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

I think you are right, that is an option. Definitely an option still to clearance frame. Just have to have mig setup at the house.

When I say intentional I mean like if I go out in a pasture to pick up a vehicle or have to drive through a field our into the woods. I live out in the country, there is no telling what I may come across. I just don't plan to run off into a mud hole on a dirt road or go ride trails with it.

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

I made links for the PS side and made a hole at 4.5" and at 5" this time. I definitely like the gap at the frame this time. At first when I bolted it up I was shocked how much better the 4.5" made the shackle angle.

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

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

However, then I took it out of 4.5 and made it 5" like the passenger side and shackle angle didn't change... Ugh. What the hell.

EDIT: I guess looking at it closer it isn't that far off I guess.

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

It's not optimal, but it will work just fine.

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

I am hoping to mess with it more when I get weight on it, for now I just didn't want it to be touching the frame. Still a long way to go that is for sure. I am just ready to have the frame modifications I need to do, done.

I really want to roll it outside and clean it all off as well. I need to clean the frame and cab as well as clean the mess it has made in the shop.

Last night I also started working on assembling the 355 engine that came out of it, I may just go ahead and put it up for sale so I won't be tempted to slap it back together as gas engine.

Edit: Also I tried "Flexing" the suspension some last night with my small aluminum jack, springs were not giving at all and as soon as the tire got off the ground the jack broke and it slammed down. I moved my big jack under it and tried again and got it way up and spring still would not give at all. I started putting a crap ton of weight on the front end but ran out of time in the shop.

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

Yea those look like stiffies. But with a diesel over them they may be about right.

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

I hope so. Roads are so rough around here I'd hate for it to be too stiff. I even considered bags on the rear.

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

So I had an interesting weekend.

Friday I left work and drove 2.5 hours to charlotte to check out this truck. 96 1 Ton Dump Truck

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

http://i1223.photobucket.com/albums/...psktqwv9oy.jpg

So the current owner has a side business welding, a customer gave him the truck just to make a dump trailer out of. The truck had been sitting for fuel issues and I guess he decided he just wanted a trailer out of it and told the guy he could sell or do whatever he wanted with the truck part, he just needed it made into a trailer. He puts it on craigslist.

I find it and ask how much for engine and he says I can have anything I want for $300 as long as I come pull it. :)

I had planned to strip this truck down of any piece I could ever use. Unfortunately, I was on a time limit and the owner had said he had a torch and was going to go ahead and cut the cab away from the trailer and cut away unnecessary stuff. That didn't happen though.

So I had to strip the truck down when I got there and was time was going away fast and I had to be home before 8. I still got everything I needed and then a little bit of extra.

Also it was really hard pulling this diesel out with the truck on dirt and his home made engine lift he had made when he was like 19 (he was well in his 50s.)

This thing is heavy!

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

Cleaned up the shop so I could push the truck forward and have plenty of room to unload and organize.

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

http://i1223.photobucket.com/albums/...ps5o8soht6.jpg

I started tinkering with it some.

Stripped off the wiring.

http://i1223.photobucket.com/albums/...psffslikg9.jpg

Looked a lot cleaner with all the extra's stripped off.

http://i1223.photobucket.com/albums/...ps88ibtpty.jpg

I couldn't help myself, I wanted to see it sitting in the truck.

http://i1223.photobucket.com/albums/...psinsi0b6g.jpg

Couldn't use the 6.5 DS manifold, I need to track down a 6.2 manifold for it.

http://i1223.photobucket.com/albums/...ps3ajcbufw.jpg

Here you can see why I had to take the AC box off.

http://i1223.photobucket.com/albums/...ps582gmjjn.jpg

http://i1223.photobucket.com/albums/...psbswr8tda.jpg

I am having a lot of problems getting it to mount to the frame correctly though. I can get one side in perfectly but the other side is about 1.5" off. I haven't put new clamshell mounts in yet. I was test fitting. I even swapped 3 different sets of mounts that bolt to engine and none of them seemed to help too much. Any THOUGHTS?

Here is the closest I could get.

http://i1223.photobucket.com/albums/...psgwpln8mm.jpg

http://i1223.photobucket.com/albums/...psdy9xjalv.jpg

I have heard people saying I need "shorty" mounts? I need to move clamshells up to the BBC mounting holes? I need to twist the engine and use a screwdriver to push up the rubber inside the clamshell? Who knows.

Check out how much larger the radiator is!

http://i1223.photobucket.com/albums/...psamm7nbyq.jpg

Also I robbed the hyrdroboost setup thinking it would be a direct swap but doesn't seem to be. From left to right we have the 79 hydroboost, the 88 vacuum and then the 96 hydroboost from donor. I have been told I can swap mounting plates or something then maybe extend or shorten the rod.

http://i1223.photobucket.com/albums/...ps274b8xgy.jpg

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

I also noticed this on the 6.5.. May need replacing for sure.

http://i1223.photobucket.com/albums/...pstvxf5ppn.jpg

I also found some time to reassemble the 355 TBI that came out the truck. Hopefully I can get it sold.

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


Also thanks to my buddy, my T56 is back assembled :)

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

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

Short of just building new motor mounts, I'm not really sure how I would solve that issue.

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

The 6.5 is supposed to mount exactly like the 6.2 which is supposed to mount exactly like the 350. I have read that time and time again. Am I wrong?

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

Pretty sure on this gen truck all the mounts are in the same spot. I couldn't get my used 350 back in last time on my crew and it looked about the same. I had just put the poly guts in my clamshells and got it home by doing the following: loosen the clamshell to crossmember bolts, both sides; drop the motorin and massage both clamshells with a bfh until it drops in, marries up to the trans and you can get bolts in both motor mounts; tighten the clamshell to crossmember hardware. Can't recall if I had to pull the motor back out for the last step. I recall the fit looked about as hopeless as yours until I backed those bolts off.

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

Yeah that seems to be quite a few people's opinion. That is should fit I just need to move the rubber mount inside the clamshell some.

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

the 6.2 will bolt up but the pipe fitting is smaller than the 6.5. my 6.5 has donuts and the 6.2 didn't or maybe it was the other way around.
how many miles on the 6.5? might just be an issue with the PMD.
love the GMT400 HD's. esp crewcabs.
you're inspiring me to jump on mine and get it back on the road.

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

Feels good to inspire someone and give them a little motivation for their own project.

Are you talking about the exhaust manifolds?

I think the engine had less than 200K but it wasn't low mileage or anything. We tried to get it to fire up, it turned over great! I unplugged the glow plugs and pulled the fuse and shot some starter fluid in and it acted like it wanted to fire up but after enough cranking over the starter made a little grinding noise so we stopped and I just went ahead and pulled it.

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

I pulled the engine back off the frame to do some checking and what not.

http://i1223.photobucket.com/albums/...ps42goco6b.jpg

I also removed most of the TBI harness that will be coming off at some point.

http://i1223.photobucket.com/albums/...psiv5bmqwp.jpg

I need to clean and paint the firewall black. What is the best thing to use on the firewall that grease/oil wont stick to? I thought about under coating it or a type of rhino liner, something that will also maybe deter a little heat? I just don't want to spray paint it but I am not set up to do a legit paint job yet either.

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

I would not use starting fluid on a diesel. lots of warning about it but I'm guilty also. I use WD40 instead now.
make sure you install the rear brace on the starter when you get it replaced. broken cast iron mount ruined the engine that was in the truck when I bought it. reason it only cost 700.00.

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

I thought WD40 has changed and isn't flammable and wont work anymore, that is why I tried starting fluid. Overall I only used maybe 2- 1 sec squirts. The discouragement is when people spray the heck out of it or leave glow plugs wired up. I think. Still learning.

I saw someone who was successful in using the 6.5 ds manifold so may still try it, it wouldn't fit b/c it still had a cut piece of the down pipe attached to it.

Starter brace? I will look into it. Starter looks perfectly fine though, the flywheel was a tad chewed up but starter still looks fine. Engine still turns over nicely as well.

Only discouragement I have is that I can't seem to find anyone who has kept the electrical pump in the swap or all of the wiring. Most just convert to the early 90's 6.5 mechanical pump, which isn't something I particularly want to do.

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

I will not use wd40 in a cummins. They tend to want to run away on it. Ether with upper end lube helps. But I agree, usually the disclaimer is for the people that want to drown them with it and things go boom. The biggest issue is people don't think of the grid heaters and glow plugs will ignite the ether and that can be seriously not good. Nice score on the 6.5 too!

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

Thanks! I think it was a good deal as well!

I used the starting fluid with the upper cylinder lube. For some reason I thought back in the day you could get some that wasn't 100% ether and was a little less harmful.

Oh well, I have high hopes for the engine. PMD is in stock location so I'm hoping it just went out. I also took manifolds off and looked down inside and it looked good. I plan to do a compression test at some point.

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

Started tinkering with the engine last night. I am trying to learn as much as I can about these diesels. First I wanted to make sure I didn't miss a remote mounted PMD.

I didn't, it was right where the factory put it, and was covered up by a rats nest! I don't know fellas but I think that may have been the problem!

http://i1223.photobucket.com/albums/...psjd9vkrln.jpg

Pulled the filter to check it..

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

Next I pulled the intake cover.

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

I also pulled the thermostat housing, I guess that is what you would call it and I looked down in the heads and down in the water pump and even in the opening where a "350 timing chain normally is." It looks ridiculously clean inside. The turbo was even really tight with no side to side or forward to back play.

I may get it where I can pull valve covers and drop oil pan and if everything looks good, slap it back together and see about getting it to run.

I will need to replace glow plugs, I wish I had an easy way of getting the injectors checked. Fingers crossed I won't have to throw money at this thing!

Also considering PMD relocate of course, as well as the newer style dual thermostat housing and any other little tricks I can throw at it that won't break the bank.

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

Was there a year the 6.5 came with a mechanical injection pump? We have had lots of those for work trucks and you need to keep a pocket of those PMD's handy. Even remote mounted we had lots of problems.

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

Yeah 92&93 came with mechanical as far as I know.

Apparently just remote mounting the pmd isn't enough it also needs a heat extractor or "cooler." Also helps to put it where the air will be blowing on it.

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

here's a link to the brace. it's an important piece, if it's been removed, something will break:
https://www.google.com/search?q=1996...Es83QNLduRM%3A
my 92 is mechanical. a little power loss didn't matter compared to simplicity.

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

I'll make sure it is there. I wish I had the 93/94 parts available to play with. It was crazy hard finding what I did find.

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

I am kind of shocked how clean this thing is coming apart for me to check it out.

These gaskets look nearly brand new.

http://i1223.photobucket.com/albums/...ps6zb4t5ym.jpg

I vacuumed out some leaves and left overs of a rats nest that was around the pmd.


http://i1223.photobucket.com/albums/...psijhxwrk0.jpg

Pulled the valve cover off as well... Still looking good in my opinion.

http://i1223.photobucket.com/albums/...psyatxih2i.jpg

I finally had some free time to go to my local junkyard where he has a lot of squares but normally charges out the roof prices.

He has a crap ton of transfer cases, I went digging. I think I may have even struck a deal with him to trade a 32 spline tcase for one I had spare from ls swap from a 2001 Silverado. However, I want to make sure I get the right t case, apart from looking at the tag and the normal identifiers I am not sure how to be 100% sure they are for a square. I found several 32 spline 208's and 32 spline 241. Of course I would prefer the 241 b/c of electronic speedo but how do I know 100% sure that it is passenger side drop and will work? Also I noticed a lot of the "hubs" that the drive shaft would bolt to vary, I saw some with a spot for u bolts, some with a 4 bolt circle pattern and some that looked like could be 6 bolt pattern. I go back on Friday to make a deal.

http://i1223.photobucket.com/albums/...pszlg3gpsf.jpg

I also found me some pedals that I have to go back and pull. Hydroboost and Hydraulic clutch. :)

http://i1223.photobucket.com/albums/...ps6r6qmubg.jpg

http://i1223.photobucket.com/albums/...ps63bkjhja.jpg

Another thing I need to figure out is drive shafts. Front and rear. I had the Th400 where it used the u bolts to bolt to the rear of trans, now I will have a slip yolk as far as rear driveshaft is concerned. I will need to modify and shorten it anyways. I would love to get rid of the 2 piece, I swear I saw someone was able to use some ford driveshaft or something at one point.

As far as front driveshaft, how many different types are there? Are they specific for the Dana 60 or will one for Dana 44 work? This is one I have that looks like it would bolt to the 208 or 241 tcase, I swear they used to extend a bit longer than in the pic though.

http://i1223.photobucket.com/albums/...psj13ehn0z.jpg

Oh yeah, bad news $ wise... I got a call from machine shop the day I was supposed to pick up my LS1 telling me it will need to be bored.. There goes an extra $600 probably. I did pull the trans am out the shop and clean it though in preparation to be hauled to my buddies.

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

Even more bad news $ wise. Machine shop cant find pistons that are 3.903 or 3.905 that are hypereutectic, only 3.908 which is max overbore for the LS1. I don't want to go max overbore when it only needs .005, so far my only choice is to buy forged pistons or go .010 over :( I haven't decided yet.

On another note, the owner of this truck is going on a cruise this Friday and wanted some gambling money. He told me if I could give him some cash by Thursday that he would knock $150 off what I owed him so now the truck is paid off and I have the title :). So that was nice.