my crew cab dually build thread

[blizzardrunner]

Well, about two years ago, i acquired a 1 ton 4x4 crew cab dually. It was an old Delmarva power truck, and it was in rough shape. it had a good running 6.2, a rebuilt th400, 205 transfer case, and the dana 60 up front.chassis was solid, and i got it for 1500 bucks.


how it arrived:
http://i38.photobucket.com/albums/e105/blizzardrunner/truck020.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/truck021.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/truck023.jpg
Starting the teardown.
http://i38.photobucket.com/albums/e105/blizzardrunner/1a67fa82.jpg

[blizzardrunner]

I started tearing it down, and gave the scrap to a buddy to haul away for me.

http://i38.photobucket.com/albums/e105/blizzardrunner/da0e5819.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/de35d844.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/100_0419.jpg


http://i38.photobucket.com/albums/e105/blizzardrunner/100_0434.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/100_0440.jpg

Just for good looks...ALL CHEVY!!
http://i38.photobucket.com/albums/e105/blizzardrunner/100_0449.jpg

[blizzardrunner]

Got these flowmasters for 50 bucks from a local junkyard, 40 series...

http://i38.photobucket.com/albums/e105/blizzardrunner/100_0519.jpg


bought a suburban for 400 bucks. Front end, one back door, full interior, a/c, and a goodwrench "new" tbi 350.

http://i38.photobucket.com/albums/e105/blizzardrunner/100_0509.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/100_0510.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/100_0508.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/100_0511.jpg

[CscottsSS]

nice, keep us updated!

[blizzardrunner]

4" lift kit on the crew cab. I had originally put single wheel rears under it, but someone offered me too much money for them, so it eventually got put back to dually.

http://i38.photobucket.com/albums/e105/blizzardrunner/100_0505.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/100_0506.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/100_0503.jpg



I will have more pictures later after i upload them. the truck isnt done yet, but the new cab is ready to go get a few holes patched. The 350 is in, and all my doors/fenders have been gone over.

[Xtremjeepn]

Cool. Glad to see I'm not the only one working on an old Crew Cab.

MORE PICS!!!

[blizzardrunner]

Alright, a few more for tonight, but i got to save some! this project is gonna be on hold for a little while, as i am busy with other things. My uncle, who does awesome body work, will hopefully be doing the bodywork on the cab. It was near perfect when i got it 2 years ago, but now it has some cancer holes in the rockers. hopefully i will take the truck to his house and have him work on it while i do what i need to do here. If it was just puttying and sanding, i could do it. but its cutting and grinding and tig welding. thats what hes good at. but here are some door and fender shots.

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0376.jpg

This is the pass. side back door off of that suburban. It was my first attempt at bodywork. its pretty smooth now, but i made all my beginners mistakes on it. Lets just say it took awhile.


http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0374.jpg

this is the drivers side door off of my dads old truck. He had it since he was sixteen, and it was only about 3 or 4 years old. Its the brown truck in the background of one of the pics above. You should have seen that truck when i was about 3 yrs old. it had 7"lift and 38" groundhawgs. Pristine cond. it just went to hell after years of abuse. finally died on him in 03. its now on its way to japan to be turned into a honda.

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0386.jpg
http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0387.jpg
http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0388.jpg
http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0396.jpg

[BHB]

Yeah, went down that road a few years ago...
I got a boxer too.
http://i228.photobucket.com/albums/ee137/greggmartucci/Truck19.jpg

http://i228.photobucket.com/albums/ee137/greggmartucci/Truck13.jpg

[blizzardrunner]

Wow, that is one good looking truck!! Im hoping to get mine looking as good as that.

[BHB]

Tanx...it was 12 years ago.

[Ivan D.]

BlizzardRunner, so what exactly are you doing with the dualy and the Suburban? What would be real cool is drop the Suburban body on the dually chassis, not many dually Suburbans out there and even fewer 1-tons. Also I hope you didn't give out the front Dana 60 as scrap, it can fetch quite a penny if sold.

[blizzardrunner]

No, not at all. I had two dana 60's, one single wheel and one dual wheel. Both front, obviously. the single wheel that was under the frame in some of them pics ended up getting sold. the duallys are back on now. And about the suburban. It looks nice in the pics, but the truth is, it would never pass inspection. considering the engne, frame, and drivetrain were pretty solid, that gives you an idea of how rough the body was. It was COMPLETELY rotted underneath. Ive seen nicer burbs at junkyards. it was way too far gone for me.

[55chevyman]

looks like a fun project I am gonna watch this one and learn a thing or two i am sure

[blizzardrunner]

Well, I am still waiting to find out about my cab, if my uncle will do the bodywork for me. In the meantime i will post a few more pictures of bodywork i have done.

passenger side door off of one of many of my parts trucks i had.

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0375.jpg

$75 suburban back door. got it from a local junkyard, this door was as close to flawless as i have ever seen an original door. i could have slapped it on and painted it, but there were a few very minor chips and dings in it, and i cant have that!! lol

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0378.jpg

pulled the trim off...


http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0391.jpg


DA sander and heat took the stubborn glue/foam off.sanded some dings and chips down on the bottom, and sanded the whole door to get the clear coat off.

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0392.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0393.jpg

primered bare metal

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0394.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0395.jpg

[Chevyforlife502]

nice man keep up the work and keep us posted can't wait to see next steps.

[blizzardrunner]

Well, I talked to my uncle today and he said he would do the welding work on the cab, but he wants to wait until its a little warmer...so until then i cant do very much. Im hoping to get my rad support and inner fenders painted soon so i can feel like im getting SOMETHING done on it. Its definantly a slow project!

[blizzardrunner]

The truck as it sits now.


http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0381.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0382.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0384.jpg

[BHB]

Lookin forward to seeing it done. Just be glad you don't have do drive it home every night like I did. (especially after doing a floor, cab support, and inner and outer rocker).

[trickedout420]

strip it to frame and have it powder coated

[blizzardrunner]

Haha, it already was stripped to frame :aniteef: but i couldnt afford powdercoating. I have paint from Tractor supply to go on the frame and underside of the cab. Its a bit harder to wire wheel and paint with the cab back on and the engine in though:damnit:

[trickedout420]

it only cost me $375 to have a frame powder coated..wasnt for either of my trucks but still..

[blizzardrunner]

Yeah, that would have been a good idea. But at this point im not turning back. Its taken long enough! If it gets torn down again though, say in the next 5-10 years, I will most likely do that. Just didnt think of it and i dont want to take the cab off again! But thanks for the good idea!

[blizzardrunner]

Taiwans Finest inner fenders. 34.95 a piece at a local Body shop supply store.

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0439.jpg

Driver side fender from a donor truck


http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0440.jpg

Pass. side fender from another donor truck.

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0438.jpg

[BHB]

:thumbup:Keep it goin man. You're bringin' back memories. I built my CC out of parts from 14 different trucks.(new parts too):thumbup:

[Hubs]

Pretty sweet build going on here. Definitely want to keep an eye on this one. Good job man!

[425xpedition]

Gotta love them old crew cabs!!!!!!!

[Greystone]

My grandfather had a 77 crew cab that was lifted and such. My father had the opportunity to buy it when he passed away about 15 years ago for $1500. It only had a straight six with a 5spd. It would have made and awesome project truck. Oh well, coulda, woulda shoulda.

[blizzardrunner]

425xpedition, I dont think this one will ever look as sweet as yours man! Im drooling over those pictures in your profile. Well, until i can find dually fenders, im going to run stock tire size on this truck. Because the truck was a power company truck, it has a narrowed factory rear. Therefore i can run straight fleetside bedsides without dually fenders. My intention in the long run, though, is to get dually fenders and spacers for the wheels so i can run big fat tires on it and still keep them under the fenders!!

[blizzardrunner]

well it isnt much of an update, but you should have seen the sears guy's face when he saw he ahd to help me put the biggest compressor they had into my dd integra. "it isnt gonna fit!"

well, it fit, kinda.

http://i38.photobucket.com/albums/e105/blizzardrunner/compressor003.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/compressor002.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/compressor001.jpg


Thats what happens when you dont have a truck, and you need a compressor so you can finish a truck!

[ikon]

Is that you standing behind the car? lol j/k

[dimerunner88]

either thats a light compressor or thats a pretty heavy duty rear suspension on the car,hardly any squat.

[sandthrower]

Now come on get those hands out of your pants and get this going... lol j/k

is all this being done outside .Cant wait to see it done

[BHB]

Is that you standing behind the car? lol j/k


Yes, but it is just a really big compressor!

[blizzardrunner]

Nah, the compressor really isnt that heavy. Its a 33 gallon sealed pump. I can pick it up and carry it, but its on wheels. Thats my 7 year old brother who had to come out to see how i fit that thing in my car! I got a chance to use it tonight, blowing rust and grease off my frame so i can paint this weekend hopefully. The build goes really slow when you work 6 days a week.

[blizzardrunner]

Well i got my frame mostly painted today, i quit because a cold front was moving in and it started snowing. When i started painting it was about 48 degrees out. when i finished it was about 33 degrees. I put a quart of paint on it and got everything up to under the cab done. Ill have pics soon when its light out.

[blizzardrunner]

Well, i got more pictures and had about an hour to go over and touch up some skippers. I got a lil farther but its STILL not completely painted. I still have the drivers side part of the frame from the middle of the cab up toward the engine to do and the front rear. Its looking pretty nice though i think.


http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0447.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0445.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0448.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0449.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0450.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0452.jpg

http://i38.photobucket.com/albums/e105/blizzardrunner/IMG_0451.jpg

[blizzardrunner]

Well, in another day or two i should be ready to start painting inside the cab and stuff. I need to paint my rad support and inner fenders yet, then im ready for the real deal. What color should i make it? I cant decide whether i want to make it a nice blue or a grey. Lemme know what you guys think!

[oates]

Cool truck man. I will be starting a crew cab build soon. I have always liked all gray with white in center, looks really clean, hides body work well too if you use the silver/gray metallic.

Depends on your budget. Make sure you jam out the truck before you start re attaching the doors for paint.

[blizzardrunner]

Yeah, i hear ya man. Im not really looking forward to fitment time. I have a feeling im gonna be fighting it alot. Good luck on your build man!

[44gmcnewf]

Thats looks like its coming together nice. Blue and grey are both my favorite colors. I stole this picture from another site if you want to see what grey look like. http://i176.photobucket.com/albums/w191/crazy_newf_2007/Huge1.jpg

[blizzardrunner]

I would like to know, is that a factory color? if not, what is it called? I was really wanting to paint my truck that color, but i didnt want to get the wrong gray. You know what i mean?

[blizzardrunner]

Ran her for the first time today!!!! I was so happy because i waited so long to hear it with the flowmaster 40 series and i finally got a chance to run it! Here is a vid, sorry about the shaky camera and the stupid things i say, i was just the happiest guy on earth.


http://www.youtube.com/watch?v=rtAgfNL4EJA

[blizzardrunner]

well, i guess maybe tomorrow i will go get some paint and start painting some of my panels. at least the inside. Perhaps the inside of the cab too. Im still trying to decide between blue and grey.

[blizzardrunner]

I got my power steering pump bolted up and all the lines plumbed to the master cylinder and power steering, but when i go to put my pulley on, it wobbles. Im hoping the shaft for the pump isnt bent.

[BagginA93chev]

cool project man!

[blizzardrunner]

Well, the shaft wasnt bent, the pulley installer i borrowed from autozone was junk. They gave me a new one and it went on like butter. The pump i had had the older v belt style pulleys on and my tbi 350 was serpentine. So iended up getting a serpentine pulley from autozone for a newer truck and pressing it on to the older power assist power steering pump.

thanks BagginA93chev, it doesnt look like much, but i can see the end product in my head and i want to get it done as soon as possible.

[kev2809]

any updates?

[blizzardrunner]

well, right now im working on the fuel lines for it. Because it was fuel injected, and the engine came out of a suburban, i have the lines that go from the throttle body to the filter, which is located halfway back the frame. on a suburban they continue from that point back the frame to the tank which sits in the middle of the two framerails. On this, im making it single tank and the tanks are mounted on the side of the frame. So im in the process of bending lines over to the tank so i can actually run it by itself. Will get pics when done.

[thirdstreettito]

This truck is awesome. Where do you get the money for all of that? What do you do for a living?

[blizzardrunner]

Thats the neatest thing about this truck. Its being built on a budget as cheap as possible. I find trucks that people just want to get rid of for 300-400 bucks, buy them, take whats good off, and scrap the rest and make most of my money back. I bought the original truck for 1500, and it just kept going from there. Honestly dude, i dig ditches for 10 bucks an hour. Im trying to get into an apprenticeship for powerline work, but as of now, Thats all i make. I know alot of the guys in junkyards around here, so they cut me deals(sometimes free stuff!) And the guys at the local autozone all know me and give me employee discount after all the crap ive bought in there. This truck is my passion now since my girl left me, so it gets all my attention ad spare time and money.
:rocking:

[daved931]

Trucks are more reliable than women.

Unless you own a Dodge.

[thirdstreettito]

Trucks are more reliable than women.

Unless you own a Dodge.

Heh, matter of opinion.

[blizzardrunner]

Haha, i have a friend who is a dodge guy, and his woman left him too. I'll have to use that on him sometime!

[blizzardrunner]

idk if this will work or not... my photobucket's down


http://viewmorepics.myspace.com/index.cfm?fuseaction=viewImage&friendID=83202914&albumID=1700136&imageID=27780987



http://viewmorepics.myspace.com/index.cfm?fuseaction=viewImage&friendID=83202914&albumID=1700136&imageID=27781052

http://viewmorepics.myspace.com/index.cfm?fuseaction=viewImage&friendID=83202914&albumID=1700136&imageID=27781000

[Xtremjeepn]

FYI, if you "right click" on your myspace photos, scroll down to
properties(click it) and copy the address. You can then post it here (click the little picture box and paste the address in the pop-up):thumbup:

http://a480.ac-images.myspacecdn.com/images01/10/l_eeafb3a34141eeb108c4423c15d51857.jpg

[blizzardrunner]

http://a977.ac-images.myspacecdn.com/images01/30/l_04c9fd07b7b4693341cb2d68b94ca538.jpg

http://a978.ac-images.myspacecdn.com/images01/8/l_83d068a7fc13304666d5fa3a450114f1.jpg

http://a387.ac-images.myspacecdn.com/images01/63/l_bfd3da6728115c186fa794b61a444d42.jpg

[blizzardrunner]

Thanks xtreemjeepn, i never knew that! :)

[Xtremjeepn]

No problem.


Truck is coming along!

[blizzardrunner]

yea slowly... i need to get back to the junkyard to get my fuel pump/taillight harness yet. Fuel lines are coming from a friend of mine who is building a cc with a cummins, so the fuel lines he has are useless to him, and perfect for me :)

[blizzardrunner]

Well, got the cab retrofitted for the A/C out of the suburban, the cab originally had heat only, and i had had to patch the old hole and cut a new one for the ac unit.

http://a97.ac-images.myspacecdn.com/images01/34/l_dbb6f25471b683b48d6110a817370450.jpg


http://a281.ac-images.myspacecdn.com/images01/55/l_36d020d8faa52d5c8d36ebf6675523f8.jpg

[blizzardrunner]

Wow its been awhile, i have some parts painted and im waiting for good enough weather to do the rest. The wiring harness is all done except for the taillight/fuel pump harness, and im still waiting for fuel lines. ill get pics asap.

[ibanender]

Thats what happens when you dont have a truck, and you need a compressor so you can finish a truck!

I been there, I know allll about that. I got the priviledge of bringing home 24's mounted and balanced, with my daily driver being a CRX. I've also had to get things like steel and a bigger welder. People are amazed at what I can manage to fit in a CRX WITH a system in it.

[blackknight]

cool build thread man, get some recent pics up so we can see the progress youve made

[hick]

can not describe my jealousy

[blizzardrunner]

Here you go

http://a869.ac-images.myspacecdn.com/images01/71/l_b67240c07b5fa71fb35a60ff2aa90464.jpg

http://a624.ac-images.myspacecdn.com/images01/104/l_a2e6096ca4b89281c695bca8f8508caf.jpg

[blizzardrunner]

I been there, I know allll about that. I got the priviledge of bringing home 24's mounted and balanced, with my daily driver being a CRX. I've also had to get things like steel and a bigger welder. People are amazed at what I can manage to fit in a CRX WITH a system in it.


haha yea i ended up grabbing my subs and yabking them as hard as i could to move them out of the way...i worried about the ripped wires and such later..:eek:

[blizzardrunner]

http://a342.ac-images.myspacecdn.com/images01/72/l_db845aeca4c31e7975fcfa29064fae9d.jpg

http://a376.ac-images.myspacecdn.com/images01/25/l_6d51838c284bdb7465d21478355bf81f.jpg

http://a559.ac-images.myspacecdn.com/images01/120/l_c0db911b733cbebc4ddfd3c69f74e31e.jpg

[joshj928]

Good chice on the new color. Can't wait to see the finished product!!!

[hick]

what is that jaw dropping, boner worthy color?

[hick]

can't use that shed on the other side of the fence as a temp shop?

i could never do some thing like this outside, i am far to anal... but props... coming along nicly

[blizzardrunner]

Thats Gunmetal Metallic its dupont centari paint. Apparently it was a factory GM color in 87. And the shed is the neighbors and they are dicks. I would prefer not to do i toutside, but i think when its done it will be cool to say i did it completely outside. Thanks man! Hey noone knows of anyone with the harness for the fuel pump and tail lights for a tbi 350 do they?

[hick]

thinned out and sprayed with gun and compressor i assume?

[blizzardrunner]

Yea i gotta redo some of it but most just needs wet sanded and second coat. I have the cab in primer until the rockers and corners get fixed. that will be last though. I just figured primer and gunmetal would look better than yellow and gunmetal until i get the bodywork done.