3/4 ton GMT400 Burb & ORD SAS and 6BT Swap

[squaredeal91]

I finished my k10 manual swap project and have other projects started but been chipping away at this major project a while, mostly by collecting and saving parts for this project for a long time. Now lately ive been getting started on it.

Platform:1999 K2500 suburban vortec 454
Build plan:
* phase 1: solid axle conversion from (ORD) using 47" leaf springs from a square and i picked up a 2000-2001 Dodge 3500 front dana 60 already converted to 32" leaf spring perches with 3.54 gears. I had another axle i was going to convert to leaf till I found this one already done and was cheap so I jumped on it. Using Zone offroad 4" front springs.
once front axle is in and steering is done CORRECTLY I will then move to phase 2

*phase 2: get current 454 running. I don't know anything about the engine other than previous owner didn't know what they were doing according to the guy I got burb from. Timing chain removed and oil pan loosened up and starter is unbolted. After engine is running and tested it will then come out.

*phase 3: 6BT 5.9 out of 97 3500 swap/manual NV4500 swap, and floor shift transfer case swap. This swap will have lots of loose ends to figure out as I will retain all functionality like cruise control, A/C and a tachometer.

*phase 4 will be interior.

Progress will be here and there. I have most of what I need now to get axle underneath it and keep me busy a while as I chip away at it.

 

[squaredeal91]

So far ive got the front differential out and all the IFS BS out. Cutoff the upper and lower control arm brackets.
Cleaning the frame up a bit with the grinder and planning my frame brace, these frames are made to carry the weight differently and they have a weak spot.
Several companies make a frame brace kit for this.I Have a section of GMT400 frame im going to cut up and make my own brace with. After that I can remove front bumper and start mounting the spring brackets. Going to need a new drill set lol.

 

[squaredeal91]

Today i was able to Start on passenger side. Removed fender liner, rear heater hose pipe assembly at engine end, and removed downpipe to make room for rear spring bracket on passenger side. I have to drill several 1/2" holes to mount it. Oh and spring bushings came in today. Going to finish cutting off the rear bottom bracket.

 

[bluex]

This swap will have lots of loose ends to figure out as I will retain all functionality like cruise control, A/C and a tachometer.

I have a 02 24v that is hopefully going in my 99 2wd dually next year. The wiring on these trucks is pretty simple, despite looking complicated. Everything is basically a standalone circuit.

Gauges are easy as they go direct to the cluster so you can just throw the stock OP an CTS on the cummins an those gauges will work.

Tach I plan on using a 6.5 alternator with the output an it wires right to the cluster too. Might need a box dakota digital sells to dial it in. I am swapping in a manual diesel cluster as well.

Speedo an cruise can be done with another box from dakota an depending on what trans your using the vss goes into that box an the output from to the speedo an cruise will get them working. Both are 8k ppm inputs iirc. Some guys have used an abs sensor for the input to that box if you use a dodge trans.

AC isn't hard either just wire the clutch signal through the safety switches when you delete the 454 pcm. There's no need to keep it for anything an you can free up some inner fender space.

 

[squaredeal91]

I have a 02 24v that is hopefully going in my 99 2wd dually next year. The wiring on these trucks is pretty simple, despite looking complicated. Everything is basically a standalone circuit.

Gauges are easy as they go direct to the cluster so you can just throw the stock OP an CTS on the cummins an those gauges will work.

Tach I plan on using a 6.5 alternator with the output an it wires right to the cluster too. Might need a box dakota digital sells to dial it in. I am swapping in a manual diesel cluster as well.

Speedo an cruise can be done with another box from dakota an depending on what trans your using the vss goes into that box an the output from to the speedo an cruise will get them working. Both are 8k ppm inputs iirc. Some guys have used an abs sensor for the input to that box if you use a dodge trans.

AC isn't hard either just wire the clutch signal through the safety switches when you delete the 454 pcm. There's no need to keep it for anything an you can free up some inner fender space.

I didn't know Dakota had some of that stuff. Ill check that out as I get closer. Gauge cluster ill probably keep what its got or get another escalade one like the 1500 has.
Going with the np241 transfer case unless I get a 205 so we'll see

 

[squaredeal91]

Im close to mounting the brackets and drilling holes. Im going to take them off when thats all done so I can paint them. There's bare metal now and im using vht hi temp engine paint. Should I just spray and go or would there be any benefit to primer it first? I kinda don't think I need primer.

Also Im planning to bake them in the oven too. Any suggestions on how long and what temperature?

 

[squaredeal91]

Today i went shopping and I bought some cutoff wheels and flap disks and then started shopping for a different front bumper lol, maybe ordering this one after taxes. Its probably not as tough as it looks but should be at least as good as stock and I like that I can add a winch in later, I have a Ramsey electric 9000 I can fix and put it there maybe. Plus it might make a good step lol.

 

[squaredeal91]

Cut a 36" piece of frame and went to work on it. Came out with 2 pieces and kept working on the smaller one and it seems to fit pretty good now. Id say 90% ready to weld on. Will clean up more and d
Holesaw the 3 holes for the idler arm bolts. Will make about the same opposite one for drivers side steering box bolts.

They sell a brace thats 1 piece and contours to the frame for around 100 bucks but its 1/2 or less as thick as what im using, thats why im not worried about using 2 pieces and there actually overlapping a little bit too. Everything seems to fit pretty good together. Ill be using a new to me millermattic on this job, Be the first time welding with it.

 

[squaredeal91]

Finished sculpting the materials and painted everything getting covered. I will scratch off for welding but just wanted it protected as much as possible. Next is to weld it in very slowly. Going to just weld about 1-1/2"at a time moving around and waiting to keep everything cool. But that will have to wait till maybe tonight.
Wait till you guys see what color the spring brackets will be painted.

 

[squaredeal91]

Looks better in person lol. Lighting sucks and its semi gloss paint because the hardware store didn't have satin. Im going to try again today because i like satin better.

Anyways spent a good 3-4 hours welding it all in slowly, moving around. Plugged 12 or 13 holes in the big piece lol, some of which were against the frame and i was able to plug weld those. Everything went good, Im happy with it. Now I can remove bumper and start on the spring hangers on the passenger side.
The welder is a Miller mattic 250 and did okay but needs a new liner because it was tricky to keep wire from sticking. Also I couldn't hear the fan running inside? Im thinking I need to check that out too. Otherwise im happy with it and no complaints about it. Ive always wanted this welder for many years because sometimes I weld allot and need the duty cycle it has.

 

[squaredeal91]

Removed brushgaurd and bumper for spring mounts then put it on the daily K1500. Looks Decent.

 

[legopnuematic]

What is your plan for the CAD system on the Dodge axle? going to leave it vacuum powered, posi loc, lock it out, or a free spin kit?

 

[squaredeal91]

What is your plan for the CAD system on the Dodge axle? going to leave it vacuum powered, posi loc, lock it out, or a free spin kit?

Going to probably modify it with an air/ vacuum switch so that its still selectable. If it wasn't going to be a daily id probably go i little different route. But For the few times a year it gets used im sure it will perform well.

 

[squaredeal91]

I never have been a huge fan of that axle actuator ever since my 1990 Cherokee lol. They make full length axle shafts to eliminate it but since my wife will be driving it the majority i want it to be actuated from inside. If I cant get the vacuum actuator to work like I want then ill devise a choke cable to it.

 

[squaredeal91]

Found a cable kit! And here's the picture that was supposed to load for the bumper swap on Wife's daily K.
3rd picture is of a later style electric actuator. I wonder if it would physically fit on the older axle? Then I could run wires to a switch on the dash.
But I do like the simplicity and RELIABILITY of the cable.