'99 Tahoe - Expedition Build!

[sparg93]

Even though this is posted elsewhere on the forum, I thought it may be valuable for those specifically interested in overlanding; apologies in advance for the dual post.

Please feel free to ask any questions!!

After quite some time planning and the last two months underneath the truck, we're finally getting close to finishing up our expedition build.

I've learned tons of information on this site, so I thought I would share what I'm up to with you guys!

Leaving towards the end of March, we are going on a multi-month expedition throughout the US, Canada and hopefully up to Alaska. On this trip, we are stopping off at a number of national parks, 4x4 events and even being FEATURED at the Overland Expo in May.

This is an offroad trip, so once we leave the east coast, most of the trek is offroad (agenda still to be finalized)

I'm not online as much as I used to b/c i'm literally under the truck 8+hrs/day, but I'll try to respond as much as possible.

Here are the plans for the vehicle:
1999 Tahoe 4dr 4x4
http://i158.photobucket.com/albums/t117/sparg93/IMG_7649.jpg

14bolt semi float swap
4" IFS RCX Lift
Viking Offroad (http://www.vikingoffroad.com/) - Synthetic Winchline - A MUST have for IFS rigs
Hydroboost Conversion
Custom fabbed tie rods - FFR Fabrication (http://go.ffrfabrication.com/Tie_Rods.php)
HD Ball Joints - Synergy Suspension (http://www.synergysuspension.com/)
Moog HD Pitman/Idler Arm
Pro Comp Extreme AT 285/70R17
Mickey Thompson 17x9
Custom rear bumper w/tire carrier
Custom torsion bars (33% stiffer) - Sway A Way (http://www.swayaway.com/)
Bilstein 5100 shocks (5150's were not valved heavy enough)
Vehicle mounted air compressor
Defender 6.5' roof rack
Volant CAI
BlackBear Tune
12vot guy (http://www.12voltguy.com/) custom switch panel - AMAZING!
220amp alternator - Iraggi
x4 170 Lightforce lights (on roof rack)
x2 KC 130w on ARB Winch bumper
Body Armor (skid plate, frame sliders, tank protector, diff protector) - Crum Custom Welding (http://crumscustomwelding.com/)
Larger trans cooler
ARB front bumper + 12k Superwinch (still need to purchase)
ARB fridge (http://www.arbusa.com/) - 60 Liter
DDM 35 & 55w HIDs w/4hi mod

Trailer:
LV416 Trailer
30 gallons water
20 gallons fuel
Holds lots of spare parts and equip

As I add more and finish up installs, I will update this first page!


Hydroboost Conversion w/PS Cooler - this is all new AC Delco components (base vehicle k2500)..PS cooler from '97 K3500
http://i158.photobucket.com/albums/t117/sparg93/IMG_8122.jpg
http://i158.photobucket.com/albums/t117/sparg93/IMG_8108-1.jpg

This was used to delete variable steering from PS pump
http://i158.photobucket.com/albums/t117/sparg93/IMG_7947-1.jpg

12Voltguy Custom Panel
http://i158.photobucket.com/albums/t117/sparg93/IMG_8219.jpg
http://i158.photobucket.com/albums/t117/sparg93/IMG_8220.jpg

Mark VIII Efan - custom wiring setup to engage both speeds automatically
http://i158.photobucket.com/albums/t117/sparg93/IMG_7279-1.jpg

Volant CAI:
http://i158.photobucket.com/albums/t117/sparg93/IMG_7282-1.jpg

ProComp Extreme AT 285/70R17
http://i158.photobucket.com/albums/t117/sparg93/9351.jpg

Iraggi 220 alt - 180amp @ Idle!!!
http://i158.photobucket.com/albums/t117/sparg93/IMG_8168.jpg

14bsf 6 lug rear w/Blue Torch diff cover - COMPLETELY rebuilt w/Timken Bearings & Tru Trac
http://i158.photobucket.com/albums/t117/sparg93/IMG_8214.jpg


Updated Fuel Injector Spider
http://i158.photobucket.com/albums/t117/sparg93/IMG_8212.jpg

Timken Hub Bearing Replacement
http://i158.photobucket.com/albums/t117/sparg93/IMG_8129.jpg

Manifold Gasket Replacement (clean manifold!)
http://i158.photobucket.com/albums/t117/sparg93/IMG_8210.jpg

Plenum Gasket
http://i158.photobucket.com/albums/t117/sparg93/IMG_8211.jpg

Electric Air Horn - 300hz
http://i158.photobucket.com/albums/t117/sparg93/IMG_7286-1.jpg

Custom Trailer:
http://i158.photobucket.com/albums/t117/sparg93/IMG_8141-1.jpg

Interior
http://i158.photobucket.com/albums/t117/sparg93/IMG_8164.jpg

Trailer Bearing Lube
http://i158.photobucket.com/albums/t117/sparg93/IMG_8163.jpg


As you can imagine, I've also swapped out every fluid (trans, front diff, rear diff, transfer case, oil, coolant)

[sparg93]

Finished prepping and POR'ing the 14bsf - now I'm waiting for my Wagner severe duty shoes and I'll rebuild the drums and bend up some new brake lines.

before
http://i158.photobucket.com/albums/t117/sparg93/IMG_8214.jpg
after
http://i158.photobucket.com/albums/t117/sparg93/IMG_8230.jpg

Replaced the Compressor, drier and orifice tube...
http://i158.photobucket.com/albums/t117/sparg93/IMG_8231.jpg
http://i158.photobucket.com/albums/t117/sparg93/IMG_8228.jpg

After installing the new system, evacuating and filling with refrigerant...the high pressure relief valve went south...and I had to do it all over again!

I also installed a new idler pulley today and fixed my hi beam HIDs!

[sparg93]

Almst done with rebuilding the 14bolt...just finished up new pads and springs...tomorrow I bend and flare new brake pipes!

I bought wagner sever duty shoes for the full float rear., not the semi float I have - for anyone that needs to know, the semi float is a 11.**" rear, the full float is 13.**" So, I ran to Parts Authority in NY and purchased the Centric full brake hardware kit and Pep Boys Platinum shoes. That wasn't my first choice, but it's the best I could find in a pinch.

old:
http://i158.photobucket.com/albums/t117/sparg93/IMG_8493.jpg

new:
http://i158.photobucket.com/albums/t117/sparg93/IMG_8523.jpg

Today we did some wheelin in the sand...some photos just for fun.

All of us:
Heavy Chevy represent!
http://i158.photobucket.com/albums/t117/sparg93/528901_848315347508_42701440_36555513_1437352961_n 2.jpg
http://i158.photobucket.com/albums/t117/sparg93/IMG_8549.jpg

Check out this oldie...rebuilt with a 302 and C4 tranny.
http://i158.photobucket.com/albums/t117/sparg93/IMG_8525.jpg

http://i158.photobucket.com/albums/t117/sparg93/IMG_8531.jpg

Stuck at the top of the hill
http://i158.photobucket.com/albums/t117/sparg93/IMG_8527.jpg

Another jeep
http://i158.photobucket.com/albums/t117/sparg93/IMG_8538.jpg

http://i158.photobucket.com/albums/t117/sparg93/IMG_8536.jpg

http://i158.photobucket.com/albums/t117/sparg93/IMG_8533.jpg

[sparg93]

I've got a lot more updates that once I can hook my camera back up to this laptop, should be some more good photos for everyone.

[BurbanAZ]

great looking build, you definitely have some really great parts in there. That 220 amp alternator is awesome, i need to get one and 180 at idle is crazy. How are you liking the procomp tires? I cant remember are you going to OX12?

[sparg93]

great looking build, you definitely have some really great parts in there. That 220 amp alternator is awesome, i need to get one and 180 at idle is crazy. How are you liking the procomp tires? I cant remember are you going to OX12?

Check out Iraggi, he made the alternator...prices are very reasonable and he can hook you up with the brackets to run a dual on that Vortec engine. I don't thnk I'm going to end up running duals, so if you want to buy my brackets (never used), I'll give you a great deal.

I like the ProComp Extremes so far. I've tested them on pavement, sand, hard dirt and mild rocks and they performed really well. Supposedly where they don't do as well is mud (gaps aren't very large in between lugs), but on snow/ice they are rated among the best....unfortunately I don't have much for a basis of comparison, but I would also check out the KM2's as everyone seems to like those. Overall though, these tires have performed really well!! One change I would have made would be to go with 16 rims...i wish I had more rubber to protect them rim when aired down

OX12?

[BurbanAZ]

Check out Iraggi, he made the alternator...prices are very reasonable and he can hook you up with the brackets to run a dual on that Vortec engine. I don't thnk I'm going to end up running duals, so if you want to buy my brackets (never used), I'll give you a great deal.

I like the ProComp Extremes so far. I've tested them on pavement, sand, hard dirt and mild rocks and they performed really well. Supposedly where they don't do as well is mud (gaps aren't very large in between lugs), but on snow/ice they are rated among the best....unfortunately I don't have much for a basis of comparison, but I would also check out the KM2's as everyone seems to like those. Overall though, these tires have performed really well!! One change I would have made would be to go with 16 rims...i wish I had more rubber to protect them rim when aired down

OX12?

good to know i may have to try and contact him to get one later. I dont have a vortec 92 is still TBI. OX12 is the Overland Expo for 2012, its probably far unless your already coming this way but its a huge get together for all expo vehicles and vendors and stuff. Here is the site for it http://www.overlandexpo.com/ Im meeting up with a group in mesa, AZ then heading up. Im also doing probably a week or so trip somewhere in central AZ.

[sparg93]

good to know i may have to try and contact him to get one later. I dont have a vortec 92 is still TBI. OX12 is the Overland Expo for 2012, its probably far unless your already coming this way but its a huge get together for all expo vehicles and vendors and stuff. Here is the site for it http://www.overlandexpo.com/ Im meeting up with a group in mesa, AZ then heading up. Im also doing probably a week or so trip somewhere in central AZ.

We're a feature truck @ the Overland Expo - didn't I send you that link a few months ago!? :)

if you want, we're wheelin with a few guys after the event for a week, more then welcome to join!

[BurbanAZ]

We're a feature truck @ the Overland Expo - didn't I send you that link a few months ago!? :)

if you want, we're wheelin with a few guys after the event for a week, more then welcome to join!

i didnt know that hopefully ill be able to meet up with u at some point while were there. I wanted to go on the trip after but i couldnt get the time off work so were going to do our own thing before the expo for a week or so

[sparg93]

That front winch bumper in your sig...who made that??

[BurbanAZ]

That front winch bumper in your sig...who made that??

i did, i couldnt find one like i wanted to buy so i just made it. Its crazy strong though ive stalled out the 12k winch i have on there a couple times and the bumper never even budged

[sparg93]

that's awesome - great work.

Any close photos?

[BurbanAZ]

thanks, heres a few closer, and kind of a build thread
http://www.fullsizechevy.com/forum/general-discussion/offroad/484992-winch-bumper-build-question.html
http://i48.photobucket.com/albums/f235/cjcuk/a78787e1.jpg
http://i48.photobucket.com/albums/f235/cjcuk/af44e1c0.jpg
http://i48.photobucket.com/albums/f235/cjcuk/58678af8.jpg

[sparg93]

very cool, thanks for posting it up

[BurbanAZ]

no problem

[sparg93]

A photo to show depth - this was steeper then a few 3.5's we've done in AZ (nothing crazy, but a lot of fun!)
http://i1250.photobucket.com/albums/hh521/O3Exp/Tucson/IMG_9415.jpg

Up one of the hills on the backside of Mt Lemmon:

http://youtu.be/lgVx-WNHUrk

[sparg93]

Down the hill!

http://youtu.be/RPGkySJm7_k

[BurbanAZ]

some of those hills on the backside are insane. We've had some fun times on the back of Lemmon

[99FLtahoe]

deff like your setup.

how do u like those wheels and tires ???

[Tahoejoe99]

how do you like that high output Alt? Were did ya order it from?

[highrider44]

Pretty cool man. Im all sorts of super jealous of all that new stuff you are throwing in the truck. Not a bad looking trailer either.

[sparg93]

deff like your setup.

how do u like those wheels and tires ???

I really like the setup - they got me through everything! The biggest surprise from the Pro Comps was just how puncture resistant they were/are. On a few occassions I thought for sure I had punctured the sidewall and was astonished to see just what abuse it would stand up to.

If I had to do it again, I would definitely have ordered 16" rims. 17" rims on 33" tires leave very little sidewall left once you air down. Otherwise, the Extreme A/Ts and aluminum rims held up famously.

One word of caution however. If you dent an aluminum rim, it's most likely garbage...if you dent a steel rim, you can field repair it.

[sparg93]

how do you like that high output Alt? Were did ya order it from?


Iraggi - he also makes a nice set of brackets for a dual alt setup for the 5.7L. The alt provided tons of power, but the bearings are going. I need to email him this week and I'll be interested to see how he handles it...i have about 14k miles on the alternator, but it lasted only 5 months before needing service.

Historically, whenever i had questions for him, he was incredibly helpful and quick to respond.

[sparg93]

Pretty cool man. Im all sorts of super jealous of all that new stuff you are throwing in the truck. Not a bad looking trailer either.

Thanks Highrider!! The trailer IS for sale and is one of the more unique ones out there for heavy duty use!

[rustyabiding]

I really like your build, I've been following your other build threads looks like you have a lot of fun!