88GMCtruck's SAS Build Thread

[88GMCtruck]

As some of you know, since I got my new truck I decided to replace the inadequate IFS in my 88 Sierra and install a Dana 44 Solid Axle. The goal is to keep it all GM, run 35's, and make it look like it rolled off the assembly line with the solid axle. I also want to keep the bill under $2,500 (will add costs later).

The Plan:

Front Axle: Dana 44 from 1977 GMC K15, 3.73s, trussed, flat top knuckles, HD shafts, spicer joints, Warn Premium hubs.




Rear Axle: 14 Bolt SF from 1993 C2500, 3.73s, G80

Transfer Case: Passenger drop NP241-C from a 1990 1500 Suburban


Steering: DT machine steering arms, Full crossover and hi-steer, Superlift 1104 Pitman



Front Suspension: Custom front spring mounts, 1977 GMC rear spring mounts, 52" springs & shackles with overloads removed from the rear of the 1977

Rear Suspension: ORD shacke flip, 4" block, Stock 64" springs

Brakes: Stock 1977 front discs, Stock 1993 rear drums, teflon/kevlar/stainless lines from ORD

Shocks: Rancho RS5000

Tires: Q78-15LT Gateway Buckshot Wide Mudders (CHANGED)
315/75R16 Mickey Thompson MTZ


Wheels: GM Factory 15x8 Rallys (CHANGED)
16x8 Raceline Renegade 6

[88GMCtruck]

Tonight the teardown began. Out goes the IFS:




Inadequete parts:

[FordeatinZ71]

subscribed!

[vic_V8]

turn all that stuff in for scrap money, it will be worth a couple hundred for you. help offset the cost of the SAS

[MC]

I'd go with lower gears... Looks good though. Subscribed.

[muddychevy98]

this is gonna be a good build, subscribed

[88GMCtruck]

Originally Posted by vic_V8

turn all that stuff in for scrap money, it will be worth a couple hundred for you. help offset the cost of the SAS

I'm going to try selling the front diff and transfer case, but the rest is pretty much scrap. Good Idea to sell it as scrap! I also have the rest of the 77 frame too.

Originally Posted by MC

I'd go with lower gears... Looks good though. Subscribed.

I'm planning on getting 4.56's next year. I can't afford to do the gears yet, so 3.73's will have to do for now.


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Last night Dad and I cut all the brackets off the frame, ready to be ground smooth.

[F4MOU$]

nice! I like the fact that you are doin the SAS and only running 35's. I think itd be sick, normally people do SAS's and run 37 + and that is huge at that point. itll be sick on your truck as well as I am subscribed to watch the build!

good luck!

[daved931]

Cool build. Def subscribing.

[88GMCtruck]

Originally Posted by F4MOU$

nice! I like the fact that you are doin the SAS and only running 35's. I think itd be sick, normally people do SAS's and run 37 + and that is huge at that point. itll be sick on your truck as well as I am subscribed to watch the build!

Yeah my intent is to basically to make the truck more capable and stronger than it was with IFS. I'm not going to wheel the living ell out of it which is why I'm only going with a D44, and I don't need it to be huge by any means. Honestly the choice of 35's basically boils down to the fact that I'm going to still be driving this regularly and large tires cost big bucks!

[F4MOU$]

Originally Posted by 88GMCtruck

Yeah my intent is to basically to make the truck more capable and stronger than it was with IFS. I'm not going to wheel the living ell out of it which is why I'm only going with a D44, and I don't need it to be huge by any means. Honestly the choice of 35's basically boils down to the fact that I'm going to still be driving this regularly and large tires cost big bucks!

yeah, whether your choices were caused by not having the funds for it, or just to do it, I think this is definatly a good thing your doin, itll be nice. cant wait to see the bitch done, whens the plan date to be done by?

[88GMCtruck]

Should be complete in about 3 weeks, I hope.

I plan to have the transfercase in tonight and the axle under it by this weekend.

[F4MOU$]

Originally Posted by 88GMCtruck

Should be complete in about 3 weeks, I hope.

I plan to have the transfercase in tonight and the axle under it by this weekend.

sounds good! cant wait to see it done!

[88GMCtruck]

More parts arrived!!!

ORD Teflon/Kevlar/Stainless Brake Lines


ORD 4" Shackle Flip


I started removing the transfercase, and started mounting the front springs.

52" spring with overloads removed


Front Spring mount built and welded


Spring hanging from front at approx. unloaded height.

[88GMCtruck]

Update on what was done tonight. Started grinding the remaining metal off from the old IFS brackets. We have added additional to the inside of the frame under the cab and one spring is fully in place We did not finish the other side as the welder ran out of wire. Tomorrow the other spring will be in and I want to start the transfercase swap and build the new crossmember for it.

[88GMCtruck]

Well I know I`ve been leaving you guys kinda hanging all weekend, so here is the update. Dad and I have worked our tails off all weekend.

The transfercase is in waiting for a new crossmember and shift linkage. We removed most of the old IFS crossmember and 1/4" plated it, and made a new set of spring hangers 1" forward and 1" lower than the previous also 1/4". The axle was fully stripped and painted.

The springs are a custom pack made from two sets of 5 leaf 1/2ton 73-87 chevy truck rear packs. Two shorter leaves were made from one pack and added. All were painted individually as well. They were installed with engergy suspension bushings.

We have everything tacked on and she is now sitting! These tires are only 29" but after measuring I think the truck is sitting at 7-8" of lift.

We are going to add an additional crossmember between the front spring perches. and build my steering soon. I have all my parts now except shocks.

She sits on her new suspension!





Front 1/4" spring hangers, boxed


Rear spring hangers from 77 GMC (they will be fully welded soon)


Flat plated crossmember




Custom 7-leaf pack


New t-case installed, waiting for custom crossmember

[alfredov]

nice 88

[GMC Sierra]

nice build

[88GMCtruck]

I will update with pictures tonight, but, here is the update.

-Crossover steering finsihed (might change pitman arms though)
-Drop transmission crossmember finished
-New front crossmember and shackle mounts finished (needs welded in)
-Figured out shocks and mounts
-Figured out tires and wheels (16x8 w/ 4.5" BS & 315/75R16)
-Found out where to grind for my CV driveline to have enough workable angle and not bind

More to happen tonight and I have tomorrow off so much more will happen then! It should be moveable by this weekend.

[FordeatinZ71]

Sweet!