Some of you might remember my old dually, "Big Otis" and the Cummins conversion I was doing before I bought a new truck. Well here's the new one!
I've been workin' on this since I brought it home back in February. It's gettin' there but there's still some long days ahead.
Specs:
'94 3500HD. Originally a 159.5" chassis- shortened 28" to utilize a pickup bed.
'93 Cummins engine, Getrag trans, NP205 transfer case
Dana 60 front with 8-lug 19.5's and 4.10 gears
Dana 80 rear, re-geared to a 4.10
Full 4" turbo-back mandrel bent exhaust
The day it was brought home
(http://i484.photobucket.com/albums/rr201/Raymo_photo/HD.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/HD.jpg)
The rockers and cab corners were perfect, but the vinyl covering had "had it's way" with the floor, as usual >:( Just yesterday I had put down a very thick layer of a two part urethane bed liner, so after the 18 hours of prep work I'm hoping that last the life of the truck body. I still have to get pictures of the finished product.
(http://i484.photobucket.com/albums/rr201/Raymo_photo/floor.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/floor.jpg)
(http://i484.photobucket.com/albums/rr201/Raymo_photo/floora.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/floora.jpg)
So after the floors had been welded up, I had set the engine and built mounts. I used the factory dodge mounts, which, when trimmed fit perfectly into the frame. I built a simple trans crossmember out of some angle, 1.5" DOM and a Chevy 4x4 trans mount.
(http://i484.photobucket.com/albums/rr201/Raymo_photo/floord.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/floord.jpg)
(http://i484.photobucket.com/albums/rr201/Raymo_photo/sittin.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/sittin.jpg)
Then it was on to the core support. I used the Dodge radiator and intercooler. The HD core support really lent itself to the use of the Dodge pieces. I still have to take a pic of the intercooler mounting, but I used the Dodge pieces cut from the Dodge core support to mount the radiator in the Chevy support.
(http://i484.photobucket.com/albums/rr201/Raymo_photo/supportbottom.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/supportbottom.jpg)
(http://i484.photobucket.com/albums/rr201/Raymo_photo/supporttop.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/supporttop.jpg)
(http://i484.photobucket.com/albums/rr201/Raymo_photo/supporttop2.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/supporttop2.jpg)
(http://i484.photobucket.com/albums/rr201/Raymo_photo/supportoverall.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/supportoverall.jpg)
So once the hard work was done on the front half, I moved to the rear. I moved the rear end up 28" by cutting the rivets and using 1/2" hardware to re-attach the spring perches and overload stops. Then I fabbed up some bed mounts out of 1.5"x 3" tall rectangle tube. Luckily, the cab and chassis rear axle is only 10" overall wider from outside tire to tire than a single wheel bed. Bushwacker came to the rescue with their 5" wide cut-out flare, which made up the difference perfectly.
(http://i484.photobucket.com/albums/rr201/Raymo_photo/hdtodate.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/hdtodate.jpg)
Then comes the 4wd conversion. I used a Dana 60 front from a '79 Dodge W300. With it's 32.5" spring pad width, it was a direct bolt in with the HD leaf sprung front end. I'm not too happy about the height gain, but for the direct bolt in, and leaving the engine crossmember alone, I can live with it. I also used a crossover steering arm on the 60 to keep with the same steering set up these trucks come with.
(http://i484.photobucket.com/albums/rr201/Raymo_photo/hdhigh.jpg)
And with all that, comes to where I'm at now. The part in the build with the 1000 little things to slow down progress.
(http://i484.photobucket.com/albums/rr201/Raymo_photo/grayhd.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/grayhd.jpg)
I've been driving this truck for two months now, and it's been great.
I forgot to mention that I used a complete universal wiring harness and a full set of Auto Meter Phantom guages on the inside.
I also used UPOL Raptor bed liner on the floor of the cab. It's some good stuff!
Plans now are to bring this thing down 4" and give it a better looking paint color, but I won't mention what scheme until I have pics of it ;D
great job man ==kp applaudd
Good job !! Looks very good !! more pics please.
Quote from: Raymo on December 03, 2010, 04:25:31 PM
I've been driving this truck for two months now, and it's been great.
I forgot to mention that I used a complete universal wiring harness and a full set of Auto Meter Phantom guages on the inside.
I also used UPOL Raptor bed liner on the floor of the cab. It's some good stuff!
Plans now are to bring this thing down 4" and give it a better looking paint color, but I won't mention what scheme until I have pics of it ;D
looks good the way it sets just get new rims and bigger tires lol
I've dug up some more pictures from the build.
This is the Raptor bed liner installed on the floor
(http://i484.photobucket.com/albums/rr201/Raymo_photo/linedfloor.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/linedfloor.jpg)
Here's the guage panel and guages. I used the Auto Meter angling cups to turn all the guages twards me, looks pretty sweet from the side. The heater and headlight switches are mounted in here also.
(http://i484.photobucket.com/albums/rr201/Raymo_photo/guages.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/guages.jpg)
The 4" downpipe before the new inner fender went on
(http://i484.photobucket.com/albums/rr201/Raymo_photo/downpipe.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/downpipe.jpg)
And an overview of the engine compartment during reassembly
(http://i484.photobucket.com/albums/rr201/Raymo_photo/overallunderhood.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/overallunderhood.jpg)
The IC pipe from the intercooler to the engine, checking fit.
(http://i484.photobucket.com/albums/rr201/Raymo_photo/intakepipe.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/intakepipe.jpg)
great truck man!
WAY KOOL .... GOOD JOB.... ++peace ++peace ++peace
Well after 740 miles, I'm averaging 12mpg loaded and empty, lots of mixed driving and 20 minutes to warm up everyday. I'm debating going toa 3.55 gear, and I think my K&N might be a little too small/restrictive.
I think next step tho, is an interior make-over. I need some carpet and a bench seat, cause I'm freezing my ==kma off in this thing.
Bad ass truck. I love that stout stance it has. Tuff as hell looking!
i absolutely love this truck looks bad ass for sure!
Well I'm tired of lifting 5' to put things in the bed of the truck, and jumping in and out, so I'm in the process of lowering my 4x4 3500HD 4" by removing the rear lift block, and doing a Spring-Under conversion.
The rear is/ was easy, I simply had to remove the 4" lift block, and install new U-Bolts. This step took about 15 minutes
Before
(http://i484.photobucket.com/albums/rr201/Raymo_photo/rearhigh.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/rearhigh.jpg)
After
(http://i484.photobucket.com/albums/rr201/Raymo_photo/rearlow.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/rearlow.jpg)
And then I've been working on the front axle. I have a Dodge Dana 60, and it's much more narrow than the Dana 70 that was fitted into these trucks. So, in order to mount a spring perch on the under side of the axle, I had to move the differential towards the center. This is because the 60 originally had one U-Bolt on the differential, and two studs cast in the housing to hold the other half of the U-Bolt plate. I added 2.71" to the short side of the axle, and after making up the difference in spring pad widths, I'm able to move the spring pad center away from the differential 1.625". I used 2.125"x .120 wall DOM to sleeve the three pieces back together, and a piece of 3.125"x .500" wall DOM to match the original axle tube. The 2.71" is the exact measurement a Ford Dana 60 axle shaft was longer than my original Dodge shaft.
(http://i484.photobucket.com/albums/rr201/Raymo_photo/newtubea.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/newtubea.jpg)
(http://i484.photobucket.com/albums/rr201/Raymo_photo/newtube.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/newtube.jpg)
More to come tomorrow after I spend some more time out in the shop.
And on to the front!
After welding in a new crossmember towards the front, I removed a large portion of the factory engine crossmember to resemble that of a factory K3500. Then I removed the old axle and all associated parts to make way for the new Spring-Under axle I had made. After playing with mounting options and height, I worked out a way to install the axle with the leaf spring in the factory position. This gave me a near stock height, and I couldn't be happier!!!
Again, here are some before and after shots.
(http://i484.photobucket.com/albums/rr201/Raymo_photo/rearlow.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/rearlow.jpg)
(http://i484.photobucket.com/albums/rr201/Raymo_photo/lowfronta.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/lowfronta.jpg)
Keep in mind, that those are 8R-19.5" tires, and measure 33" tall.
Here's a shot of how the drivers side sits.
(http://i484.photobucket.com/albums/rr201/Raymo_photo/springunder-1.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/springunder-1.jpg)
There is still some work to do, I have a couple loose ends that need attention, and I have to make a new Panhard bar. But overall, I've had fun and it hasn't been too challenging of a job.
NICE! Makes me wish I had better fab skills and a shop! loll
Looks a heck of a lot better with the SUA then the SOA, IMHO.
Thanks guys
There's a few benefits to lowering it, I don't have to jump in or slide out after a long work day, I can run a smaller tire to get more tread pattern options, and finally, I have a rake, rear is 3" higher so now the truck won't look so bad with a trailer on it ==doh
Now that it's lower, I'm also going to be putting a plow on it, something similar to a Western Unimount so I can drop the pump and everything. Been missing out on plowin' money this year and the truck has to work a lil' harder to pay for itself lol.
looks like a lot of time and effort paid off....very nice truck
your a crafty dude! great truck
you did a nice job on the truck I think
LOOKS KOOL MAN. MINES UP AND RUNNING NOW..........LETS HAVE A PULL OFF............LOLL
both of you guys can gain mpg and power by playing with your pump! my old 92 was gettin 25 best mpg
Very nice work !! did a hell of a good job on that axel ! good job on truck looks sweet !! applaudd applaudd applaudd
Quote from: cnoswalt78 on January 09, 2011, 01:06:51 AM
both of you guys can gain mpg and power by playing with your pump! my old 92 was gettin 25 best mpg
I've done a few pump mods in the name of drivability, makes a world of difference with little money, especially with a 5-speed.
Thanks for all the compliments guys ++peace
And Al, we'll have to meet up sometime and check out each others rides. If you haven't done it by then, maybe I'll give you a hand tuning your pump.
I'm still waiting on some steering parts to show up, and I'm dropping to a 3.55 gear 'cause im averaging only 16mpg, and with my mild pump tune, I can get a few more with a gear change.
Quote from: D60KING on January 09, 2011, 01:23:10 AM
Very nice work !! did a hell of a good job on that axel ! good job on truck looks sweet !! applaudd applaudd applaudd
RIGHT ON MAN............... applaudd applaudd applaudd applaudd
looks like a lot of work! ==kp
Quote from: bkctwp13 on February 19, 2011, 05:34:20 PM
looks like a lot of work! ==kp
It sure was, not too sure I would do it again to this extent.
After lowering it 7" in the front and 4" in the rear, I started driving it again TODAY after a month and a half doing the spring under. I'll get some more pictures soon, the bumper height in the front matches our '93 K1500 so I'm very happy with how it turned out.
Here it is with it's new stance, solid as can be and much more user friendly.
To the top of the bumper measures 26", and to the top of the wheel well is 40", just 4" higher than my father in law's C3500.
(http://i484.photobucket.com/albums/rr201/Raymo_photo/finishedfront.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/finishedfront.jpg)
Next step will be Gooseneck and Fifth wheel hitches, a nice interior, better paintjob, and a second fuel tank.
did you part out big otis to build this one ? I was in awe of your fab skills when we pulled 355 I see youve gotten better applaudd
Quote from: bigmud44 on February 23, 2011, 05:39:22 PM
did you part out big otis to build this one ? I was in awe of your fab skills when we pulled 355 I see youve gotten better applaudd
Thanks man! Yeah Big Otis got picked apart pretty good, us damn kids just can't leave stuff alone ;D
did your name on here use to be Hardiman think i seen this today in my neighborhood
Quote from: Boggenjoesbrother on February 26, 2011, 08:35:05 PM
did your name on here use to be Hardiman think i seen this today in my neighborhood
Negative, trucks been in the drive for the past few days.
And I've always been Raymo!
oh alright was just wondering
Quote from: Raymo on February 26, 2011, 09:58:41 PM
Quote from: Boggenjoesbrother on February 26, 2011, 08:35:05 PM
did your name on here use to be Hardiman think i seen this today in my neighborhood
Negative, trucks been in the drive for the past few days.
And I've always been Raymo!
cool project! nice work!
Sweet build, my plan for my diesel is 4x4 and a 12v and a 5 or 6sp I've got a 6.9l with a c6 and I have the pump up, I can only do about 55 without sucking fuel down, and as far as duel tanks its nice, run a transfertank/toolbox in the bed, just run a switch and lines to it
I've thought about running a transfer tank in the back, but decided on the factory rear mount tank. In the near future I want to build the framework to make the bed dump, been thinking about central hydralics to work the bed and a plow eventually.
I figure if I make the dump bed "lockable" I can mount my hitch rails right to the framework.
Done some tinkering with the truck today. I went over some loose ends and started fitting my new front porch loll
I'm going to straighten it up a bit, replace the diamond plate on top and add in some bracing underneath for pushing duty.
(http://i484.photobucket.com/albums/rr201/Raymo_photo/securedownload.jpg) (http://i484.photobucket.com/albums/rr201/Raymo_photo/securedownload.jpg)
nice job looks good
that was the bumper i was going to get last weekend. thats where it went off too
WellI've been tinkering with the looks of the truck now that it's proven to be a good truck.
I got to thinking how I'm not a fan of the Bushwackers out back so I pulled out my old dually fenders and got to thinkin'. So this is what I've come up with... Chopped 4" from where it meets the bed to match up with the C&C axle.
(http://i484.photobucket.com/albums/rr201/Raymo_photo/flarea.jpg)
(http://i484.photobucket.com/albums/rr201/Raymo_photo/flare.jpg).
I also ditched the winch bumper for the chrome stocker with an air dam, and fit a gnarly bumper on the rear. Once this stuff is figured out, I'll be looking at paint options again.
nice project applaudd