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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #400 on: February 20, 2019, 09:01:56 PM »
I thought that was everything, but it turned out to be most of what I needed

Starting with this:
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #401 on: February 20, 2019, 09:03:43 PM »
As per Ken's recommendations I pulled the plastic heater fittings and just replaced everything rubber while I was at it. He and Tex said that these things just fail with time, and that is not something I need to happen, so, "Off with the old"
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #402 on: February 20, 2019, 09:04:41 PM »
And on with the new
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #403 on: February 20, 2019, 09:08:59 PM »
Now, the old spider pipe because it goes everywhere had a plug and play end that bayoneted onto the end of the firewall plastic fitting thing. The new Gates hose ended with just a nipple which would accept another push-lock pipe end, which I do not have. In an emergency, I could slide the hose over the end and clamp it, but that is not the way of the GM. So, I have to figure out how to 1. get that bayonet fitting, and, 2. how to seal the heater hose to it in some professional looking manner. When I solve that puzzle the cooling system will be as finished as it is going to get before the trip.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #404 on: February 20, 2019, 09:09:36 PM »
I have created, yet, but another mess!
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Offline wyorunner

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #405 on: February 20, 2019, 10:55:22 PM »
I have created, yet, but another mess!

We must have different definitions of what a mess is. Been grinding/welding every day this week and haven’t cleaned the floor yet.... because it only get nasty again tomorrow. Hopefully can make enough progress so I can clean this weekend.

Offline Bigdave_185

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #406 on: February 20, 2019, 11:07:30 PM »
Please forgive me guy but.... what are these hoses you are replacing done? Looks like coolant hoses going into the firewall?  What does it do? Why is it just a cheap plastic clip?

Does my duramax have these things?


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Offline cj7ox

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #407 on: February 21, 2019, 01:44:08 AM »
...when the fan in the air handler in my house decided to catch fire.

Hopefully no damage to the house???
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Offline JR

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #408 on: February 21, 2019, 02:14:59 AM »
They do fall apart, good thing you are going there. Not sure on our Dmaxs Dave, but you know GM.
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Offline TexasRedNeck

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #409 on: February 21, 2019, 08:11:20 AM »
I never understood why they needed a QD on a heater hose that gets changed every 10 years. Been a long time but I think I just slid mine over the heater outlet nipple and used a clamp.


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Offline KensAuto

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #410 on: February 21, 2019, 08:14:46 AM »
They're the quick connects for the heater core. On the Tahoe/suburban types with rear heater, they are tees instead of just one connection. Pretty sure the dmax has them up to 2010 , but can't remember for sure.

Faster assembly at the plant Charles. All about the dollar.
« Last Edit: February 21, 2019, 08:16:35 AM by KensAuto »
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #411 on: February 21, 2019, 09:19:45 AM »
Please forgive me guy but.... what are these hoses you are replacing done? Looks like coolant hoses going into the firewall?  What does it do? Why is it just a cheap plastic clip?

Does my duramax have these things?


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Dunno, Dave.

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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #412 on: February 21, 2019, 09:20:10 AM »
...when the fan in the air handler in my house decided to catch fire.

Hopefully no damage to the house???
Nossir, dodged a bullet with that one!
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #413 on: February 21, 2019, 09:23:54 AM »
I never understood why they needed a QD on a heater hose that gets changed every 10 years. Been a long time but I think I just slid mine over the heater outlet nipple and used a clamp.


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That would be quick and simple.
But
Would like to score a factory band "Squeezer" clamp instead of that gaudy worm gear, step ladder lookin, "Gonna cut ya someday" hillbilly, red-neck lookin, 1960's, out of place, cobbled up, "Lost ma factory stuff" rigged, POC thing that I don't like!
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Offline Bear9350

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #414 on: February 21, 2019, 09:52:19 AM »
They're the quick connects for the heater core. On the Tahoe/suburban types with rear heater, they are tees instead of just one connection. Pretty sure the dmax has them up to 2010 , but can't remember for sure.

Faster assembly at the plant Charles. All about the dollar.

I would take a guess and say it actually is about $1 per vehicle.  That doesn't seem like a lot but when you build 1 million vehicles in a year it adds up to $1,000,0000 per year.  You would be surprised how many times you can validate spending thousands of dollars on testing to save $.05 per piece.

Offline cudakidd53

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #415 on: February 21, 2019, 10:41:06 AM »
Steady, quality progress Don!  Glad to hear Pre-ranger and HH6 are making positive progress towards health - continued prayers their way.  Glad to hear you avoided something on the scale of the "Great Candybar Wrapper Fire" on the air handling unit in the Casa - :grin:
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #416 on: February 21, 2019, 07:05:29 PM »
Today the suspension comes off
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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #417 on: February 21, 2019, 07:06:37 PM »
Starting with the most obvious task, remove the dust covers and undo that 35mm nut that secures the axles to the hub

And thus the junk pile starts
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #418 on: February 21, 2019, 07:08:50 PM »
And then it was procedure of attacking one component at a time.

I was disappointed when nothing I did had any affect on the front caliper bolts. I broke an impact socket with my new HF 1/2" impact. THat thing is powerful. It zipped stuff apart like it was child's play
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #419 on: February 21, 2019, 07:09:07 PM »
And the pile grew
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #420 on: February 21, 2019, 07:10:14 PM »
Eventually yielding some clear space
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #421 on: February 21, 2019, 07:11:15 PM »
Then I pulled the aft crossmember and the front axle
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #422 on: February 21, 2019, 07:12:36 PM »
Creating even more junk

Of this the axle will be rebuilt, 4.88 gears installed, and bolted back in. The axle shafts are good, so I will dedicate them as spares
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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #423 on: February 21, 2019, 07:14:24 PM »
But there is no removing the calipers and therefore I will lose the factory hubs. I broke one socket, then I rounded off one of the caliper bolts, and bent a breaker bar. This stuff is done. I will remove the lower control arm for reuse and toss the rest of it
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #424 on: February 21, 2019, 07:15:26 PM »
Tomorrow will see some lift kit components being installed
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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #425 on: February 21, 2019, 07:16:29 PM »
With the floor cleaned off and drying overnight, this is where it all sits when I stopped for the night
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Offline wilsonphil

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #426 on: February 21, 2019, 07:25:44 PM »
Are you going to use Deaver on the rear spring?

And do you have a drainage issue with your driveway, looks like it drains into your garage!

Offline JR

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #427 on: February 21, 2019, 08:31:45 PM »
Those caliper plates are a pain, Never broke a socket on one or bent a breaker bar but sure I was close.

Looks good though. You know shafts are east to find. 50 less # to carry around.
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Offline KensAuto

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #428 on: February 21, 2019, 09:15:19 PM »

I would take a guess and say it actually is about $1 per vehicle.  That doesn't seem like a lot but when you build 1 million vehicles in a year it adds up to $1,000,0000 per year.  You would be surprised how many times you can validate spending thousands of dollars on testing to save $.05 per piece.
Yeah. I remember when Ford came up with using quick connects on every a/c line connection back in the 80's. Sure kept me busy...actually still keeps me busy to this day.

Don, that's just the way those calipers are sometimes. Using a torch to free the Loctite helps, along with a long breaker to get them loose before hitting with an impact. Those china sockets don't like the ratta tat tat on something that tight.
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Offline stlaser

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #429 on: February 21, 2019, 09:51:13 PM »
Yep, little bit of heat goes a long way sometimes.
Living in the remote north hoping Ken doesn’t bring H up here any time soon…..

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #430 on: February 21, 2019, 09:52:14 PM »
Are you going to use Deaver on the rear spring?

And do you have a drainage issue with your driveway, looks like it drains into your garage!
No

and

No

;-))
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #431 on: February 21, 2019, 09:54:21 PM »

I would take a guess and say it actually is about $1 per vehicle.  That doesn't seem like a lot but when you build 1 million vehicles in a year it adds up to $1,000,0000 per year.  You would be surprised how many times you can validate spending thousands of dollars on testing to save $.05 per piece.
Yeah. I remember when Ford came up with using quick connects on every a/c line connection back in the 80's. Sure kept me busy...actually still keeps me busy to this day.

Don, that's just the way those calipers are sometimes. Using a torch to free the Loctite helps, along with a long breaker to get them loose before hitting with an impact. Those china sockets don't like the ratta tat tat on something that tight.
I might get after the bolts, but there is that one I rounded off. kinda kills the possibility of saving that hub assembly
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Offline stlaser

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #432 on: February 21, 2019, 09:58:00 PM »
You still own a welder right?

Edit: Duane sighting, I called it first!!!  :tongue:
« Last Edit: February 21, 2019, 09:59:16 PM by stlaser »
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Offline Bear9350

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #433 on: February 21, 2019, 11:04:38 PM »
Picked up a couple pallets of steel this afternoon.



This is basically all of the steel for the front and rear bumper.  Just need to add some tubing to this pile for the guards and swing arm.  You might not be able to tell but this pile is kind of sorted.  I know how about 95% of these will go together.



But this is the rest of the pile of steel that I picked up.  There is another front and rear bumper in there that I need to get finished up before I can get started.  Should get most of that taken care of this weekend. 



Offline Bigdave_185

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #434 on: February 21, 2019, 11:26:27 PM »
Did you get that paint match ordered bear?


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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #435 on: February 22, 2019, 01:09:04 AM »
They're the quick connects for the heater core. On the Tahoe/suburban types with rear heater, they are tees instead of just one connection. Pretty sure the dmax has them up to 2010 , but can't remember for sure.

Faster assembly at the plant Charles. All about the dollar.

And faster when you gotta pull the engine or cab.


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Offline KensAuto

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #436 on: February 22, 2019, 08:56:57 AM »
That's one heck of a puzzle you have there Bear. I dare you to send it like that to Don.


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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #437 on: February 22, 2019, 09:12:43 AM »
That's one heck of a puzzle you have there Bear. I dare you to send it like that to Don.



You stop that right now!
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #438 on: February 22, 2019, 09:16:33 AM »
I think I felt "A tremor in the force" yesterday. While I was under the truck tearing off the suspension, I had this strong desire to continue and tear off the bumper as well...

Now I know why!

Bear: Looks well, puzzling! Please show the construction of all that on this thread as we see the stack of flats transform into a combat ready, Prius killin' bumpa... ;-))
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Offline Bear9350

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #439 on: February 22, 2019, 09:38:59 AM »
That's one heck of a puzzle you have there Bear. I dare you to send it like that to Don.

So that was originally kind-of the original plan, but worse.  I was going to email him the files and Don was going to have them cut out local.  Normally that doesn't work out to bad.  But between the modifications to the front bumper, the material thickness changes and all the extra stuff I was doing a lot of head scratching last night trying to figure out what was what.  I would have hated sending this out to somebody like that and trying to help them figure out what goes where over the phone.

Generally I can just look at the parts as I unload and stack them according to how I will need them as I build the bumper up.

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #440 on: February 22, 2019, 09:47:25 AM »
I think I felt "A tremor in the force" yesterday. While I was under the truck tearing off the suspension, I had this strong desire to continue and tear off the bumper as well...

Now I know why!

Bear: Looks well, puzzling! Please show the construction of all that on this thread as we see the stack of flats transform into a combat ready, Prius killin' bumpa... ;-))

Hoping to get started on these Tues/ Wed next week.  Hoping they should be ready to ship around the week of the 11th.  Probably going to be dependent on how long it takes to get some of that brush guard tubing formed up.

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #441 on: February 22, 2019, 02:50:56 PM »
If you do end up documenting those 2 bumper builds (I know, you have your hands full as it is), I would guess everyone on here would appreciate it.

I would start a thread just for that tho. ...you think Don? or keep it in here?
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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #442 on: February 22, 2019, 05:17:23 PM »
If you do end up documenting those 2 bumper builds (I know, you have your hands full as it is), I would guess everyone on here would appreciate it.

I would start a thread just for that tho. ...you think Don? or keep it in here?
Ken, FOr Brian's sake and to advertise his business, I think I'd do both. A detailed one elsewhere and a readers digest here. But if I had to choose, I'd say post here. THis thread will be one of those living things like SquareD and be read by many people over the years. It would undoubtedly lead to a lot of bumper builds/sales for Bear Claw Bumpers.
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Offline JR

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #443 on: February 22, 2019, 06:08:41 PM »
Just take lots of pics, then edit and write with the work done.

No square body stuff if I recall? My sub needs help.
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Offline swbhobie16

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #444 on: February 22, 2019, 07:01:40 PM »
Just take lots of pics, then edit and write with the work done.

No square body stuff if I recall? My sub needs help.

2nd’d

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #445 on: February 22, 2019, 09:53:25 PM »
I'll do my best to document what I can.  Once i get started I'm not real great at remembering to take pics.  I will at least document the major progress points.

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #446 on: February 23, 2019, 06:29:36 AM »
No square body stuff if I recall? My sub needs help.


Pretty much all you need for a square body


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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #447 on: February 23, 2019, 11:10:34 AM »
Lol Charles. Funny and true.
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Offline JR

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #448 on: February 23, 2019, 04:36:45 PM »
And that is all I plan for the rear on top of the receiver. Will be a nice air tank too being 4x6.

But I need to cut off some of the parasitic stuff here;
« Last Edit: February 23, 2019, 04:37:31 PM by JR »
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 2
« Reply #449 on: February 23, 2019, 10:50:32 PM »
Shiny stuff first. Picked up some new clevis links for Brian's new burb bumpers. These blue ones are super beefy
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