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

Was that donor truck in a demo derby or something? Jeeze that thing is rough. Cool project as well. Looking forward to more progress.

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

I don't think so. It was just used to haul wood that was cut back and forth. The truck was originally from up north as you can tell. The body was almost rusted completely away. Most of the floor was riveted or screwed sheet metal. IT was definitely a lot rougher than I was hoping.

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

I was wondering the same thing. Still a good deal for a set of one ton axles and a motor trans tcase.

I've always been curious about those 3/4 ton crews. Looks like the web on the frame is the same height as the one tons. You should measure the spring center lines on the rear to see how they compare.

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

Pulled the 350 and sold it to get some $ back. Still shocked that it ran so well. However, I could turn the flywheel while loosening the torque converter bolts with one hand.

http://i1223.photobucket.com/albums/...psxabr3zbl.jpg

Trans and tcase are both good as well.

The more and more I look at it, the more certain I become about converting my 88 crew to 4x4 instead of doing a body swap. The 78 frame is trash, I don't even think I could make it into a trailer.

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

Subscribed. Will read the whole thread later!

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

Thanks! Hopefully this one wont be as much work as the 87... It has kind of snowballed into doing every damn modification I can think of to make it somewhat unique.

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

Finally something worth posting! The bed is off!

http://i1223.photobucket.com/albums/...pskdphpghs.jpg

Now I need to decide the best way to shorten the frame. Then I will be fixing a head gasket and swapping the Dana 60 under the front.

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

I got it in the shop. Which was kind of a feat considering how nasty my driveway is.. I had to improvise with some 2x6's and what not but it is in.

PS fuel tank is off, DS is on its way. Hoods off and I am starting to take the front radiator core support off. I plan to swap in the 89-91 style while I am doing the front end swap and fixing the head gasket. I currently have a 89-91 Chevy grill but need a GMC one and maybe the wiring harness or at least pigtails.

http://i1223.photobucket.com/albums/...pslbhusjzh.jpg


Now I need to find the exact information on shortening the frame. I think it is 6" back from rear cab mount then 14" with the "Z" cut. Then a few inches off the rear of the frame.

Also need to decide if I am going dual 16 gal tanks or the k5 tank.

This is why I didn't get to make much progress..

http://i1223.photobucket.com/albums/...psxf0wd88r.jpg

http://i1223.photobucket.com/albums/...psm72ipuvk.jpg

http://i1223.photobucket.com/albums/...pscmgm7wwu.jpg

http://i1223.photobucket.com/albums/...psqct83dlv.jpg

I hate this ****tily done addition..

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

starting on post 156, this is what scotts62 did:
http://67-72chevytrucks.com/vboard/s...=369443&page=7
might be an alternate instead of cut/weld.

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

That is very interesting! I assume it would work the same on the squarebody frame but I don't really understand why he went that route unless he just really did not want to cut and weld the frame. Neat though.

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

later in the thread i asked him. he did end up cut/weld but said it rode good.

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

So today I found some stuff of interest on craigslist. I never ever thought I would find a NV4500 for "cheap" but it is possible I just did. It is out of a 94 3500 chevy from behind a 6.5 TD. He wants $500 for it and $700 for the running 6.5 TD. They have like 120k miles. Before I spend the money which I really shouldn't do...

What options do I have for transfer case that would be cheap? I know the trans is hydraulic so what would I need for that? Also I guess I would need to find clutch pedal assembly somewhere. Any info I need before progressing?

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

Search for DirtyLarry's NV4500 swap thread. Very comprehensive.

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

that IS a good deal. need the clutch pedal switch also.

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

I started to strip down the crew cab some to prepare for the work I have to do to swap to 4x4. Also it will make it easier to fix the head gasket.

http://i1223.photobucket.com/albums/...pslrpdaeui.jpg

Then I found one of the valve spring cup pieces that sit on top of the spring between it and the rocker had broken. I will need to fix that. I don't think any pieces made it into the engine, they were all sitting right beside the spring. Head has to come off anyways.

http://i1223.photobucket.com/albums/...ps9imnsg58.jpg

Next was to get my 4x4 components off the 78 4x4 crew frame. Time was limited so I just had to go borrow my dads cutting torch which ended up costing me $200 b/c he was out of acetylene and o2... It got the job done though.

http://i1223.photobucket.com/albums/...psuhu8cdfr.jpg

Here is what is left.

http://i1223.photobucket.com/albums/...pszbqu5cnl.jpg

Also while I was doing that I had my buddy trying to fix my driveway to the shop somewhat.

http://i1223.photobucket.com/albums/...ps5hmqxsvx.jpg

So stoked about the NV4500!! The 6.5TD fell through, not because of me but because the sellers boss sold it the night before and didn't even tell him.

http://i1223.photobucket.com/albums/...pswvldvafb.jpg

I like this shot :) 2016 the year for manual swaps.

http://i1223.photobucket.com/albums/...psvypvie54.jpg

Hopefully I can get some more work done in the coming weekend. I need to get the th400 pulled and sold.

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

Good progress!

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

Thanks. It sucks the diesel fell through. I was ready to yank out all the tbi stuff and put it up for sale...

Now I guess I will get the NV4500 behind that 350TBI once I put a new head gasket on it and wait for my diesel.

I need to find:
The right clutch/brake pedals.
What bellhousing that will work that isn't expensive.
What xmember I need to work
A 32 spline NP208 or NP241...
Dana 60 locking hubs

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

I wonder if it's possible to run triple tanks (duals plus Blazer), might be nice in a truck that size.

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

That would be a lot of damn fuel! My buddy has a 40 gal tank in his K5 blazer. I think it was from a diesel suburban maybe. This truck had 2-20gallons, but since I will be shortening it I will have to go to dual 16 gallons or just the standard K5 blazer tank.

Supposedly with the diesel I should be getting 20MPG so I don't think all that is necessary for this build. Although I may do an auxiliary tank beneath the tool box just in case.

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

i carried a freightliner 100 gallon aluminum tank in the bed of the 96 for years. when fuel creeped up i took it out. i could go 3 weeks between fill ups.

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

That is nice! At some point though the extra weight you are hauling negatively effects the MPG you could be getting so there is that.

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

true. i had removed the heavy bumpers so it was compared to only putting in half the fuel weight. i still plan to put in a 50 bed tank and install a short bed by moving spring perches.

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

So I made a little bit of progress over the weekend. In total about 6 hours worth of work. A few on Friday and then some last night.

I need to sell the TH400

http://i1223.photobucket.com/albums/...psulcnb78n.jpg

This 350TBI is in good shape & will have to do for a bit until I can find a good running 6.5 TD or rebuild the one I am picking up soon. Found out not only was the headgasket on the DS leaking at the rear but the passenger side had blowby as well across cylinder 4 & 6. I will be taking the heads to be checked. They were rebuilt heads, they had the heat sensors on them. Engine looks like a remanned one, rear main seal was even leak free.

http://i1223.photobucket.com/albums/...ps3xlahcab.jpg

I got the front hangars off the 2wd frame and started working on the sway bar and the front xmember.. Getting there.

http://i1223.photobucket.com/albums/...ps5dfmdybv.jpg

Started stripping down the Dana 60 as well.

http://i1223.photobucket.com/albums/...psjbiwjxat.jpg

I need to order some parts.

Mainly the parts needed to attach dana 60 to front end & longer U bolts for my 4" lift springs.

Still need to find some Dana 60 locking hubs. I am trying to avoid getting real spendy on this build. As well as clutch pedals for hydraulic clutch and hydroboost brakes. Then I need to find a reasonably priced 32 spline transfer case!

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

Maybe you can find a good used set of hubs on eBay? What all do you need to attach the 60 to the frame?

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

I am hoping. I have been searching but they just are not cheap at all apparently.

Just to be able to attach it to the frame I need the front spring hangars. I was able to save the rear spring mount at the 2 links, they were fine. Need all new bushings though and new bolts. I need longer U bolts for the 4" lift springs I have as well. The original front springs were trash, ds was cracked then broken at the end and the ps side wasn't in the best shape either. I ended up using the torch on them anyways.

Then I need to fix the bent link, new tie rod ends, x over steering and on and on.

Most important part right now is to mount the actual thing to the frame. I need to get measurements of where to drill and everything. I can have the 2wd stuff off really quickly.

I am searching LMC right now. The front hangars off my 4x4 donor were rusted super thin.