Improving the ride...

[ENafziger]

I finally got a chance to get started again on the suspension. I got the rear shock mounts in progress finally! I'm going with a fore/aft design rather than the OEM steep inboard lean.

For the upper mounts, I reused a stock shock mount crossmember. I cut it in two pieces, and rewelded as shown. The mount is as high as possible, with just enough clearance to prevent having to notch the bed.

Mounting a 14" travel shock is a challenge without extending the upper mount into the bed area. To help compensate, the lower mount will be dropped down slightly... but won't go lower than the bottom of the rear differential. I chose to make the lower shock eye mount about 8" from the centerline of the rear axle to give a much larger moment arm for better axle-wrap control.

Here's the passenger side top shock mount:
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Picture of one of the lower mounts in progress...
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New driver's side top shock mount:
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I hope to have the complete suspension done by this weekend. The new wheels and tires should be here either Friday or Monday.

I'll be installing 315/75/16 Toyo M/T tires on Pro Comp 7028 wheels, along with Centramatic balancers.

--Eric

 

[Grey Wolf]

Looking good

 

[ENafziger]

Got a little ways on saturday. We finished up the rear shock mounts, re-did the lower front shock mounts, and mounted up the new wheels and tires. I installed some centramatic balancers, and fabbed a new Carli Bilstein 7100 steering stabilizer to fit as well.

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Again, not really taking an extensive amount of time to document the how/why/what's involved with doing this as it doesn't seem to be a big topic of interest. However, if anyone has specific questions, I'll be glad to help and expound on things some more!

--Eric

 

[stoneagemaxx]

hey, ive got the general gist of these spring swaps and im just about to start on my '93 and am very interested in the swap, looks great i'm sure your going to love it, how much weight are you planning on towing? keep it up i'll make sure to start a resto thead when i get some work done, Be safe



Tim

 

[ENafziger]

how much weight are you planning on towing?

I have the '06 truck for HEAVY towing, and am building an '87 Dodge for rockcrawling/heavy offroad, so this '91. 5 is going to do everything well, but nothing great.

My goals for the '91 are mainly ride quality, a great daily driver with some spunk, and a decent offroad machine that can tow moderately.

That being said, I expect to be able to have 2,000 lbs in the bed without being too squatted... and expect to be able pull my 30' tri-axle 21,000 lb bumper pull when needed.

If the rear suspension isn't up to this, then I'll see about designing a long-travel set of air bags!

--Eric

 

[pwerwagn]

Dammit Eric!!!! This is not the thread I needed to read!!!!

I have a 74 with the "shaggys" monster rear on it. LOVE it. Made the ride crazy good. I have been considering building a first gen 4 door, and turn the 04 into a more serious off road vehicle (I know... backwards). This thread has really lit my fire man. I didnt see this build on DTX, did you post it up there!?!??

That truck looks sick with those tires/wheels.

Now im considering selling the Class 7 ranger I just got driveable yesterday, to do this on a 4-door.

Really, seriously, I hate you now.

--Jeff (from DTX)

OH... and on the rear shock mounting, I discussed with Bill Cook (from ORE/Shaggys) about going to the shock mounting style you did, and we had a few convos here and there, and I ended up not doing it because he said axle wrap shouldnt be an issue... But, it was on a small block truck too so with the diesel it might be?

 

[pwerwagn]

This is my 74, but I cant remember/tell if this pic has the monster rear setup or not. EDIT: DEFINITELY NOT THE MONSTER REAR... THAT WAS STOCK LEAFS AND SHACKLE FLIP IN THAT PIC... .
I used pro comp leafs though, at the time they were supposed to be the "softest". I ended up with ~7" lift using the springs I did, the shackle setup, and 2" blocks. The springs were softer than I thought/was told.
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This is the ranger I think you are now obligated to buy...
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And this is my 04 (youve seen it on DTX im sure)... I want to build a first gen crew to match this truck. Trailer products fenders, 37" toyos, walkers, etc...
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[ENafziger]

Dammit Eric!!!! This is not the thread I needed to read!!!!

I have a 74 with the "shaggys" monster rear on it. LOVE it. Made the ride crazy good. I have been considering building a first gen 4 door, and turn the 04 into a more serious off road vehicle (I know... backwards). This thread has really lit my fire man. I didnt see this build on DTX, did you post it up there!?!??

That truck looks sick with those tires/wheels.

Now im considering selling the Class 7 ranger I just got driveable yesterday, to do this on a 4-door.

Really, seriously, I hate you now.

--Jeff (from DTX)

Hey sorry for the late reply... I've not had access here lately!

Well, glad I could get you motivated!!!! I'll be updating here shortly. It looks like the G56 trans in my '06 has lost 4th and 6th gear, so I need to get the '91. 5 going as soon as possible!

--Eric

 

[ENafziger]

Well, a little update. Since the transmission is out in my '06, I now have a bigger motivation to get this done quick!

I worked last night awhile, and got the engine bay cleaned up a little and painted. I've still got a ways to go, but it's looking a little better! I found some 600° burnt copper paint I kind of liked, so I decided to give it a try.

I also got the new exhaust manifold installed, EGT thermocouple, and am fitting up the HE351CW.

List for tomorrow:

• Flare brake line and reconnect in rear bypassing ABS
• Unplug the ABS module behind the glove box
• Fit modded HE351 turbo
• Mock up exhaust, weld flange
• Mount U. S. Gear exhaust brake
• Mod '06 factory air box to fit
• Relocate coolant overflow reservoir
• Finish fuel line routing from Raptor pump up to engine
• Set bed back on truck and connect taillight wiring, etc
• Nightshades paint on taillights and marker lights
• Diagnose a couple speakers that aren't working on the new stereo
• Begin mounting for 1995 model seat

Here's a few pics of the progress...

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--Eric

 

[pwerwagn]

wow, I would have said that would look dumb, but I kind of like it!!! Its different for sure, and it looks like you did a GREAT job doing it.

 

[HHhuntitall]

Yeah, I would have shook my head on the copper color, but it looks pretty good. It definitely stands out..... is that a handprint on the alternator bracket? He he, couldn't wait to pull wrenches? I can relate to that!!

 

[RSchwarzli]

Holy fungooley! That is amazing! And I thuoght my crew cab motor was clean!



I am a little green now! That looks great! I would not have thought that color to look so good!



Soooo, did you just mask it off, or did you remove all the non painted parts that I see are not copper?

 

[ENafziger]

is that a handprint on the alternator bracket? He he, couldn't wait to pull wrenches? I can relate to that!!<!-- google_ad_section_end -->

Good guess! It's actually a little black paint smear that came off the newspaper I was using as an in-place overspray shield.

Holy fungooley! That is amazing! And I thuoght my crew cab motor was clean!

I am a little green now! That looks great! I would not have thought that color to look so good!

Soooo, did you just mask it off, or did you remove all the non painted parts that I see are not copper?<!-- google_ad_section_end --> <!-- / message --><!-- sig -->

Ah, come on now... my little re-do can in no wise be compared to your build-up! What I did was like putting on more aftershave and fresh deoderant but never taking a bath :-laf

While this truck was VERY clean for original form, I spent probably $60 at the car wash in 5 separate trips, degreasing and getting most of the 20 years of accumulated crud off. I really didn't plan on cleaning up the engine like I did. I just happened to get a $10 free coupon from Pep-Boys for my birthday, and was browsing the paint aisle. I saw the burnt copper color high temp paint, and grabbed the two cans they had.

I already had the turbo off and was replacing the exhaust manifold, so I started on that side of the engine. I got a piece of newspaper and used it as an overspray shield to pretty much keep paint going where I wanted. I taped off the Cummins nameplate and a couple stickers. I also taped around the alternator a little. The only things I removed were the air intake hose and top beauty valve cover. Everything else was in-situ painting with the newspaper and a little bit of gymnastics involved!

I had cans of black and intense blue pearl coat as well, so when I oversprayed onto something I didn't mean to, it was no big deal. With as many projects as I have going on right now, I've learned a lesson. I spent 3 hours total painting and it probably looks like a 8. 5 - 9... I could have spent about 60 hours and had a full 10 perfect rating. But, in all honesty, it looks good enough for me. I'll be using it like a truck, and it looks better than it did, and that's what I was after

--Eric

 

[RSchwarzli]

What I did was like putting on more aftershave and fresh deoderant but never taking a bath :-laf

Now THAT was funny!:-laf

Ah, come on now... my little re-do can in no wise be compared to your build-up!

Ah but yours looks really good in that color!

 

[BIGNASTY]

After all its a TRUCK I can understand why you dont want you pregnant significant other to ride in the thing after all the baby might stutter.

 

[pwerwagn]

Sooooo how's it ride?

 

[ENafziger]

Sooooo how's it ride?<!-- google_ad_section_end -->

Well, it's not driveable yet.

I removed the ABS block in the rear, re-flared the brake line and bypassed it. I unplugged the ABS module behind the glove box, and got the bed and bumper installed. The rear half of the exhaust is in, and hangers are welded. (I had to re-do the exhaust to clear the flex of the new springs). Oh, and I got the 3rd gen air box mounted. I made a new wastegate bracket for the HE351cw that had to be re-clocked, and got it welded to the compressor.

Unfortunately, there's just too many other things going on. Funeral tonight, and then helping my brother in law move a 12' x 20' shed.

Believe me, I'm as anxious as you are to get it going!

--Eric

 

[pwerwagn]

Come on Eric, updates!!!!

did you do a thread on DTX too?? I couldnt find one.

 

[ENafziger]

Well it's running!!! I drove it to work today

My first thoughts... the fuel pump (Raptor 150) is WAY too loud and annoying. It's so loud that I can barely hear the straight-piped 4" exhaust!

The steering is pulling to the right... the direction the 7100 stabilizer is pushing. I may have to let out some more Nitrogen?

The tires are very fishy and washy... I had another set of Toyo MTs do this right after I rotated them. Within 100 miles it returned to normal, so I think this will take care of itself.

I definately need to get the M2 fuel pin installed and tweak the pump. I can't even make the truck puff the tiniest could of smoke with the he351!

The front springs and shocks definately need broken in. I hope to do some pretty good trail pounding this weekend!

The flex is incredible!!! I've never personally seen a vehicle flex like this. It's night and day more travel than my 2. 65 Carli kit on the '06.

98% of all vibrations are completely gone. There is still a slight vibration at ~62 mph. The Fat Mat, Centramatic balancers, and new transmission mounts must've helped alot!

More to come...

--Eric

 

[ENafziger]

Oh... I bypassed the ABS module on the rear driver's side frame rail. I also unplugged (what I thought at least) the ABS module behind the glovebox.

The red brake light is still on on the info center. Is this right?

--Eric