Let's Build A 1 Ton Crew Cab 4x4

[NastyBuzzard]

Got a few things done.

Prototyped my brake setup, finally!!

















My friends also came over and we set the engine in the frame after getting her back on her front wheels.



Anyone know where I can find the hardware to attach the ac setup to the firewall? I have lost my hardware.







Showing my oil pan clearance w/ my xmember.





I need to spend some money on clutch and what not to get the trans in and start wiring and plumbing this thing up!

[NastyBuzzard]

Next revision worked like a charm!















Even tested drivers side.





Also worked on getting the NV4500 in.









Is there a cover for this??? Would love to find it and get one.



Cleaned up the Tcase.



Painted pedals as well.



Anyone know what size bolts it takes to mount tcase to the trans? I lost mine.

Still need hardware to mount the ac box back on as well. No clue where that went.

[83GMCK2500]

Originally Posted by NastyBuzzard

Is there a cover for this??? Would love to find it and get one.

Anyone know what size bolts it takes to mount tcase to the trans? I lost mine.

Bellhousing cover for the diesel engine/starter: 15699054

Bolts: 3911926, which I think is just a 3/8-16 x 1" bolt of grade 8ish variety.

[NastyBuzzard]

Woo! Why are people charging so much for that cover! Looks like I will be making my own.

Thank you for the bolt size. I ended up using about 3/8-1.5" and now I know why that was a pain in the ass. 1" would have been so much easier, those 1.5" took forever to thread all the way in. Lesson learned.



Did some more tinkering with driveshaft lengths. Was able to swap one I had for a longer one at the junkyard but I overestimated and got one 2" too long so got to go back and swap for a bit shorter one. Just excited I was able to swap and save the $ I was going to spend on getting a shaft made. Seems I need one around 76", the 78" one is the exact length from the axle flange to the back of the tcase.



Also got the trim piece I have been needing for the bed for free!! Needs a little bit replaced on it b/c of rust but it fits perfectly!!!



Latest and greatest of the brade adapter arrived!





This spring has to be used, AC delco hardware kit, dorman one comes with a normal spring that rubs the hub.

















So since I noticed the rear axle was a bit forward b/c of my flip bracket I made. I ordered some EZ inch, new Ubolts and the Ubolt flip bracket. So I had to drop axle. Hopefully, I can get all that in soon and axle back under.



Also for reference this is the diameter of the oil cooler line piece for the 6.5.



If all goes to plan I should be going to pick up an 02 2500HD 4x4 DirtyMax this week. It will be our CutBros. truck, at least it is a start. We have intent to design lift parts for it as well.

[mcmlxix]

Nice work on the rear disc conversion.

[NastyBuzzard]

Thank you! In a couple of weeks I will have the adapter for sale

[MTCK]

Good work! You are making good progress.

[deejaaa1]

love those D-Max rims.

[Dieselwrencher]

Nice work and you guys are making some good progress with your business. Are you marketing the rear disc mounting brackets or are they available some where else?

[NastyBuzzard]

Originally Posted by deejaaa1

love those D-Max rims.

Originally Posted by Dieselwrencher

Nice work and you guys are making some good progress with your business. Are you marketing the rear disc mounting brackets or are they available some where else?

You actually like those bullet holes? I am trying to find stock-os or something to replace them currently. I mean, I don't mind them but im not a huge fan. They definitely remind me of my square

Yes, we plan to market them. We have a page on facebook showing them off and what not. Should be available in the coming weeks for purchase. Just need to create a website and all that jazz. Working hard on finishing the plasma table.

[deejaaa1]

yeah, those bullet holes would look good on my 93.

[NastyBuzzard]

Quick solution to the oil cooler issue. Just picked up these 1/2 NPT fittings from lowes to make a short bypass for now until I get it all figured out.



At least that was the plan, then I went to the junkyard on Saturday and found a complete 6.2 radiator setup.



Now I just need to figure out lines from block to these long aluminum lines pictured below the radiator.

Started cleaning up a tad... Started admiring the truck, then decided I wanted to put the bed on.















Wheel is back in the center!!!





So as of right now it is 1-1/4" higher up front. It is also still missing a lot of weight up front and the 4" lift springs are new and haven't settled. I may go back and add the overload spring to the rear which will bump it up about 3/4" of an inch.. Otherwise I will be swapping the front 4" lift springs for 2.5" lift springs.

[MTCK]

Well heck yeah! If you put the bed on you have to do the front fenders! Looking real good. How far back did you move the rear axle? I'm about to embark on a shackle flip myself. Remember when you are measuring height that the front wheel opening is larger, so measure to the body line. I learned that when I was complaining to tuff country that my front springs sat too high.

[NastyBuzzard]

Yep! I had to bolt on one fender just to see, ya know! Even if its coming right back off.

I moved the axle back 1-1/2" with the EZ Inch block.

Yeah, my measurements are done off the body line.

Fun part was putting the bed on by myself, at least its a short bed now. I need this 6.5 to run before I fall in love with the Duramax.

[NastyBuzzard]

Doing some test fitting.

(I realize I have it backwards) EP158 screwed right into the TBI lines! Which makes that a lot easier.



All this is really tight but it fits. Curious if this is really the way to go.



Super tight fit between banks turbo and the alternator. Is this ok?



Also, which valve to use? I figured use the banks one, but how to plug the hole in the valve cover? Or does it need to be routed elsewhere?

[NastyBuzzard]

So I have been trying to get this thing together enough to fire it up. I want to make sure this engine is ok and doesn't sling apart first time I fire it up.

My buddy came over Saturday and started rewiring and repining the 83 6.2 fuse block, engine wiring and cab wiring for me to work with the 88 steering column and what not. He does amazing work I am so glad to have his help that is for sure.



I have ran into some slight hangups though.

First one is I can't get a bolt in this spot for manifold, the frame is in the way.



Had to modify the banks oil return.





Another thing is where to find a new bushing for the throttle cable. Also I need the retainer clip to hold throttle cable on.



Also, since I am running the 6.2 IP stuff on the 6.5 will I have to do something funky for throttle cable linkage? I have the 6.2 linkage, I removed the cruise control piece from it and still have to put the other piece back on the IP.

I have decided to use the 6.5 stock fuel filter setup for now.

I bought a 6.2 OPS... Where does it mount? I tried taking out the plug in the back of the block but it was same size thread as the 6.5 OPS. Or should I just use the 6.5 OPS and wire in the plug for it? Is there some type of 90deg adapter I am missing? I remember those on the old 350s.



Also working on hooking up steering components.

Does this look right? Angle wise I mean.

[wildwilly4x4]

Way too much angle on that drag link....need it flat as possible or its gonna be very screwy to drive. They make a steering block that fits on the axle to raise the arm up higher.

IIRC on the exhaust manifold bolt on mine, I was able to get just enough clearance by jacking up on the motor and pulling that sides motor mount bolt.

I don't remember having to modify my throttle linkage stuff for the 6.5 manifold, but I did have to notch the 6.5 engine cover for the cable.

[NastyBuzzard]

That's what I thought. I was like wait a minute... I used the drop steering link that mounts to the gear box. I think its because currently I have around 5.5" of lift instead of 4". Once I swap down to 2" lift springs I should have around 3.5" lift up front instead. Otherwise I will definitely have to find one of those blocks.

Yeah I will try that, didn't think of that. Didn't want to have to notch frame for it.

Good to know about the cover.

Any clues on the adapter for the oil pressure sensor/switch? Or the throttle cable?

[NastyBuzzard]

Working on engine wiring. Thanks to my buddy it is turning out to look quite nice. Had to bring one piece into work this morning for some soldering because of damaged ends.



Since I elected to use the 6.5 fuel filter setup for now I had to clearance the bracket that mounts to it for the 6.2 vacuum pump.



Any way to clean up these glow plug wires? Also I am using a 6.5 dipstick & tube but it doesn't seem to jive well with the 6.2 manifolds. Do I need a 6.2 dipstick?



I also need a 45deg or 90deg adapter for the oil pressure switch 1/4 npt male to 1/8 npt female. Having a tough time trying to find one of those.

Also, I purchased a 88+ throttle cable b/c the bushing in mine was shot. It was a GM cable off ebay, I heard you could use them with slight modification. Ending up not fitting in my bracket so basically paid $30 for the line just to take the bushing out of it and put into my 80s 6.2 throttle cable. Also, is this really called the idle air control valve?



Few more parts to order this week. I need hydroboost lines, and the older style temp switches/sensor.

[NewType72]

Absolutely incredible detail work in this one. Really love the build and makes me dream of the 4x4 short crew that is mocked up on the longest back burner storage room we have

[wildwilly4x4]

That's a fast idle solenoid.

[NastyBuzzard]

Unfortunately, it isn't my best work but I am trying. I really wish I had the extra time and funds to use an entirely new engine but I have got to see if this one is going to run or sling apart first. Still a long ways to go for sure but I love it!

[daddyjeep]

Originally Posted by NastyBuzzard

Unfortunately, it isn't my best work but I am trying.

You are doing just fine. You are not building a show truck here. Just like my build, it will be a nice truck when you are done that can still be used as a truck.

[NastyBuzzard]

Exactly, this is very much so a purpose built truck.

Now of course I would like for it to look good and be reliable so I am working towards that.

[NastyBuzzard]

If anyone is interested in the 14BFF disc brake adapter brackets I designed please let me know or contact me. I have some extras.