CTD + Crew Cab - who's doin' 'em?

[Shadrach]

Shadrach - I went with 2nd gen units, intercooler being a PDR one too!

I was thinking of using a Dura-Lite cooler. It is basically a HD version of the stock one. It has silicone rubber grommets between the core and end tanks for vibration, flows better than stock, and a million mile warranty. Besides we sell them at work so I get a good price. I didn't think it was worth spending the big bucks for a BD or Spearco. DURA-LITE Charge Air Coolers They are built in Calgary AB. It will still be an improvement over the stock 92.



For a rad I am looking into getting a new one built to 97 specs but with metal tanks.



I have been asked when and where will I stop with the rebuilding and replacing of parts. You start at the front and you stop when you get to the back. People say that I could buy an 03 or newer one for that amount of money. I just reply " But then it would look like an 03" :-laf Shadrach

 

[Shadrach]

This truck is a '92 Dodge Crew Cab short box with the Cummins. I think it was built by the same people in Northern Alberta Robert referred to. He is the guy who owns the red long box I looked at earlier this year. You can see it in the background. Unfortunately it hasn't been looked after, although it has about a million km ( 600,000 miles ) on it. Of the 6 Dodges on this guys farm the red crew is the only one without a Cummins in it.

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Shadrach

 

[RSchwarzli]

Shadrach - That is awesome!! I have never come accross another cummins crew conversion by these folks! That is amazing!Oo.



Few questions that I noticed on mine. Did they relocate the fender tag from the original? How about the vin? Front doors?? Frame crossmembers?? Tell me more!!Oo. Oo.



In regards to your truck, I have people tell me that too!! And in fairness, it would be MUCH easier and cost effective to buy new!! But agreed. It does not look like a 1st gen!!



There is just something about these old trucks... .



Robert

 

[Shadrach]

I didn't ask him the details about his "92 crew ", but I will next time I see him. I saw a 4X4 one advertised in the AutoTrader several years ago in Brooks AB ( East of Calgary ) but they wanted $18,000 for it and I didn't want a 4WD. I now know that that isn't too much.

Robert is your truck registered as a 93? Any hassles ? Did you add a rear heater/ A/C unit by any chance?

Shadrach

 

[TJarecke]

If someone needs a crew cab dually conversion. HERE

 

[Flexiheep]

add me to the club

Well, I got my crew conversion on the road last saturday after 4 1/2 months of working on it. I got the Cab and doors from Mad Max almost 16 months ago, and finally started the project last July.



Highlights:

started with a 93 W250 with 280K miles

used an ex Air Force cab and doors

stretched my frame to match the new cab (16")

moved muffler and most of exhaust outside the frame

installed second factory 30 gal tank on pass side

full 4" exhaust from DP to tip

used a 2000 rad/intercooler setup with a 93 A/C condensor

removed factory oil to water transmission cooler and used 2 fan assist Derale coolers under cab

Crossover steering with borgson shaft

Skyjacker 2" front springs 10" travel Bilstein 5100 shocks (had to lengthen mount 1. 5 inches for these using the factory bumpstops.

Added the flip up towing mirrors from an 04, mirror control is the same as the 93, and then I just ran wires for the heaters.

switch/gauge panel under ash tray.



Left to do:

find a set of power front doors to use as donors to do full power in the rear doors.

install the GSK and PDR 190 injectors I have.

buy a HX35 with 14 cm housing some day

repaint in spring to the factory 93 color combo.

ingtegrate mirror mounts more smoothly into door

I'll make her a dually if I find some fenders.

lots of other little things.



Pictures in the gallery link to the left under my name.

 

[RSchwarzli]

Sweet job!!Oo.



1 - Now a few questions! What did the 2nd fuel tak come out of??





2 - Is the exhuast routed THROUGH the frame rail??



3 - Do you have any more pics of the rad core support and the brackets that were done to do the 2000 rd and 93 condenser?? I am in the process fo doing exactly that and a map of what to do is always good!!



Thnaks! Nice job!



Robert

 

[RSchwarzli]

Another crew cab for sale!!



Cars For Sale: Car Details - AutoTrader.com



Robert

 

[RSchwarzli]

And yet another!! Oo. They are everywhere!! One for everyone!Oo.



Cars For Sale: Car Details - AutoTrader.com



Robert

 

[Shadrach]

I talked to the owner of the grey and blue short box crew( the one I posted a picture of earlier ) yesterday. It is actually a 91. 5 and he told me the cowl was cut off the donor diesel and attached to the crew body. I don't know the detail of the frame stretch. He bought it used. He said it cost the original owner about $7000 extra over and above the price of the new truck, which jives with what I had been told by others.

I like the dually in NE best if those truck, but then I don't need a dually.

I too want more info about the 2nd gen rad install.

Shadrach

 

[Flexiheep]

Second fuel tank is out of a Dodge truck, about an 88 or so I think it is actually 25 gallons, I just mounted it on the other side which makes some clearances close. I would look around for a better fit if I was to do it again, but it did work. You could also do the ramcharger tank behind the axle for 35 gallons, but you would loose the spare tire.....



Yes the exhaust goes through the frame.



I don't have any real good pictures of the rad/intercooler mounts, but the mounts themselves were pretty easy. the 93 and 2000 use the same style lower pin mounts, I just cut mine off and rewelded them out where the 2000 stuff needed them. I really followed the sticky in the 1st gen forum and used angle iron to replace the verticle braces you have to remove on the front of the core support. The trick is you have to get the intercooler as close to the core support as you possibly can, I thought I did pretty well and just barely got my grill on. Literally even an 1/8th of an inch can help here. I used a stock 2000 lower hose and I had to lengthen the 2000 upper hose about 2 inches to reach (93 upper was 4 inches too short). The lower rad hose and the inlet pipe of the intercooler are very close to touching on my truck because I sat the radiator as low as I could (offset the clamps from each other).

 

[Shadrach]

Qoute... . You could also do the ramcharger tank behind the axle for 35 gallons, but you would loose the spare tire.....



We did this on both of my buddies 93 W350's. We used a non EFI Ramcharger tank, so we wouldn't have to deal with the in tank fuel pump. We mounted an electric fuel pump, activated by a dash mounted toggle switch, to transfer fuel from the back tank to the front tank. Since the ramcharger tank is bigger you must watch your fuel gauge so you don't over fill the front tank. By doing this you don't have to worry about dual return lines. You also have some "reserve" left in the back tank. I am going to do the same on my crew cab. Shadrach

 

[RSchwarzli]

I did the same thing with the Ramcharger fuel tank. Only difference is I used a new in tank pump from NAPA. Wiring was done the same - wired it into the dash to pump to the front tank.



The overfill thought did cross my mind as well during the installation...



Robert

 

[Flexiheep]

I thought for a long time on how to plumb my second tank, selector valve, transfer pump, even just linking them with a 1" hose to make them 1 tank together... ...



I almost just linked them like the medium duty trucks at work, 1 fill location would have been nice. In the end I just tried to make it work like "factory" so I bought a selector valve and a switch and plumbed it up.



My build theory through my crew conversion was how would it have worked it Dodge had done it? I wanted to reduce or eliminate the "little strange stuff" that can make big projects seem kinda strange to people other than the builder. I am not talking about the ones you want to be diffrent like if you want a manual shutdown or something like that.



Any idea why the "factory conversions" a couple posts up would have taken the time to weld the new cowel to the old body? There are a few diffrences, but I don't know that I would have welded the 93 cowl to the 85 body... My vin number moved over with my dash. :-laf I did find it interesting that only 2 of the 3 mounting holes for the wiper were the same between the two years... . I guess in a production environment if wouldn't be that hard to set up a jig.

 

[RSchwarzli]

I wondered about that wiper thing too!!



Robert

 

[Shadrach]

Here's one possibly why someone would weld a 93 cowl on a crew shell. The floor of this crew is totally rusted at the drivers feet. Sorry the weeds are so tall. I chose not to use this one simply because of the cost of the labor to weld the new cowl on. It would make a good "Mega Cab" candidate for Mad Max:-laf Shadrach

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[RSchwarzli]

That looks so sad... ... . I lone crew cab... ... ... . all alone... ... ... ... in the long weeds... ... ... ... ... ... ... so lonelly in this Christmas season... ... ..... with cancer growing rapidly... ... ... ... ... ... :{:{:{:{:{:{





Someone! Someone please rescue it!!:{:{







Robert

 

[Shadrach]

Sold to the man from Ontario :-laf Shadrach

 

[RSchwarzli]

Oh boy!:-laf:-laf:-laf:-laf



Its what I always wanted, another project!Oo. Oo. Oo.



Robert

 

[Flexiheep]

more picture up.

Hey guys I found a couple pictures of the intercooler/condensor mounting I did, going to put them in my photo album under my name.



Again I used the stock lower mounts and moved them to match the spacing on the new parts, the you can see I just did tabs off my new angle iron braces.

I drilled the condensor on the pass side to mate up with a boss in the 2000 intercooler and on the drivers side I built a small hoop out of 1" angle iron to hold it.



Also a picture or two of my new gauge and switch panel.