1991 V2500 Suburban
 

I was getting a little tired of making threads doing random things so I decided a build thread where I will continue where I will be leaving those threads off, but first some history I got the suburban 2 years ago off of craigslist and it already had a 4in rough country suspension lift and 36in military tires. Went there picked it up drove it back fine and for about a week drive it around until my starter went out going down the road which was the first of many parts

Also being a Scottsdale it had nothing, so I also had another very rusted out 1991 V2500 I swapped over the front clip *core support and wiring* and under hood light for some reason I didn't get everything else but I sold that to my cousin who swapped under 2-1/2ton rockwells and is now doing 5.3 swap

http://i1199.photobucket.com/albums/...52201535_o.jpg

1991 V2500 Scottsdale Suburban Parts list
Starter - 100$s?
Spark plugs - 20-30$?
Front clip conversion - free
Under hood light - free
Steering column conversion - free
3in body lift -150ish?
38.5in tsl's -1500$ came on a truck I bought whole and sold for 2500$
Headliner redone - 40$
Center console - free *Might use*
OEM power mirrors - free *Not using*
Broke passenger side inner/outer axle and u-joint - free ;-p
Dana 60 front swap - 850$ with matching rear axle I'm not using
Dana 60 swap plates and lift block 60-70$? 4wdfactory.com pieces
Dana 60 kingpin pieces - 20$?
2004ish 10.5 FF - 800$
Spring perches - 20-40$? - ballistic fabrication.com

Parts currently under construction
Custom shock mounts - free
http://i1199.photobucket.com/albums/...811519_o-1.jpg
http://i1199.photobucket.com/albums/...529179_o-1.jpg
http://i1199.photobucket.com/albums/...0274843_o1.jpg
Modified D60 swap plates - free *To accept sway bar again*
http://i1199.photobucket.com/albums/...896854_o-1.jpg
1999 rear bumper - free *Will be trading for orignal*
Bucket seat brackets - free *Might put old stlyle buckets in*
http://i1199.photobucket.com/albums/...989256_o-1.jpg

Parts to come
6.0 - one day
4 bucket seats - Late model
Center console -Old style or late model
Overhead console - Old style or late model
Crossover steering

Re: 1991 V2500 Suburban
 

Totally diggn the burb. I have three that I drive. Just got a 4x4 burb recently to toy with. Will be built on the cheap. I like that you make your own parts

Re: 1991 V2500 Suburban
 

I actually started making my own parts this week because one i could not find anyone that made a stock style shock bracket and to me a high demanded product that should be simple for any company to make the bucket seat brackets, i didn't want to buy an electric cut off saw or anything to cut some out of a junk yard when i could build them free while they are slightly thicker than original i dont think that will be hurting anything and the shock bracket is slightly thinner than original which i also think will be fine but only time and my right foot can tell lol

Future updates most likely within the week i will be testing out a 99 center console/rear bumper/over head console *if its there*/bucket seat *possibly, just to see what the fit is* and for sure a 91 suburban bucket seat to see if the brackets i made are correct

Also waiting on a piece from offroaddesign to re mount my sway bar and should be finishing the front spring plates reinforcing pieces tommorow or at least one, it should look kind of like a regular plate but will not be solid metal but i think it will hold up fine, if it break won't hurt much but my ears and finish at least one of the shock brackets, here's some old links for some of my old builds

D60 swap http://67-72chevytrucks.com/vboard/s...d.php?t=481550
14 FF swap http://67-72chevytrucks.com/vboard/s...d.php?t=460547
Bucket seats *Took out* http://67-72chevytrucks.com/vboard/s...d.php?t=445802

And last but not least trying to invest in another tow truck as i sold my first one which was dumb but i found a nicer one hopefully that goes well and i get the new job i've been testing for

Re: 1991 V2500 Suburban
 

I managed to do a little yesterday and today wasn't much in the mood to work on the truck so tomorrow ill be working on it and the weekend here's the small amount i did do

Here's the bracket i built it sat a little high because one the right side leg wasn't bent up far enough and if you look closer the seat bracket hits the top because these are a little wider than original, so i grinded the edges down and fixed the bend and it sat in perfect all the whole lined up
http://i1199.photobucket.com/albums/...4-47-15_57.jpg

This is with the suburban seat which i finally might be able to buy hopefully even though id rather have a late model set but this will do for now

Re: 1991 V2500 Suburban
 

I managed to do a little yesterday and today wasn't much in the mood to work on the truck so tomorrow ill be working on it and the weekend here's the small amount i did do

Here's the bracket i built it sat a little high because one the right side leg wasn't bent up far enough and if you look closer the seat bracket hits the top because these are a little wider than original, so i grinded the edges down and fixed the bend and it sat in perfect all the whole lined up

http://i1199.photobucket.com/albums/...983144_o-1.jpg

This is with the suburban seat which i finally might be able to buy hopefully even though id rather have a late model set but this will do for now

http://i1199.photobucket.com/albums/...504101_o-1.jpg

And this is it with the newer console in, which i like way better than the old and yes the air ducts get in the way but i want those so ill figure that out later, but ill be using an old console for now possibly

http://i1199.photobucket.com/albums/...614244_o-1.jpg

and here's my truck sitting next to my old one which now has a running but not driving 5.3/4l80/241/2.5t rock well setup

http://i1199.photobucket.com/albums/...090529_o-1.jpg

Re: 1991 V2500 Suburban
 

I haven't got to work on my truck much if at all with the new job and we are working saturday's so now i just don't work on it but i did manage to finish the shock mounts

I might weld them in tomorrow not sure

Re: 1991 V2500 Suburban
 

I have a 6.0 being shipped so now i have to get all the parts ready for that to go in as well so much to do so little time and never enough money

Re: 1991 V2500 Suburban
 

double post

Re: 1991 V2500 Suburban
 

Re: 1991 V2500 Suburban
 

Slightly large update got my 6.0 and my mounts done and today was the last saturday i work for a little bit so not i got some time on my hands sucks its cold out

Re: 1991 V2500 Suburban
 

got the old 5.7 out and the new 6.0 in had some problems with dirty dingo mounts and ac compressor so the compressor was taken off and its a dumb spot anyways ill put it back up high whenever i feel like i need ac again slowly making progress, also using edelbrock shorty headers fit perfect on driver side the passenger side needs slight hammer work because frame notching is out of question, and installed off road design steering brace still gotta got motor completely done like tighten bell housing and torque converter etc etc then off to get wired and running from someone

Re: 1991 V2500 Suburban
 

Subscribed!

Re: 1991 V2500 Suburban
 

Got a few things done still have a list to do, but mainly got the power steering lines after figuring out the fitting is the same as the old one which is a real pain to put on when the motor is in the truck, used 99-00 radiator lines which fit perfect, other things include fuel pump, fuel lines, evap lines, gas tank vent line, vacuum ideas etc

Re: 1991 V2500 Suburban
 

Haven't done much if at all to the suburban besides get basically the whole interior out of a 2000 fully loaded suburban and finally did get my new tow truck for it an 2004 4wd cummins dually 6spd and loving it glad i got another

Re: 1991 V2500 Suburban
 

Back from the dead... got laid off from work and im officially done with welding so looking for a new job/career then my diesel and camaro gave me problems both needed starters and the cummins needed an NSS which was 100$ so i wired it direct instead now for the suburban I've almost got the fuel system done which ill post pics of tomorrow and then i gotta do the grounds still and hammer massage the headers some more plus some other small stuff and hopefully be sent off for wiring by friday
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Re: 1991 V2500 Suburban
 

Small update.

First pic shows a PTFE braided line with a regular fitting which is wrong. Solution - ordered regular braided line which fixed the gap problem and is meant for those fittings as PTFE lines takes only PTFE fittings

2nd picture is my corvette regulator moved a little bit further forward and mounted directly in line with the tank feed line basically like an original TBI gas filter

3rd picture is my original 91 350 temp sensor that was turned down to 12mm/1.5 im pretty sure, then you take out the pipe plug in the back of the passenger side cylinder and and install it there

4th picture is the temp sensor installed

I also put the driver side fender on because its getting wired this weekend and the battery is on that side which is where I am putting the computer as well basically like the stock gm setup hopefully it runs by the 13th for the truck pull or even better the 20th for an awesome party

Currently it needs coolant, oil and filter and temporary block off plate, air intake assembly which im using from my 2003 temporarily, fender and hood put back on, front driveshaft installed, new rear drive shaft, wired, tuned, gas cap, and probably some other stuff that i'll find out the hard way

Re: 1991 V2500 Suburban
 

Got a new welding job after i decided to quit welding... so.... still waiting for the guy to finish the wiring then i have to get a new driveshaft, shock brackets etc etc eventually this will possibly... maybe see mud

Re: 1991 V2500 Suburban
 

Well time to bring this build back to the top along with my newly acquired crew cab money pit. I had actually forgot about owning my suburban for awhile until a friend brought it up, as i left with at the guys house whom is wiring it and hadn't heard anything back since forever but he called me up and its nearly done but a couple of things need addressed.

Problem 1. Old 4l80s obviously didn't come with that neutral shifter signal thing on the side but i have to put one on well another thing is since the old 4l80s didn't have them there are no bolt provisions cast into the housing but nothing some fab work can't fix.

Problem 2. Is my water temp sensor is not in the harness for some reason not sure what happened there still need to investigate

Problem 3. My oil pressure still needs the adapters or a custom machined fitting i haven't decided which i want to do.

Also although not necessarily needed but headers as well which i will probably go with the newer hooker ls manifolds hopefully they work and full exhaust with it

Although some of you may not have wanted to wait as long as i did after finally meeting him and talking with him about aftermarket harness's and all the swaps he has done im pretty confident it will turn out great as nothing was just hacked out of the harness and tossed aside. My fuses and computer will be mounted driver side inner fender which obviously they were designed to be here already i will see how well it fairs in a mud truck =-p

Re: 1991 V2500 Suburban
 

Well i had my doubts but after some fuel issues which was not getting enough pressure because the rubber line that connects the pump to the sender had a hole in it, replaced that got pressure fired right up nice and loud with open headers but i won't run it long until i get the exhaust and oxy sensors in so stay tuned... as its almost back in my possession

Re: 1991 V2500 Suburban
 

Thanks for keeping us updated!

Re: 1991 V2500 Suburban
 

Been awhile since an update i got it home open headers and all, the neighbors love me i bet. Any who i've been waiting on these here hooker ls swap manifolds and i got them today and put them on tonight and it seems they are what i have been looking for. They don't come anywhere near the frame or motor mounts although the passenger side is close to starter and the driver is kinda close to the 4l80 dust cover ear neither i believe will be a problem especially since i would assume they designed the manifold to clear the starter but who knows. Pics to enjoy.

Passenger side
http://i1199.photobucket.com/albums/...ps5dc6cbe6.jpg

Passenger motor mount clearance
http://i1199.photobucket.com/albums/...psdcb5ad06.jpg

Passenger underneath
http://i1199.photobucket.com/albums/...psdae6c280.jpg

Driver side
http://i1199.photobucket.com/albums/...ps42e02f5a.jpg

Driver side 4l80 dust cover ear
http://i1199.photobucket.com/albums/...ps983cad39.jpg

Driver side 4l80 dust cover ear
http://i1199.photobucket.com/albums/...ps97b09ffd.jpg

Overall i think none of it will be an issue because the dust cover ear sits too far back to hit the flange and where the pipe actually exits the manifold is pretty far away it just doesn't seem that way and the passenger side starter i don't think will be an issue either but ill found out eventually lol

Motor pics

http://i1199.photobucket.com/albums/...ps58830426.jpg

Seems a little cluttered but for some reason looks better in real life i still have to move some wires into their spots but for the most part it will look like this but i will put the cover on

http://i1199.photobucket.com/albums/...psec88108f.jpg

Computer and fuses are on driver side upper fender kind of like they are originally but up higher, some may think its a problem being a mud truck but i don't think it will be since its a mud truck and not a big water hole truck which is a big difference. And i already talked to him since it was my original concern and i can move it but i want to see how it does before i do anything if it ends up being a problem ill move it into cab if it does fine its staying there.

Stuff left on it goes as follows.. exhaust-oxygen sensors-power steering box bolts-new rear drive shaft-oil pressure switch adapter

Re: 1991 V2500 Suburban
 

Good to see!

Re: 1991 V2500 Suburban
 

Well the bad news is for the manifolds is they won't fit backwards because they hit the motor mounts and even if you cleared them the cross member would be in the way as well, why this concerns me? Because i wanted a turbo lol but you can flip them up so im still laying out the plans for that but that's a ways away. But if i had my way i would go with a whipple but superchargers are $$$$$$$+$$$$$=$$$$$$$$$$$$$$$

Re: 1991 V2500 Suburban
 

Well there's a mud bog in robertsville, mo coming up so i decided to quit being lazy since the snow is melting and its in the 30-40s so i can work outside again lol, as an update i used my old SF shock brackets because i couldn't sell the axle on clist for 75$ plus they're the same unlike the ones like i made where one was original and one wasn't i want them to look the same. Plus i believe i lost them anyways.

http://i1199.photobucket.com/albums/...ps208b396d.jpg
http://i1199.photobucket.com/albums/...psb96b9fb7.jpg
http://i1199.photobucket.com/albums/...psaa395c4f.jpg

So my next order is to bolt the shocks to the brackets and tack weld them to the axle then pull the shocks off, tie them up out of the way and weld the brackets on. After that i will have a custom drive shaft made so i can move it around at decent speeds then continue on with exhaust and finish the 6.0 swap up. Stay tuned.

Re: 1991 V2500 Suburban
 

Don't worry people my builds are not dead i just got tired of trucks and got back into quads again but i just finished cleaning up the rear shock mounts for the suburban and put the driveshaft in so i could turn it around and tack weld them on then i plan on having a new driveshaft built, slip yoke front-1410 rear and continuing on finishing the 6.0 swap here is the latest pic with my 88R-89V30-91V20

http://i1199.photobucket.com/albums/...ps068cd143.jpg