1996 K3500 Dually Build
 

As if I don't already have too many projects, i'm starting another...
Hope you like to read because I like to type lol.

I was needing a crewcab again and after looking at a bunch of 99-00 CCSB trucks that were way overpriced and absolutely shot and GMT800 trucks being through the roof, I pretty much gave up until this came along. I've never owned a dually but i've always wanted one and this one fit the bill for being a GMC, 95+, a crewcab, and cheap. Wasn't totally wanting a big project but I figured i'd be searching forever and probably overpaying for something that isn't what I really wanted. This being cheap enough, it's pretty much a blank canvas to build the exact truck I need.

My 95 K2500 is my main tow/work rig right now and the poor thing is just getting so rusty and being an extended cab, it just isn't worth fixing now with a family being started. Makes me a little sad because I absolutely love the truck and how it looks so my idea with the dually is to recreate my 95 in dually crewcab form, color, drivetrain and all.

Now for the intro to the dually. It's a 96 SLE with a Vortec 454 and 4L80E and 163K rough miles. Very nicely optioned which made me happy, pretty much only missing leather. Has rear defog, overhead console, power seats, etc. The motor is bad which didn't matter because i'm building a 6.5 for it. I have tons of donors for parts laying around so the swap will be easy.

The truck is honestly pretty rough unfortunately... It was a farm truck and lived on gravel roads so it has rust and dents but not totally roached where it can't be fixed. Frame is solid for the most part, just minor pitting on the rear half although i'm going to replace the rear spring hangers. Floors seem solid so far, just going to need full rockers and cab corners. Doors, fenders, and the entire box is shot but I found a good box and I have everything but rear doors laying around.

This will be a complete frame-off/nut and bolt build that will cost me too much money but i'm all in... The final product plan is a Burgundy/Silver two-tone CCLB dually with burgundy interior, fresh 4L80E, fresh built 6.5 similar to the one in my current 95. I eventually want a slide in camper for it so my wife and I can travel a little as well. This will take awhile so I probably won't update regularly but I hope to have the truck of my dreams within two years.

The day I picked it up.
https://i.imgur.com/40Wzdu8l.jpg

https://i.imgur.com/friXE1Ol.jpg

https://i.imgur.com/M6IBti5l.jpg

https://i.imgur.com/xx6Mjkfl.jpg

https://i.imgur.com/sbaYTuAl.jpg

https://i.imgur.com/16mDWqjl.jpg

https://i.imgur.com/GpOD3tEl.jpg

https://i.imgur.com/h3nNDg5l.jpg

Re: 1996 K3500 Dually Build
 

Started right away getting the old box off and stripping it down to get a better look at at what i'm dealing with. Was happy ALL the bed bolts came right out. With the box off it revealed some lovely farmer esque welds and a gooseneck plate... that and a receiver hitch that was welded to the bumper brackets and frame.. So a lot of cleaning up is gonna have to happen here. Was just happy to find no actual rot in the frame rails or anything.

https://i.imgur.com/GsLWLH6l.jpg

https://i.imgur.com/LCZpOIsl.jpg

https://i.imgur.com/yzUngpvl.jpg

https://i.imgur.com/XeT0i8Ml.jpg

https://i.imgur.com/JjBD7CRl.jpg

Re: 1996 K3500 Dually Build
 

This is about where I stopped for now. I started gutting the front end also but didn't take pics. Right now i'm waiting for my new garage to be built so I can bring this home from the farm and really go to town. Plan is to bring just the cab on the rolling chassis since that's basically all i'm using anyway. Probably going to start on the patch panel stuff first, then strip the chassis and get that all done.

I did get my rockers and cab corners from mill supply the other day.

https://i.imgur.com/QfzfBRAl.jpg

https://i.imgur.com/10ZJ0J4l.jpg

And here's my super mint dually bed I picked up friday. Came from the PNW and was a real good price so I was happy about that.

https://i.imgur.com/Mmq06VMl.jpg

Re: 1996 K3500 Dually Build
 

This is my current 95. This will be the color scheme i'm going with, love it too much to not paint this truck the same way.

https://i.imgur.com/sbOqQPml.jpg

Re: 1996 K3500 Dually Build
 

Last but not least, I picked up a set of 99-00 GMT800 2500 knuckles. This will allow me to do a GMT800 brake upgrade using all stock parts.

https://i.imgur.com/i9Gm8HXl.jpg

Re: 1996 K3500 Dually Build
 

Very cool, that's a good project. Glad to see the big dually saved. They look fantastic in white, but I understand your fondness for your color scheme - your 95 is a great looking truck. Not as much traffic in this part of the forum, but I will be following along. By the way, also, howdy from another drummer.

Re: 1996 K3500 Dually Build
 

I'm in! :wave:

Re: 1996 K3500 Dually Build
 

So because i'm way too particular and love spending money, I decided to change plans for the cab corner replacement.... Turns out there were still a few C pillar panels available for a GMT400 crewcab from GM, so I called my local dealer and they ordered them in for me. I feel like this will be the best method for rust repair because it will get rid of a patch panel seam on the rocker since I will be replacing the whole panel, and is as close to factory as it gets. Will only require the factory spot welds to be done. Also the right side of the cab had a bunch of dents on the corner for some reason so this will also eliminate fixing those issues also.

Another thing is I wasn't totally pleased with the quality of the patch panels I got and this would take a lot less work to get right since it's GM parts. The rocker replacements I got aren't too bad but I don't really have a choice there because uni-sides aren't available for these anymore if I wanted to go that route. But at least the only repair seams will be in the door pillars. I just want this as solid as I can so i'm not doing rust repairs again in short order. Now would have been the time to add in the style line to this piece that crewcabs don't have but I don't really want to get that deep into it... I believe regular cab B pillars fit the same as crewcab C pillars but those aren't available anyway.

https://i.imgur.com/XwL6ZOQl.jpg

https://i.imgur.com/POYHCPJl.jpg

Re: 1996 K3500 Dually Build
 

Sooo unfortunately the dually bed I got had an issue I didn't notice till I got home. The drivers side dually fender had been replaced at one time with a fiberglass aftermarket unit. Honestly the fit isn't the worst but me being me, I know it's going to drive me nuts so I did the right thing and spent more money... Luckily GM still has a few drivers side only dually fender available so I ordered one in at my local dealer. The aftermarket fiberglass one doesn't fit all that bad but where it bolts up to the bottom of the bedside, it's too short, i'd have to lengthen the tab somehow. Also the lines where it meets the bedsides aren't sharp like factory, it's bulky and it bothers me lol. A little modification could make it look decent enough but i'd rather have original GM quality, and SMC looks better also.

Have no idea how many of these exist so if you need one, i'd get on it.

https://i.imgur.com/Ab8kJCDl.jpg

https://i.imgur.com/gQuLcY6l.jpg

https://i.imgur.com/KKdGItil.jpg

https://i.imgur.com/dsD3E5Yl.jpg

https://i.imgur.com/LCdIBSgl.jpg

https://i.imgur.com/zlGjQpBl.jpg

Re: 1996 K3500 Dually Build
 

So an opportunity popped up that I couldn't refuse, and ultimately it's the best route for this truck. Will post updates when I get everything home.

https://i.imgur.com/62enQaDl.jpg

Re: 1996 K3500 Dually Build
 

talk about a cliff hanger! any updates? looks like you are on your way to a solid dually!

Re: 1996 K3500 Dually Build
 

For REAL!:waah: