Project Family Chummins
 

New project....pictures first:

http://i149.photobucket.com/albums/s...dgecummins.jpg

Might be wondering, what the heck is a Dodge doing on a chevy site. Well its step one of Family Chummins

The basic idea is (edit) 92-00 chevy crew cab with a 12v cummins - 5 speed - 4wd. My plan of attack is to put the crew cab body on the dodge frame. It will require lengthening the frame. Since I have to modify the frame anyways, I'm leaning towards making it a short bed cause I think it looks a little better and it will fit in my garage a little easier. (if I can get it in height wise :) )

I don't have the crew cab body yet, and I'm not real sure how quickly I will get one. Depends on a couple of things (selling house in WA, selling 69 pickup (aka No-buck))

In the mean time I'm going to drive the dodge and work on some of the issues it has. I just got it today and found it needs a few things: outer tie rods, front panhard bar, front tires, a radio, A/C fixed, speedo/tach fixed, tail light, cruise control.

The engine seems to be stock other than a straight pipe exhaust (think it might be 4", but I'm not sure). It also has rear helper air bags and a tank. I assume there is a compressor hidden some where. Right now the bags aren't filling up using the controler in the cab....so I'll have to look at that.

So other than the crew cab body, other plans are 17" mickey thompson classic (maybe 18" or 20") on 33s or 35s. Kinda depends where the ride hieght ends up...I'm thinking I might end up with a mild body lift getting the body on the frame.

I haven't decided on colors, but it will most likely be a maaco type paint job with possibly putting some bed liner down low along the rockers or maybe up to the trim line.

I'm not planning to go wild on power. I'm going to do the simple/cheap mods to the engine, so probably around 300-350 HP. Mainly looking for reliability and mileage.

Should be fun, and will be a cool rig when I'm done with it.

Re: Project Family Chummins
 

Can't wait to see what you do with this one!

Re: Project Family Chummins
 

I'll follow along. Should be another cool Ack build.

Re: Project Family Chummins
 

subscribing
good luck with the build bro sounds interesting

Re: Project Family Chummins
 

So I got a chance to do a little tinkering with the truck tonight. Got the tail lights taken care of.

Man there is some scary wiring under the bed. Mainly for the brake controlers (one for regular hitch and one for gooseneck). The wiring includes household wiring and wiring nuts.

While I was under there I noticed the scrader valve for the air tank, filled up the air tank and the air bags work! No on board compressor, but no biggie.

Measured the exhaust, its 4" :D

Re: Project Family Chummins
 

Some of the 80's & 90's Caddy's had on board air compressors for their ride leveling suspension. Pretty small but should do the trick.

I put one on my old 66 El Camino to fill the supplemental air bags out back when I had to load it up.

Re: Project Family Chummins
 

Looking forward to this...I've said it before but one day I will have a crew cab...either a square or a custom made 67...

Re: Project Family Chummins
 

Nice score on your donor truck!

Re: Project Family Chummins
 

I've made a little progress on the Dodge, I'm trying to get it up to where its dependable for daily duty for now.

I changed the fuel filter, tightened up the tie rod adjuster and track bar (hopefully that will decrease the amount of slop), removed the brake controler, and just got a decent set of front tires (and a spare).

I tried to charge the A/C system. Good news is I could jump the low pressure switch and the A/C clutch/compressor engaged. Bad news is there is a hole in the low pressure line, so I have a new one of those coming. Hopefully I can change that out, charge it up and have A/C.

I also have a kit to fix the "killer dowel pin" and new thermostat (truck was running about 140 degrees going 75mph, so I'm not even sure if it has a thermostat in it right now).

Re: Project Family Chummins
 

Good idea. That is what killed my brothers truck a few years ago only a week after he bought it. It was on his to do list but he hadn't gotten to it yet when it dropped.

Re: Project Family Chummins
 

Little more progress: I got a used set of front tires that should last me until I get the new wheels and tires. I also got a spare wheel and put the one good tire off the front onto it, so now I have a spare tire if I need it. I still need to get a jack for it.

I got the new low pressure A/C line. It uses some quick disconnect fittings that I had a heck of a time getting seperated until I finally realized that fuel line quick disconnect tool would work on it, then it was easy. I put the new line in and pressurerized it and let it set there for about a half hour to make sure the pressure didn't drop (indicating another leak). Everything looked good, so I vacuumed it out.

In the past I rented a vacuum pump from a rental shop for about $35/day (3 times for "no buck"). That gets a little spendy, so I noticed a pnuematic vacuum pump from Harbor Freight, and picked that up for only $15. You just hook up an air line to it and it will pull a vaccuum on the A/C system. It worked great, pulling a deeper vacuum than the rental vacuum pump would! After about a half hour a having a vacuum on the system I charged it up and the A/C works great.

Then I started on the Killer Dowel Pin. Overall it wasn't too hard, but it took awhile, mainly because trying to get the fan off took awhile. I borrowed a fan clutch tool set from Autozone, but it didn't have the right sized wrench in it. So then I tried to make one (using a scrap piece of metal from No-buck) but it started to bend and slip. So then I went to Orielys and there wrench set had the right size of wrench in it. Came back home and got the fan off. The rest of the job went together pretty easily.

So now that I'm comfortable with driving the dodge (good tires, not going to have the dowel pin fall out) I'm going to get "No buck" cleaned up and ready to sell.

Re: Project Family Chummins
 

Thanks for the input on the HF vacuum pump. I was looking at that one. Can't hurt to try it out for the money.

Re: Project Family Chummins
 

I've used the harbor freight air thing, they are noisy, hard on your compressor, and don't pull down enough for me. I now have a compressor from a bottled water cooler I use for a vacuum pump. freakin works awesome, and it was free! probably could get one out of a window a/c unit as well.

Re: Project Family Chummins
 

The best thing to do first is to pressurize the system to atleast 250-350# with nitrogen. Check for leaks with soapy water and make sure your pressure doesnt drop. Buy just pulling a vacuum without a thermister guage wont show if you have a leak. Unless its a big one. I know that not everyone has or knows someone who has the right tools but I thought I pass on some info for you all. The same goes for any other A/C or refrigeration system you may have. If you hire a service co. and they repair any leaks, if they dont do the above you theyre not doing their job properly. And with the new 410a they use in our home A/C, it needs to be pressurized up to 600 #.

Re: Project Family Chummins
 

my harbor freight one pegged out my gauge. That was more than the one I got from the rental store.

Re: Project Family Chummins
 

Yesterday I drove the Dodge down to wichita and back, about 300 miles round trip. It was about 105 degrees out and the truck (including the A/C) worked great. The truck runs very cool, about 150 degrees even with as hot as it was out. I managed 18.2mpg doing about 70 the whole way. Not quite as good as I had hoped for, but not terrible either. Apparently I can pick up some mileage if the truck runs hotter (~190 is best I've read).

A slight change of plans. I decided to go with a 92-00 (I think thats the last year of this style of that body style). I decided to do with this for more modern ammenities and less rust. So I found one today.

I picked up a 97 GMC crew cab dually. 454/4L60E/2wd. The cab is rust free. The hood has a few dings in it as well as a few other dings on the body. The is a "conversion" truck, meaning that it has "upgraded" interior that is very dated and tacky with wood and plush leather. Well after 15 years, it is beat, dirty, and nasty. So it will be getting a lot of cleaning, some removal of items, and some new stuff. The drivers seat is totally shot. The center console will have to go at least to make room for the 5 speed.

http://i149.photobucket.com/albums/s...ewcabphone.jpg

I'll be parting out the truck starting in a few weeks. I figure I'll get the most for the engine if a buyer can drive it, so I'm not going to pull the engine yet. Hopefully it won't take too long to sell.

Re: Project Family Chummins
 

What are you asking for the motor and Trans
Posted via Mobile Device

Re: Project Family Chummins
 

Nice score on the truck!

Re: Project Family Chummins
 

It will be a great truck when you are done. Nice choice for the change.

Shouldn't be too hard to find all the interior parts you need as the Suburban & Tahoe share a bunch with the crew cabs of the same era.

Re: Project Family Chummins
 

So here is what a chevy shortbed looks like on a Dodge:

http://i149.photobucket.com/albums/s...s/CIMG9346.jpg

Ha ha

I picked this up today. It is rust free, but has a few dings here and there. No biggies. It did not come with a tailgate. I hope the dually tailgate will fit. I'll have to try it out in a few days.

Here is what I have to deal with in the crew cab. The interior needs some help:

http://i149.photobucket.com/albums/s...s/CIMG9354.jpg

http://i149.photobucket.com/albums/s...s/CIMG9355.jpg

http://i149.photobucket.com/albums/s...s/CIMG9356.jpg

http://i149.photobucket.com/albums/s...s/CIMG9357.jpg

http://i149.photobucket.com/albums/s...s/CIMG9358.jpg

Re: Project Family Chummins
 

I'm in for this one. Should turn out to be a pretty useful truck.

Re: Project Family Chummins
 

Think I will keep an eye on this one too. interesting. The tailgate from the dually will fit. most all of the body parts from that gen truck are interchangeable and easily found. good luck man!

Re: Project Family Chummins
 

that's good to know

today I was driving the ol' dodge for work and stopped and got some fuel and checked the oil. I noticed that the fan belt was shredded on one rib. The alternator had the wrong pulley on it even though it was fairly new.

So I drove home (about 25 miles) and while I was driving I could hear the fan belt clinking against the fan and other things, but I pressed on and made it home.

Upon inspection that rib of the belt had clearance itself and was not sitting nicely in the alternator pulley. But I knew it was damaged and not correct, so I picked up a new alternator and fan belt (know one could get me just the pulley :( ) So I'll keep driving it tomorrow :D

Re: Project Family Chummins
 

I figured it was time to actually start working on this project, so I pulled the crew cab into the garage and pulled off the hood. Its kind of a tight squeeze to get it in there with the dually fenders as well as its length, but it fits.

http://i149.photobucket.com/albums/s...s/CIMG9370.jpg

So after I got the hood off, I decided to start tearing apart the interior. I pulled out the seats and center console. I ended up making about $2.50 out of my work. Then I removed all of the seat belts, and then did a quick vacuum job. I'm hoping to be able to clean the carpet on re-use it, but its pretty nasty right now. My thought though is with young kids, its going to get dirty anyways, so I guess we'll see.

Then I pulled off the drivers side doors.

http://i149.photobucket.com/albums/s...s/CIMG9371.jpg

http://i149.photobucket.com/albums/s...CIMG9372-1.jpg

A lot of the interior pieces are pretty dirty, but should clean up to be useful. Not a bad start for just a few hours of work.

Re: Project Family Chummins
 

You could pull the carpet and pressure wash it with some degreaser cleaner (tuff stuff is one I have used) and then wash it with Gain laundry soap. Clean and fresh....least good enough for everyday stuff.

Re: Project Family Chummins
 

i know a guy who did this kinda swap on a nbs burb using the front frame of the cummins with the back half of burb frame he had about 8 inches of body lift he said but the truck is kinda a hack job the way it looks your gonna make yours looke awesome cant wait to see the finish project

Re: Project Family Chummins
 

Very good progress. Looks like you have your hands full again:)

Re: Project Family Chummins
 

The Permatex hand cleaner that comes in the blue & white tubs at the auto parts store works miracles on greasy carpet.

http://www.oreillyauto.com/site/c/de...x+hand+cleaner

Re: Project Family Chummins
 

I got the carpet out and did some power washing and it looks like i should still be able to use the carpet. Its not perfect by any means, but good enough for now, especially with little kids.

When i pulled the carpet I did find some rust. I'm guessing the A/C was leaking water inside at one point, soaking the carpet padding, and then rusting out the floor below.

http://i149.photobucket.com/albums/s...20725-1705.jpg

I also got the passenger side doors off:

http://i149.photobucket.com/albums/s...20725-1705.jpg

I also got a few interior parts from jtj143. Got a center console, overhead console, dash bezel, and a few other little things.

http://i149.photobucket.com/albums/s...20725-1634.jpg

Re: Project Family Chummins
 

Keep up the good work. When you cut the dodge frame to lengthen it, I recommend boxing it while you have it open. These frames like to flex while in stock form and crack in front of the rear axle.

Re: Project Family Chummins
 

Good to know

tonight's progress:
I had noticed quite a bit of gear lube on the concrete under the dodge, so the other day I crawled under there and determined that the transfer case was leaking around the output shaft. I went to the parts store and got the appropriate output shaft seal and fluid. However, the fluid that is required for the transfer case is ATF. The fluid on the ground was NOT atf. So a little reading on the cummins forum, and found that sometime the tranny output shaft seal will leak and will appear as though the TC is leaking. It sure looked like to me though, that the transfer case was leaking.

So tonight I start tearing it apart. First I drop the driveshaft, one of the ujoint cap pops off as I'm taking it off, and there is a thick paste and a needle missing. So I will be replacing that.

When I pull the drive shaft out of the TC, sure enough: gear lube comes out. I try to pull the two piece TC output shaft cover as a unit with no luck. So I have to pull off the first cover, then remove a snap ring, and then remove the second one. The lock ring was a PITA since there wasn't the little holes to put the lock ring pliers into, but I managed to get it out. Then slid the 2nd cover off. I started to clean it all up in the parts washer. I'm going to go ahead and replace that rear output shaft bearing that is in the second cover since I"m there and have potentially damaged it with the water/solvent in the parts washer.

Nothing real exciting, but a little work that will make the truck a little more reliable in the end.

Re: Project Family Chummins
 

I'm in to watch

Re: Project Family Chummins
 

it always sucks having to go behind someone that does half azzed work. but it sounds like you are making an effort to do it right and with pride. keep up the good work!

Re: Project Family Chummins
 

Digging the new project. :D

I'll be keeping an eye on this.

Re: Project Family Chummins
 

Just an FYI, if there was gear lube in your tcase, I'd pull it off the trans, seperate the 2 case halves, clean and inspect it. These tcases have an oil pump in them located on the back of the main shaft just under the 2nd cover you removed, also known as the speedometer gear housing. Those pumps will get damaged and wipe out a tcase from gear lube beeing ran in it. It isn't much more work to get the tcase off and the parts are rather cheap for them. If you need parts for it, let me know. I can get you the parts and have them drop shipped to you.

Re: Project Family Chummins
 

Went to the salvage yard today to look for a clutch pedal with no luck (anyone have one) but I did manage to score a homelink garage door opener piece that goes into the overhead console. Figured $10 was a pretty fair price considering a new garage door opener is $30 :)

Re: Project Family Chummins
 

This is going to be a sweeet build.

Re: Project Family Chummins
 

Got some work done today.

On the Dodge, I got the transfer case put back together. It took way too long, it was a PITA. The new bearing was maybe 1/16" too thick and I couldn't get the snap ring back on, so I ended up putting the old bearing in. There is nothing wrong with it, but would have liked to put a new one in while I was there. Then I got to the rear u-joint and the bolts were rounded off enough that I couldn't get them tightened down, and then couldn't get them back out. So, I had to cut the bolts off and go get a new u-joint strap "kit" The whole thing turned out in to a big time waster. Hopefully it doesn't leak any more though :)

Then I moved on to the crew cab. I removed the bumper, grill, core support, front fenders, and then started on disconnecting the engine. I have just a few more things to disconnect and the engine will be ready to pull.

http://i149.photobucket.com/albums/s...s/CIMG9373.jpg

http://i149.photobucket.com/albums/s...s/CIMG9374.jpg

Oh yeah, I was wrenching this whole time in the garage while it was 106 outside. It sure is nice having an A/C unit in the garage, thought its not really big enough to keep up. By the time I quit for the day it was about 82 (was about 72 this morning). I can't complain much :)

Re: Project Family Chummins
 

I think the cover needs to be on the 68 back there! Looks like shes gettin dusty!

That 454 is calling my name...

Re: Project Family Chummins
 

It's for sale, come over and get it! 410 ft lbs of torque ar ar ar (in the voice of tim taylor)