.photobucket.com/albums/...ps5zpjhqia.jpg

I got my T56 rebuild kit in and cleaned up the trans. I am taking it to my buddies for us to rebuild it or just overhaul it because it had 170k and worked fine.

http://i1223.photobucket.com/albums/...psmivg7fkn.jpg



If my front mounts for front springs would have arrived liked they were supposed to I would have gotten a lot more accomplished.

So I have a few QUESTIONS

My GM DANA 60 was from a 79 that was "full time 4x4." How do I convert this to locking hubs?

My rear driveshaft needs to be shortened, but what about the front? It was behind the Th400 so it bolted to it, but I am trying to find a NP208 or NP241 (without much luck) so it will be a slide in, what to do?

Also what xmember to mount the nv4500? SM465?

What should I do about the front spring rear hanger shackles, just measure the 78 and put in exact location and hope for the best?

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

Glad to see I'm not the only one to cut their truck in have in the last few days. :) Looks good.

For your locking hubs question, I know you can buy a conversion kit to replace everything, but I would think you should be able to get factory components and swap them in. I haven't researched that, but it just seems to make sense. Hopefully someone that knows what they are talking about will chime in.

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

It was a scary feeling making the cut!! One thing I messed up on is I did too much swapping with my cutting devices. I planned to cut with sawzall all but right at the top and bottom. For that I would use the grinder and cut of wheel.

However, once I got the grinder out I just started using it then switched back to the sawzall when it was convenient. I should have stuck with my original plan.

Well it turned out just fine. We beveled the edges, left about an 1/8" gap and he welded it and then went back on top of his weld.

I made fish plates but unless we welded them outside he said he couldnt fit rod up in there to weld it fully so they will have to be mig welded in. I will do that before I do anything on the road.

What were you cutting?

EDIT:

WHERE DO I FIND the conversion kit at? I saw that I could buy just the lock hubs but is that it?

I also need to find some cheap U bolts for the rearend that will work for 4" blocks. 14bolt full floater.

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

For the hubs, any set of lockouts is all you need. I believe superwinch makes some for cheap? Otherwise just used original ones. Rear u bolts are probably cheapest through ord again. Maybe eBay if you can find them somehow? Depending on how much it would end up costing, the Dodge 208s had a standard (non slip) rear yoke on them and can usually be found on eBay. 241 slip yoke eliminator kits are made by several companies and I think aren't too expensive but so too sure. Just search "241 slip yoke eliminator" maybe could find a used one. Born where to mount the spring hangers, if you are getting those eBay ones, you can get realllllly close by just bolting up the core support body mount to it. Otherwise yes, just measure from the 4x4 frame's body mount forward to figure it out. If you don't want to mess with making the frame the same shape as the 4x4 in the shackle area I do think you can just mount the shackle hanger too low and then run castor correction shims on the axle to fix it.

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

What? No links this time? Lol. Just picking.

Yes I bought those eBay ones but for 81-87 bc I'm using 91 core support.

I will try to mount like you said, I don't think I can reshape frame at this time.

So u bolts for the 14 bolt ff are same as like 6 lug axle? Actually ord was not the cheapest on the front u bolts, they charge a really heft shipping charge. No clue why.

So I can just buy any Dana 60 lock hubs from eBay? All I need is that hub assy?

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

I was cutting exactly like yours. I stuck with the sawzall the whole time. It will be fun to weld in the fish plates. There isn't much room between the cross members now.

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

Sounds like yours turned out well too. I've seen a lot of horrible pics of beds being cocked up or down or wheels not being in center of wheel wells.. It's intimidating but it worked out. I was so stoked when the bed went on perfect. Just wish I didn't have to take it back off.

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

Well, I don't have a bed yet so the jury is still out. :) I feel good about it though. I did a lot of measuring and everything is true and square within 1/16".

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

Sounds like you should be fine then.

Another thing. I was planning to run cross over steering but after more research it seems like the original steering would be better for me. Considering I don't plan to go rock climb or play in the mud with this truck. It will be on the highway 90% of the time pulling a trailer.

I worked some last night on getting the rear hangers off. It isn't the easiest process but it is slowly coming along. I only got maybe an hour out there last night. Hopefully more to come during the week.

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

I think the hardest to find part for this build with be a clutch pedal assembly. It will have to be for hydraulic clutch and hydroboost brakes. I haven't had any luck this far.

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

Are you on any of the chevy Facebook groups?

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

Yes any locking hub for your style 60 will work. And no, u bolts for the 14 bolt are not the same as a 6 lug axle unless it's a. 14 bolt semi float 6 lug. Those will use the same u bolts. What info did you need now? I don't quite recall.

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

Yes I am on quite a few of them. National Squarebody Association, Square body nation, 73-87 Square body classifieds, 73-87 Chevy/GMC trucks... so on. Why do you ask?

That is good news about the locking hubs, hopefully I can score a set for less than $100. Funds are going to get tight here soon.

I found ORD's U bolts for 14bolt, but all I saw was the flip kit where the u bolts mount upside down and come with their plate. $80+$16 shipping is expensive in my opinion so I am looking for a cheaper solution. Now that I know the U bolts are 5/8" diameter and 3.375 wide that helps.

For now I have to get the new rear hangers on and mount the front hangers and get my front axle mounted. So that's enough work for this week probably.

Then I have to put my 4x4 crossmember in and probably change the other front xmember that the sway bar mounts too as well.

After that I need to mount my fuel tank in rear and do fuel lines. Then I need to swap over to hydroboost and do new brake lines.

Then find a crossmember to support the NV4500.. Then a transfer case for the NV4500. Then hydrooboost brake pedals with hydraulic clutch pedal. Then I have to figure out drive shaft, I need to shorten my rear portion then change front portion to go to whatever tcase I get. I swear I saw someone do a crew cab short bed and use a 1 piece drive shaft.. May have been from a 70s model 4x4 ford??? I cant remember, wish I could find that again. I hate 2 piece shafts.

Then mount trans and get ready to see what it will take to mount the 6.5 TD.

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

My local Napa will bend whatever U bolts a guy could need. I'm not sure if it is just my store, but have you checked locally for the bolts?

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

No I haven't yet. I got the set for dana 60. I don't think my napa can but I will definitely call and ask for sure.

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

Hmm I would try eBay for the u bolts. Or, if you call ord, they will sell you just the rear u bolts.

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

Yeah I have been searching ebay and the net.. Seems like longer U bolts that are 5/8" diameter and 3.375 wide are just really expensive. Cheapest set I have found was like $70 with shipping. For that price I should just buy ORD's U bolt flip kit, which is like $87 plus shipping so probably $100. I haven't decided.

I did find a cheap set for like $30 but turned out they were just grade 5 and I don't trust that. Especially when it isn't supposed to be torqued over 110#.

Still no luck finding clutch/brake pedals for what I need and no luck on a reasonably priced transfer case either.

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

I had to look long and hard for the hydro clutch pedal setup. Eventually bought one from a guy advertising on pirate. All the junk yards I looked at were cleaned out and it ended up costing me close to $300 for the pedals, mater, slave, line and reservoir. Good luck. Oh and I can have custom u bolts made locally, so maybe check that option in your area.

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

Unfortunately, I live in a very rural town out in the country. The town I commute to for work is larger but really doesn't have jack in it as far as getting stuff like that done but I do have some calls to make.

Yeah that price sounds about right.. I have seen pedal assemblies for $300 just for the pedals at least you got the other parts. I have a few places to go look but I don't have high hopes.

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

It's your store. I asked the one near me a week or two ago about U bolts and they suggested some other places.

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

Yeah my napa acted like they didn't even understand the question.

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

I got all of the rear hangers off. Plus the little hanger support for the rear which I noticed I am missing for my 4x4 hangers. May have found one though so that's not too big of a deal.

http://i1223.photobucket.com/albums/...pstiv8igsq.jpg

I started to mount the rear last night but was kind of hesitant. I am going to pull my other 4x4 up to the shop to take measurements. I want to place these in the correct position the first time.

http://i1223.photobucket.com/albums/...psem1sswiq.jpg

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

Teaser

http://i1223.photobucket.com/albums/...psueob6xa7.jpg

http://i1223.photobucket.com/albums/...pscybf9bir.jpg

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

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

Looking good. How much did you cut out of your frame?

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

To make it a short bed? If so, I've cut out 14" behind cab but I still have a few to cut off at the rear of the frame just haven't done it yet.

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

Yes, to make it a short bed. Thanks for the information. Keep it up. :metal:

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

Nice work!

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

Nice work! I've always wanted a short bed crew cab square and can't wait to see how yours turns out :metal:

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

Thanks!! I'm liking it more and more that is for sure!

Just wish I could get my dang engine!

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

I will start off by saying this was very scary to me and I hope I did it right! What I did was measure exactly the same as the 4x4 donor frame then drop it down 1". I hope this will work out. For some reason drilling this 2" hole with my hole saw and little dewalt drill took 45 min and lots of breaks. The other side took like 15 but I used my giant milwuakee drill.

http://i1223.photobucket.com/albums/...pszzvhou3q.jpg

This was a good feeling. I am worried about the rear shackle angle. However, not a lot I can do without all the weight on it.

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

I also finally opened up the 79 rear diff to see what gears it had so I would know what gears my Dana 60 has. Turns out it is 4.10's which is exactly what my 88s stock gears where so no worries about not matching gears anymore.

http://i1223.photobucket.com/albums/...psxzz1xy2s.jpg

One thing I could really use some HELP on is the engine crossmember. Most threads I have read people used DIY4x crossmember or something other than oem stuff. I am having problems with fitment so I will need to figure out what to do here.

http://i1223.photobucket.com/albums/...pszm32n7mc.jpg

I wanted to see what it would need to take to get this thing level so I threw some temporary blocks on the back.. I hate blocks and doing this motivates me to buy what I need whether it is 4" springs or the shack flip kit which is way too expensive now a days. I may just make my own.

http://i1223.photobucket.com/albums/...psou3lzkap.jpg

I feel like once all the weight is on it will sit somewhat level but I tell you, it is a heck of a lot taller than I thought! Which isn't bad or good but still shocking me at this point.

http://i1223.photobucket.com/albums/...ps04bf8fou.jpg

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

I would think the shackle flip could be built quite easily for about $40 versus almost $200 to buy it.

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

It is ridiculous! I remember when DIY4x was cheap!

My friend has a design for one so I may just get my other friend with plasma cutter to cut it out and weld it together. Temporarily though I have to track down just 2 u bolts 2.5" wide and about 13" long. I am even having a hard time finding that for a reasonable price.

I have to find someway to get the engine crossmember in so that I will feel safe removing the front crossmember that the brake proportioning valve is bolted to so I can replace it with the 4x4 version. Which I heard may not just fit right in either.

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

I seem to recall that there is a frame height difference between 2wd and 4wd in the engine crossmemeber areas? What is your fitment problem? I remember seeing in one thread that the 4x4 engine mount brackets were too tall to fit in the 2wd frame so a guy just made some kind of 1/4" slots in the brackets so they would slide into/onto the upper frame rail lip. Is that the trouble you are having?

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

Yes the problem is that the 4x4 engine mount brackets that attach to the crossmember seem too tall to fit inside the frame rail like they are supposed to.

The crossmember itself slides in no problem.

I am not understanding what you mean when you say they slotted them to make them fit.

I haven't spent a lot of time trying to make them fit either.

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

On my 76, I used 2wd rear spring/shackle hangers, a DIY4x shackle, and no block to get my rear suspension up. This required cutting the spring perches off the rear axle to reset pinion angle though. It was cheap and works. In the pic, I still have to make or install the lower half support bracket for the hanger.