1991 Chevy V3500 Cummins

It started as a 1991 Chevy V3500 with a 350 mated to a SM465 and NP205. My family bought it in 2000 and drove it up from Wyoming to Alaska, I finally convinced my Dad to sell it to me in 2011. It is a pretty clean truck with rust on the cab corners and a little on the bed. Two years ago, I swapped in an NV4500 (MW3) and kept the NP205. I should have swapped it years ago.


Last summer I bought a single owner 1996 Dodge 2500 Cummins from Southeast Alaska. The frame rusted through; seat brackets completely rusted away, but mechanically was well taken care of with 130K.


Well, it is finally time to get this project started.

I turned the star wheel up and ground the fuel plate before I pulled the motor.

I kept the core support with the radiator, intercooler, ac, cruise control actuator and anything else I thought might be helpful.


Has anyone set up the cruise control?

Anyone have information on using the cruise control for high idle? I saw to a long time ago but cannot find it now.


My planned upgrades:

Advance timing to 18deg

Full forward AFC

Mack Rack Plug

Killer Dowl Pin

Boost Elbow

3 or 4k Gov Springs (suggestions – I know if you do 4k you need to do valve springs)

4” exhaust

High Mount AC

Factory AC Chevy mated to the Dodge compressor

Exhaust Brake


Rob Bonney Crossmember and mounts

Rob Bonney Front Frame Boxing


South bend dual Disc Clutch

South bend Dodge input

Dodge bell housing for the NV4500

Twin sticking the 205


Suburban fuel tank OR

Two saddle tanks mounted between frame rails. (I did this with my 1985 Buggy with 6.0 Swap. They are 34 Gallon tanks out of GMT800 trucks. They are tight but did fit.)

Fast Fuel

Custom Flat bed


6” lift

Front: Springs

Back: DIY4x Shackle Slip and short block

2” Body lift

Crossover steering

Bilstein 5100 Shocks

ORD Traction Bar

37-38” tires

Amp steps


Dakota Digital HDX

Gauges (Fuel, voltage, speed, tach, temp, oil pressure, boost, EGT, fuel pressure)


It will be getting power doors and windows

It already has bucket seats and center console from square body suburban

I’m debating on changing to a newer style.

Sound damping mats inside cab

Cab corners fixed and painted.

I’m thinking a darker metallic blue with a dark gray center. two – tone style


I will be pulling 9k-14k a fair amount.


Please make suggestions!

I’m going to start ordering parts in beginning of January.

I do not have a huge budget but also want to do it right and have plenty of power not going to want to start upgrading right away…. I know stock is huge improvement over the 350 but I had a 6.7 Cummins for little while that was tuned up some so want something I won’t be disappointed in.

Ambitious, for sure, but you will have what you want in a great looking truck. I did not see upgraded towing mirrors on your list! If you need something from the Peninsula, let me know.

I’ll chime in on the Gov spring and the clutch. I’d go with a 3200 gov spring depending on what your plans are for the truck. Like you said, much more than than and you’ll need valve springs. As far as the clutch, unless you’re planning on making 600hp is stay away from a dual disk. For daily driving they are clunky and loud and stupid heavy no matter how good your slave is. Buddy of mine has one on his 1300hp 6.0 power stroke and it’s terrible but it’s the only thing that will hold that power. Is this truck gonna be a daily driver? Towing?

and cool project.

AKguy said:

Ambitious, for sure, but you will have what you want in a great looking truck. I did not see upgraded towing mirrors on your list! If you need something from the Peninsula, let me know.

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I have a set of the extendable stock looking mirrors. I have considered using west coast mirror. I typically do not like the newer mirror on the square body Chevys but the one in the picture below I think looks good however the drawback is you lose the wing window.

Thank you, I will keep you in mind.

hunters628 said:

I’ll chime in on the Gov spring and the clutch. I’d go with a 3200 gov spring depending on what your plans are for the truck. Like you said, much more than than and you’ll need valve springs. As far as the clutch, unless you’re planning on making 600hp is stay away from a dual disk. For daily driving they are clunky and loud and stupid heavy no matter how good your slave is. Buddy of mine has one on his 1300hp 6.0 power stroke and it’s terrible but it’s the only thing that will hold that power. Is this truck gonna be a daily driver? Towing?

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Thank you for the suggestion. It will be probably half and half. I typically use it just for hauling and towing right now but I have the feeling after I do the swap I will be driving it a lot more. I have heard they are loud, I was going with it so I didn't have to upgrade later when/if I start pushing 600hp.

Sounds like an interesting project! I dream someday of finding a K30 Crew Cab.

@AKguy
I was thinking the exact same thing. AMBITIOUS. It’ll be sweet when done. definitely gunna follow this one.

Well there has been progress slow but progress.
Far as motor I put on the new tappet cover, delivery valves, killer dowel pin, freeze plugs, coolant bypass, and lots of paint done. The paint itself was a nightmare. The blue would change half way through the can. I thought I got a bad can so bought two more. They did same thing and I shook the crap out of them.

This weekend I tore truck down and sold the 350. Hopefully got the ball going and will speed up some.

I ended up getting a rob Bonney full frame kit and mounts/cross member from a Guy that was selling his new kit and happened to be coming to Alaska. I had only planned to box the front section of the frame.... now debating if I want to go through all work to box the entire frame since I have it.

What is your plan for the radiator and intercooler? I saw that you said you held onto the core support from the dodge, are you going to graft that stuff in?

TheFishBox said:

What is your plan for the radiator and intercooler? I saw that you said you held onto the core support from the dodge, are you going to graft that stuff in?

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Yea the plan is to use the dodge radiator, intercooler and possibly the condenser. Which condenser will just depend on which fits better. I have watched few videos and the dodge radiator works well.


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Getting some progress. Been a fight, I thought I was only going to have to repair cab corners, but further looking it needs driver bottom rocker and passenger fender has rust through where battery tray mounts and the lower part.
I am planning to just cut lower out and weld tube to it as a rocker slider/mounting place for steps. I did this on my buggy and works great.

I cannot figure out lower radiator hose because the radiator is close to engine and the water neck that the high mount a/c uses. Any suggestions?

I set the GMT900 seat in and with just the driver side mount cut off sets in at a pretty good height.

Hey, new to the forum and definitely new to swapping a Cummins. Just sold my 2015 GMC duramax for a fist full of dollars and some how stumbled into and bought a 1989 Chevy V3500! I am piecing together the 5.9 12V swap and wondering which NV4500 to get? I have the SM465 and NP205 combo behind a 454 currently. I am wondering if I can get the Dodge NV4500 with the 29 spline input shaft and still be able to use the GM transmission mount currently on the frame? I am thinking Dodge NV4500 29 spline just becuase it is already paired for the 5.9. I am seeing the GM and Dodge NV4500 pair up bolt for bolt 96 and after. Any links and advice is greatly appreciated. I know this is ambitious but I am driven.

td1973 said:

Hey, new to the forum and definitely new to swapping a Cummins. Just sold my 2015 GMC duramax for a fist full of dollars and some how stumbled into and bought a 1989 Chevy V3500! I am piecing together the 5.9 12V swap and wondering which NV4500 to get? I have the SM465 and NP205 combo behind a 454 currently. I am wondering if I can get the Dodge NV4500 with the 29 spline input shaft and still be able to use the GM transmission mount currently on the frame? I am thinking Dodge NV4500 29 spline just becuase it is already paired for the 5.9. I am seeing the GM and Dodge NV4500 pair up bolt for bolt 96 and after. Any links and advice is greatly appreciated. I know this is ambitious but I am driven.

Click to expand...

Using the Dodge 4500 seems simple enough with your original t-case:

I appreciate the reply!

I decided to have a NV4500 built from TransGear Performance. Dodge front 1.25/10 spline and Chevy tail with long 32 spline out. Just need the NV4500/205 adapter sleeve from Advance Adapters. Waiting on the bellhousing from Advance Adapters to become available now. Bought the Southbend 425hp single clutch and planning on the Tennessee Diesel Conversions master/slave setup.

I know I need to make a new build thread instead of commenting on someone else's. How do I do that? Thanks