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Old 11-16-2009, 07:18 PM   #1
49ZR2
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49 Chevy on a 2000 ZR2 low buck build

It was suggested that I start a thread on my build. I'm not sure many are interested, so if you want more let me know.

My build started out in life as a 1/2 ton, worked hard enough to enjoy a 14 year retirement in an old navy store. Now it's making a comeback as a 3/4 ton, NAPCO looking truck sitting on a 2000 ZR2 frame and drive trane.
I didn't set out to build a 4x4 but got lucky and came across a ZR2 that had been rolled over. It belonged to the owner of a scrap yard and had been sitting inside without a body since he got it in 2001 with 18,000 miles on it. He was liquidating the place and after hearing about about it at 11:00am one morning I owned it when the auction ended at 5:00pm. Here's what it looked like when I first saw it June 08. Just try and get the stock radiator to fit under those fenders! So much for my low cost build. Did I mention this is my first build. So much to learn,, so little time.
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Old 11-16-2009, 07:51 PM   #2
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Re: 49 Chevy on a 2000 ZR2 low buck build

this is going to be interesting, can't wait to see how it progresses. Welcome
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Old 11-16-2009, 09:09 PM   #3
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Re: 49 Chevy on a 2000 ZR2 low buck build

more please.............
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Old 11-16-2009, 09:46 PM   #4
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Re: 49 Chevy on a 2000 ZR2 low buck build

Within a couple of days of bringing the ZR2 home I started to realize that besides all the mechanical fitting challenges ahead of me fitting these two trucks into one, I hadn't given much thought to the wiring issues of a vortec. I quickly decided that I needed a complete cab harness (wrong) and quickly went back to the yard and bought half a truck cheep before he closed. I was told that the wiring was the same on a 2001 S10 4x4 as the 2000 ZR2, no problem (wrong again) and so I stripped the cab of its harness. After trying to mate them together I realized I had gotten poor information.
The extra half a truck showing up out back didn't get by the wife or neighbors either.

After trying to hookup the harness the challenges became soooooo obvious. And only a few extra wires.

I just kept reminding myself how much fun I was having.
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Old 11-19-2009, 10:41 PM   #5
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Re: 49 Chevy on a 2000 ZR2 low buck build

Hey 49ZR2, What is the width of the rear end from that Blazer. I know a guy near me that bought 4 brand new rear ends from the ZR2 and I need to know how wide they are to see if it will fit on my original frame. Is your 4 wheel disc, 3:42 Posi?
Thanks
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Old 11-19-2009, 11:06 PM   #6
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Re: 49 Chevy on a 2000 ZR2 low buck build

MORE MORE MORE!!!!!!!!!!!
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Old 11-19-2009, 11:37 PM   #7
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Re: 49 Chevy on a 2000 ZR2 low buck build

Atomsplitter, I think the width of the rear end is 63". I have noticed that the wheels have quite an offset. I will have to add a 1 1/4" wheel spacers on the rear end so the wheels will clear the box sides. So they start to get close but I like the look. The pic below is without the spacers yet.
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Old 11-20-2009, 03:42 PM   #8
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Re: 49 Chevy on a 2000 ZR2 low buck build

ZR2 rear axle is pretty close to 63" wide. I used a regular 4wd rear axle in mine (60"), with stock 2wd s10 wheels (less backspacing than 4wd wheels) and I still need 1" spacers for the tires to clear the inner fenders. I think the ZR2 axle would be perfect for someone who doesn't want to tub the bed.
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Old 11-20-2009, 04:36 PM   #9
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Re: 49 Chevy on a 2000 ZR2 low buck build

got any pics of where you mounted your cab mounts? thanks
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Old 11-22-2009, 11:46 PM   #10
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Re: 49 Chevy on a 2000 ZR2 low buck build

53GMC, I'll get some for you over the holiday weekend. I know they are modeled after some I found on this forum. I hope that's soon enough.

BlueJeep, I think I'm going to try and shorten the box and running boards as you suggested. It looks like mine could go forward about 3". I'll take more specific measurements and cut it down next weekend.
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Old 11-23-2009, 11:11 AM   #11
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Re: 49 Chevy on a 2000 ZR2 low buck build

Quote:
Originally Posted by 49ZR2 View Post
BlueJeep, I think I'm going to try and shorten the box and running boards as you suggested. It looks like mine could go forward about 3". I'll take more specific measurements and cut it down next weekend.
That makes sense. Your tire size (and technically cab placement) will dictate what will look the best on your truck. With the 31's, I'd expect you'd cut more than I did with my 235/75R15's to keep the front edge of the tire out from inside the front of the rear fender.

One thing to maybe consider is that the rear mount on the running board where the bracket goes to the frame won't work in "stock" location...that would send it straight into the leaf spring mounting bolt. If you remove that bracket from the running board, you could move it forward a little more and make mounting of the running boards a little easier. I haven't done that yet on mine, I only have the front 2 brackets for each board done so far.
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Old 11-23-2009, 01:28 PM   #12
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Re: 49 Chevy on a 2000 ZR2 low buck build

That sounds good 49ZR2....im lookin for where they are placed and what side and a few other things...but any and all pics will be greatly appreciated! Thanks again!
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Old 11-27-2009, 08:33 PM   #13
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Re: 49 Chevy on a 2000 ZR2 low buck build

53GMC
I went back through my notes and found a drawing of the mounts I used. There made out of 3" tube cut on a diagonal. As you can see in the images of the actual mounts I have them bolted on until everything is lined up. Then I will weld them in place. I will also add a short support on top of the rail. The mounts are based on drawings I think I found on this forum by Jeff51. They are however a different size. I used the stock ZR2 rubber mounts on top of them. For the back of the cab I simply used the stock mounts and through bolted them for now.
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Old 11-27-2009, 09:08 PM   #14
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Re: 49 Chevy on a 2000 ZR2 low buck build

So, what about the wiring harness?
"stay focused, forget the rear end, what about the wiring??"
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Old 11-28-2009, 09:56 AM   #15
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Re: 49 Chevy on a 2000 ZR2 low buck build

Bill, yesterday was thanksgiving and thanks to you and other vets like you I was able to enjoy another day with most of my kids and grandkids. Thanks for all that you vets do and have done!

"Focus" -- I started out trying to reuse the entire wiring harness from the trucks. After all they had these neat little snap together plugs, who could resist. After about a year of calling and emailing --- everyone I spoke to just wanted to sell me a new complete wiring harness. While I didn't think I needed a $1500 harness. Finally I stumbled on Larrys Electric http://www.larryselectricsite.com/index.html
Larry was the first guy that took the time to listen to what I was trying to do and then try to give me some options. I decided to send Larry my motor and transmission harness and PCM. He reworked the harness ($400 I think) and re-flashed the PCM $100. I will buy or build a harness for the cab and lights. The harness worked fine right out of the box.
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Old 11-29-2009, 08:25 PM   #16
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Re: 49 Chevy on a 2000 ZR2 low buck build

Shortened the box this weekend

Bluejeep pm'd me with some pictures of how he shortened his box and running boards to match his wheel base. What an inspiration he was......where was he while I was trying to do it? Just kidding it was as easy as he said it was for someone who knew how to weld. I didn't so I did some research online and got started. After drilling out the welds I cut the box down 3", cleaned up the stake support brackets and welded them back on. It took most of Friday and Saturday but I'm stoked. I think it looks great! What are your thoughts? Below are the before and after.
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Old 11-29-2009, 09:38 PM   #17
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Re: 49 Chevy on a 2000 ZR2 low buck build

Looks much better, good job!
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Old 12-21-2009, 09:46 PM   #18
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Re: 49 Chevy on a 2000 ZR2 low buck build

I decided to leave my motor in it's stock location. It's a little tight upfront but I thought it was a little easier and less expensive than making new motor mounts, moving the trans mount, and making new drive shafts.
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Old 12-21-2009, 11:56 PM   #19
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Re: 49 Chevy on a 2000 ZR2 low buck build

49ZR2, I'm glad to see that you have a build thread. I have some questions for you now. I've read in a couple different forums that the 4x4 frame with these body styles are a bit difficult to use. Did you have any problems with mounting your body? How high are you off the frame? It looks to me about 4". Last, are you driving it around yet? It looks like you could be.

Nice work on your build. Post a lot more pictures of you truck it looks awesome!
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Old 12-22-2009, 03:26 PM   #20
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Re: 49 Chevy on a 2000 ZR2 low buck build

Nick, your right it sits about 4" off the frame in the front and 3.75" in the back. Thanks for the kind words

I did have some challenges alligning the front clip but it didn't have anything to do with the 4x4 frame. It was because it had been disassembled and in pieces. I really haven't found the frame to have caused me any real challenges. In fact sometimes after reading some of the other posts on this site mine build seems to have been pretty easy.

Driving has been limited to the neighbors for a beer or two.

I still have to mount the box and running boards, install a wiring harness and gauges, then disassemble everything and weld all the brackets in place. Then I can reassemble and take it for the big test ride - this spring I hope.
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Old 12-22-2009, 10:52 PM   #21
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Re: 49 Chevy on a 2000 ZR2 low buck build

Nick -
49ZR2 is right about the 4x4 frame not actually being that difficult. I used a 1996 V6 Vortec 4x4 S10 and it did not pose any major problems for me - in fact, the height that i was able to set my on the 4x4 frame actually made the clearance for many things a little easier in my opinion....

49ZR2 -
i left my motor in the stock location also...because we both have a 4x4 suspension and frame (although yours sits a little higher because its a ZR2) i think our projects are startin to look a lot identical!

you are doing an awesome job...every picture you take really helps me out so keep em coming!!

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Old 12-26-2009, 05:20 PM   #22
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Re: 49 Chevy on a 2000 ZR2 low buck build

Hood Adjustment Blues - I've been surfing the site today while recovering from Christmas and noticed a post by snoopy0775 http://67-72chevytrucks.com/vboard/s...77#post3693777 In the post there are some pics from Richard H and Solidaxle that make my hood alingment look like crap. I probably will have to go back and play with the cab tilt again. My front clip came in pieces so I never saw it properly assembled. If any of you have hood alingment pics and advise please post them.
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Old 12-26-2009, 06:58 PM   #23
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Re: 49 Chevy on a 2000 ZR2 low buck build

truck is looking good, so how did you get ahold of it? every time I see one of these trucks sitting somwhere as a prop I think its such a waste.
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Old 12-26-2009, 10:54 PM   #24
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Re: 49 Chevy on a 2000 ZR2 low buck build

I will work on gettin you some pics 49ZR2.....i had mine all mocked up and had some motor fabbing to do so the moment i get it all back on i will post pics to this thread...ill try to hurry haha
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Old 12-26-2009, 11:11 PM   #25
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Re: 49 Chevy on a 2000 ZR2 low buck build

Thanks 53GMC, i'll watch for them. I thought I was really close until I saw what some of the other guys were able to do. So now before I start welding the mounts in place I should try adjusting the fit one more time. I think it's probably down to adjusting the cab front up or rear down 1/4" or so. Any close up pics of how the hood fits into the fenders is appreciated.
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