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

Some new pictures.


Smoked out the entire shop within a few seconds of it running.


As you can see I have a leak and it appears to be coming from the fuel filter housing. Damn thing.


Here you can see also what I am having issues with a thermostat crossover. I have the original dual tsat from the 96 that won't clear the mechanical linkage and the idle adjuster and the 83 single tstat xover that clears that but ends up sitting right where the ac compressor should go.


Also a picture of the 06 Navistar engine I am due to go pick up.

What’s the story with the Navistsr engine?
You going to use it for this truck?
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Re: Let's Build A 1 Ton Crew Cab 4x4
 

I found the navistar for sale pretty close by at a price I just can't ignore. It will be my back up for this 6.5 considing I have already found a hair line crack in one of the mains.

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

Cool about the find. Not so cool about the crack. It's an NA motor then?

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

Yeah I have always known my 96 6.5 had the hair line crack but gonna run it until it dies I guess.

The seller said it was NA setup that was going to be put into a suburban. I am not entirely sure what that means. I don't know that much about them. I just know it has the better design so would be better suited to build up to replace the one I am currently running.

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

82GMCK.. guess what issues I am running into...

Also! Screw (pun intended) that stock 6.5 FFM. I have a duramax one on the way!

Any help or more insight on the plastic intake box meeting the cast air intake box of the banks setup? I remember you said it was a pain.

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

Stripping it down for paint! I moved everything but the cab and frame to my painters place last night. Super excited about the color change. We are stripping it completely down for the recolor.

I am also removing the dash to replace with one that hasn't been cut up and beat on, so that should be interesting.

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

Awesome
What color are you going with?

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

I am a simple man, I love black. So black it is. Ive asked him to get some GM/chevy black and give it like 4 coats of clear.

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

Cool. I do love the way black looks.
I don’t love trying to keep it clean.

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

Same. I have a black 2010 CTS-V and I love it to death! I just need a fully enclosed garage for it, otherwise if I want to drive it I have to wash it like 2x a week. However, I do need to do a ceramic coat on it and that would probably help some.

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

Anyone know of a place that sells a weatherstripping kit? I need the front windshield, back glass, all 4 doors weather stripping that goes on the body as well as the weather stripping for the door glass. I see plenty of places that sell it bit by bit or a small kit of this and so on.

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

Working on my front xmember for the 4wd conversion so I can incorporate a steering gear box brace and be able to attach the factory 4wd swaybar. Also venturing into making a clearance transmission crossmember. The one pictured is for 1/2 & 3/4 tons but I plan to make a 1 ton version that could go along with the 4wd conversion stuff.

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

Started tinting some of my glass and got the 1 ton style crossmember designed and made to put on my truck.

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

Test fitting the adjustable sway bar links here.

Also finally got a teaser picture from my painter. I am loving it.

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

Guys, Photobucket is up to something....

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

I can still see your pics, but I'm running a browser plugin (Chrome) that fixes the broken photobucket links after their BS policy change last year.

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

need more info.

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

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

Any updates on your build?

Still in paint prison! Starting to drive me a little crazy! Haven’t worked on my own project for 8 months.
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Re: Let's Build A 1 Ton Crew Cab 4x4
 

Had a somewhat huge setback. The stand for the bed collapsed not too long after it was completed and we were going to swap the cab out... So that's getting fixed now.

I was informed my tailgate wasn't so nice underneath several layers of hidden bondo so I had to get a new one and a few other parts as well.

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

Ugh.... that sucks about the bed. Glad you stopped by though. :)

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

Thanks! Wish I had more to show, if anything else happens Ill be glad to show it too. This dang truck is going from just a driver and something to haul a camper to probably a whole other level once it gets back from paint.

I have been building a little c10 short bed pickup to so we can develop some parts for it.

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

Awesome work! I just finished reading through the entire thread.

I've been trying to research how to 4x4 swap a 2wd 1 ton and so much of the information out there is wrong or does not take into account the differences between the 1/2, 3/4 and 1 ton frames. Thanks for taking the time to document everything you've done its been an immense help.