REAL MAN TRUCKWORKS & SURVIVAL

VEHICLES, CAMPERS, and BOATS => Build Threads => Topic started by: Flyin6 on March 25, 2019, 10:57:09 PM

Title: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 25, 2019, 10:57:09 PM
Up to part 3 already!
Once the threads get to something near 40 pages, i think it is a good idea to just start the next part.
I look for a good point to break from where the truck was before especially if there is a paradigm shift

I sort of believe that is what took place today. Up to this point I was rebuilding some things, or moderately improving other things such as adding the cam to the motor or the shift kit to the transmission.

But starting with this very post I am turning the corner to some pure modifications, and not necessarily of the bolt on variety such as a lift kit. We are about to get into the addition of a mugo (no crap) militarized rear axle and we will start with the shackle flip that sets the stage for the mounting of all that new business in the rear suspension.

Starting with the stock setup, I went to work grinding the steel rivets off so I could remove the factory shackle mount
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 25, 2019, 10:59:02 PM
It took some time and the job was a dirty one, but in time the old yielded to the grinder
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 25, 2019, 10:59:54 PM
Which allowed me to set the spring onto the ground
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 25, 2019, 11:02:05 PM
I had a set of shackles that were just slightly longer than the factory ones, so I think they are a good place to start. I fully expect to eventually have to change the lengths to get to the optimal length, but for now these will serve a purpose
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 25, 2019, 11:04:37 PM
The spring bushings are in great condition, so I have no worries reusing the spring as it is currently installed

While all that was going on, I coated the new flip bracket with KBS epoxy paint, allowed that to set up, then applied two coats of gray enamel over top of that.

They should be ready to drill in and mount tomorrow
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 25, 2019, 11:06:36 PM
I also got after the front suspension punch out list beginning with mounting the factory snubbers. When i compressed the suspension a few inches, they slipped right into place without any modification
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 25, 2019, 11:09:31 PM
I connected the anti lock reluctor cable on each side, and secured them in a close to factory configuration. All that remains for me to do now is to tighten the actual frame mount and lower control arm bolts once the front end is resting on its suspension.

After that I finally installed the front courtesy light bulbs with brighter LED's
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 25, 2019, 11:11:15 PM
Since the paint was not cured on the shackle flip bracket, I started the roof rack.

Here are the various pieces of the 80/20 extruded tubing system.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 25, 2019, 11:13:22 PM
I will extend the new rack to a point just shy of the windshield. I will need all available space with the mugo tent that is coming

So off came the front roof rack rail mount and both cross bars. They will net be reused
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 25, 2019, 11:15:04 PM
This stuff allows for complete customization and gives you so many choices where to mount things. It is easy to work with and is dead flat with perfect 90 degree angles
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 25, 2019, 11:17:52 PM
I built one side first, forming it from two sections of 1" X 2" 57" long

I used two 90 degree gussets and a two hole tab to fasten the two pieces together.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 25, 2019, 11:18:31 PM
I had a pile of hardware to start with.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 25, 2019, 11:21:17 PM
These tabs slide into the recess in the tubing and are secured to something on the outside of the tubing with a 1/4 20, 1/2" long allen head screw

Next I attached the center 2" wide crossbar which will carry some of the weight of the tent
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 25, 2019, 11:23:07 PM
I also have the option of fastening pieces at a 90 degree junction with these angle pieces that slide into the tubing recess and then held by tightening a set screw
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 25, 2019, 11:24:01 PM
I attached one to an end to serve as a guide, then attached the other outside long rail
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 25, 2019, 11:25:58 PM
Following that, I divided the crossbars and started attaching them

I had to stop to get ready for my monthly fire department board meeting, so back to this bubba tomorrow after finishing the shackle flip mod
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on March 25, 2019, 11:29:24 PM
Don I have questions about placement of the rear shackle mounts

I know the GM design is flawed.  You can’t take the springs out with out grinding off the bolts as other parts are in the way?

What do you gain from the new shackle mounts? 
The GM has a drop mount than everything mounts upward of that for some reason

Never had any experience with shackles or anything like. Just the standard lift that ya buy from the local 4x4 shop they installed.   I have a two inch something block in the back of my 2500.  They have flaws like axlewrap and wheel hop and so forth.   Does this thing your adding change that?

Does it go directly into the rivets you ground off?



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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 25, 2019, 11:43:33 PM
Don I have questions about placement of the rear shackle mounts

I know the GM design is flawed.  You can’t take the springs out with out grinding off the bolts as other parts are in the way?

What do you gain from the new shackle mounts? 
The GM has a drop mount than everything mounts upward of that for some reason

Never had any experience with shackles or anything like. Just the standard lift that ya buy from the local 4x4 shop they installed.   I have a two inch something block in the back of my 2500.  They have flaws like axlewrap and wheel hop and so forth.   Does this thing your adding change that?

Does it go directly into the rivets you ground off?



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Good questions Dave!

Removing the drivers spring would force you to drop the gas tank, since there's no way to get to the bolt without doing so. So yes, I couldn't lower the spring without first removing that mount

What I gain from the new shackle mount/location is a bunch of things

First of all, I need 5" of lift to complete the lifting of the truck. Simply flipping the shackles gives me exactly that. Secondly, I can use a standard factory arch spring which I already have. Remember, the deaver high arch springs were around $1,000, and will now not be needed. Then there's the lift block. I think a 1" to 2" block is OK and commonly used, but beyond that the leverage caused by a heavy vehicle going around a curve really pushes on those blocks, and taller blocks are flat out unsafe. I will not need any block at all, and the axle will mount to the spring just like it did from the factory. I would have had to use a 5" block and uber long U-bolts.

Next, the blocks cause the spring to wrap up under acceleration torque. when they snap back into shape the "Kick" bounces the tires off the pavement causing a bouncing of the rear end. This is all kinds of no good. Can break stuff like axles and U-joints and cause the vehicle to become uncontrollable. I will have to deal with none of that. Finally the gentle rolling forward of the axle helps align it to the driveshaft, again keeping things close to factory alignment.

I will have to drill new holes to mount this thing, but it acts like a plate actually reinforcing that area of the frame that it scabs over top of.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on March 26, 2019, 12:07:40 AM
How do you determine where the new plate will go?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 26, 2019, 10:41:36 AM
How do you determine where the new plate will go?


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That's easy

Straight up/down

Here's why:

So at full spring extension, (relaxed state) the shackles will be straight up and down. When you lower the vehicle and place weight on the springs causing them to flatten somewhat, they will lengthen. That will push the shackles aft to some angle.

So when off roading and you encounter an obstacle where a lot of flexing is required the spring can both unload and the shackle can travel forward to the vertical...And continue to angle forward as the spring pulls downward. This effectively increases suspension travel. In a IFS suspended vehicle, 70% or more of the suspension flex is in the rear. Suspension travel as we know allows tires to stay in contact with terra firma. More travel means the tires can stay in contact, providing traction over larger obstacles than a stock suspended vehicle.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 26, 2019, 10:42:50 AM
Picked up 4-3/8", 1- 1/4" and 1- 5/16" cobalt drill bits just now...$48!!!!!!!!!!!!!!!!

Man stuff is getting expensive!!!!!!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on March 26, 2019, 05:57:40 PM
Picked up 4-3/8", 1- 1/4" and 1- 5/16" cobalt drill bits just now...$48!!!!!!!!!!!!!!!!

Man stuff is getting expensive!!!!!!

Sounds like a really great deal, I’ve never seen a 4 3/8” drill bit but would have expected that alone to be more than $48......

What are you drilling that you need that large of a hole in?


  :tongue:  :facepalm:  :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wilsonphil on March 26, 2019, 06:49:35 PM
I think he means 4 3/8 long
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Sammconn on March 26, 2019, 06:50:24 PM
I’m thinking 4@ 3/8” , 1@ 1/4”, and 1@ 5/16”
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on March 26, 2019, 07:08:50 PM
Commas and decimal points are really important. Especially in finance


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Sammconn on March 26, 2019, 08:16:23 PM
Agreed.

And if it were the behemoth sizes listed I’d say 48 bucks is cheap...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 26, 2019, 09:07:27 PM
I’m thinking 4@ 3/8” , 1@ 1/4”, and 1@ 5/16”
Winna!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 26, 2019, 09:11:16 PM
So I mapped out the rack based on what I think I may want to support the tent on the back end, and maybe mount a basket up front
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 26, 2019, 09:13:19 PM
I treated the clean areas of the roof that are covered by the factory mount fixtures with the amber rustproofing. I really thing it is nothing more than cosmoline.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 26, 2019, 09:14:38 PM
And then I through-drilled the rack side rails into the existing roof rack aluminum bars in six places on each side
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 26, 2019, 09:15:55 PM
The front will need a mount which I will fab up and mount at each corner. Without the mount the rack is pretty stout, but it should be secured properly to remove any doubt
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 26, 2019, 09:16:33 PM
Alignment worked out very well.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 26, 2019, 09:17:29 PM
The paint was cured on the shackle flip mounts so I loaded them with poly bushings and greasable bolts
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 26, 2019, 09:18:05 PM
And secured them temporarily to the springs
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 26, 2019, 09:19:49 PM
I used a floor jack to push the springs and bracket up into place and would you know it, it lined up exactly where the factory mount was before. I slid it aft 1/4" to closely fit a frame crossmember and drilled it into place
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 26, 2019, 09:21:17 PM
I used 6 ea M10 X 1.5, 10.9 grade bolts to secure the mounts to the frame. It came out very strong and rigid
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 26, 2019, 09:23:21 PM
I tore it back down to paint the shackles with the KBS epoxy paint. It starts out looking like you see here but flows out and reacts to come out looking quite smooth and uniform. While I was at it, I painted the same stuff onto the exhaust pipe extension to keep that thing as rust free as I can make it
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 26, 2019, 09:25:54 PM
I was just about to fire up the grinder and remove these factory jounce bumpers to make room for the air bags when my daughter called asking if I could watch the kids while she went to the hospital to have a baby.

So like any good "Poppy" (as I am known to the little people) I shut down ops and started being a granddad...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on March 26, 2019, 09:38:06 PM
Let me know the kit you are using for the lifted truck. I may put some on the bus


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: DDS on March 27, 2019, 07:25:57 AM
The front will need a mount which I will fab up and mount at each corner. Without the mount the rack is pretty stout, but it should be secured properly to remove any doubt

The front of that roof rack would be a perfect spot for a light bar...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 27, 2019, 07:45:48 AM
The front will need a mount which I will fab up and mount at each corner. Without the mount the rack is pretty stout, but it should be secured properly to remove any doubt

The front of that roof rack would be a perfect spot for a light bar...
I guess it would
But
The glare off the hood would blind ya!

I have often wondered how folks deal with all the glare from overhead lights...???
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 27, 2019, 07:52:01 AM
Oh and I have to report on the Cooler's performance

That thing really works

So two saturdays ago around 1000 (That's AM for you civies) we dropped a 5 lb bag of ice in it. The following saturday it was still there!
Sunday it was maybe 30% cold water the rest ice
Monday, 50/50 or thereabouts
Tuesday still cold

So it went 10 days with a lot of ice, 11 days with a lot of cold, 12 days still refrigerating milk which we pulled out and used. It was icy cold
Yep this thing was a great idea.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: swbhobie16 on March 27, 2019, 08:40:35 AM
used as long period storage coolers.. the hefty ones make sense (i can’t recall exactly which brand you got..) but ppl kill me when they go get a $300 yeti to bring beer to a concert bc it ‘holds ice for a week!’ like.. use a $20 walmart cooler you don’t mind getting sand in if you’re opening the thing every 2 min. hahah
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on March 27, 2019, 09:13:51 AM
used as long period storage coolers.. the hefty ones make sense (i can’t recall exactly which brand you got..) but ppl kill me when they go get a $300 yeti to bring beer to a concert bc it ‘holds ice for a week!’ like.. use a $20 walmart cooler you don’t mind getting sand in if you’re opening the thing every 2 min. hahah

but this makes too much sense to those people..... :facepalm:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: BobbyB on March 27, 2019, 07:32:43 PM

The glare off the hood would blind ya!

I have often wondered how folks deal with all the glare from overhead lights...???

You either paint or apply a matte black,grey or a similar darker colored decal to the hood to negate any glare. Or slide the light back away from the front of the cab a little bit, or a combination of both.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 27, 2019, 08:25:14 PM

The glare off the hood would blind ya!

I have often wondered how folks deal with all the glare from overhead lights...???

You either paint or apply a matte black,grey or a similar darker colored decal to the hood to negate any glare. Or slide the light back away from the front of the cab a little bit, or a combination of both.
I actually wanted to matt-black the hood to reduce glare, so that just may be something I might be interested in doing. But I'd save that for post trip. Too much to do to get ready to go to worry about a roof light just now. The light holes in the bumper Brian built has plenty of holes needing to be filled right now
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 27, 2019, 08:26:38 PM
So, I got those rear suspension compression bumpers cut off the frame
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 27, 2019, 08:30:48 PM
Had planned to start the truck this morning, but the battery developed an internal short. It measure 0.1 volts, and would not take a charge without tripping off the charger.

So I pulled it and purchased a new 800 CCA battery at OReillys.

When I pulled the old battery. I had a little corrosion on the tray, so I wire brushed it clean, then thoroughly cleaned it, then sprayed it with bed liner. It took all day long for the stuff to set up, so I never did get that first start done

The factory battery felt liner was still there and good shape, so I laundered it and it sits ready to wrap yet another battery in this old truck
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 27, 2019, 08:32:30 PM
I cleaned up the factory springs, then gave them a fresh coat of paint, then after air drying, bolted up the newly painted shackles to complete the shackle flip mod.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 27, 2019, 08:33:35 PM
I wire brushed off the frame in the back to get it ready for a fresh coat of undercoating
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 27, 2019, 08:34:28 PM
Found a spot to collect some of my old Army and contractor patches...

And a new one...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 27, 2019, 08:37:16 PM
I picked up another estwig hatchet/axe. This one should get the job done for tapping in ground pegs and chopping and splitting wood for the evening fire.

I mounted it on some velcro blocks I placed on the aft pillar opposite the flashlight
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 27, 2019, 08:39:12 PM
I kind of wanted to start on the Dana 80 axle, but I was working broken periods around running the pre-Ranger here and there. So I made up the front supports for the roof rack. I plan to install a couple of Nut-serts into the roof and bolt into those.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 27, 2019, 08:40:53 PM
I figure I'll just tap out the bottom hole in the extruded tubing and bolt into that from the roof just aft of the windshield. That should make for a clean limb riser the way I have it all angled
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 27, 2019, 08:45:00 PM
I calculate that I will have room for a decent sized roof basket.

The tent is 76" wide. I'd set it right on the aft rib so it would only take up the 76". Give it say 3" to have room to work around it, so I'd eat up 79" of space. Fudge in another 1" and call it an even 80" out of a rack that is 114" long. That's 34" of rail to mount something.

I am currently looking for a roof basket that is 30-32" long and 48" wide. If I find one and buy it right, it will be showing up on that rack right after the tent gets attached.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 27, 2019, 09:51:53 PM
Well, I just found a smittybilt 48" X 48" bolt together unit made from 1" .120" wall tubing with 4" tall sides.

I noticed that it is broken down in three sections

My thought is to leave the center section out and bolt the front and back together into something hopefully just under three feet.

I need this to store the camp chairs and the annex room and possibly a camp potty/tent.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:02:32 PM
I charged the battery to 100%, hit the key and on the second-third revolution it fired right up!

The lifters were clacking for a few seconds, then it settled down to an idle.

It has that classic 60's muscle car idle. Choppy but not lopey. It warmed up and settled into a 650 RPM idle that just sounds good. The Magnaflow muffler is doing a good job of keeping things toned down, but it definitely has a nice rumble and a good bark when you blip the throttle. I think the added compression made for a faster pickup when leading in with the pedal.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: dave945 on March 28, 2019, 09:04:32 PM
Nice, glad to hear it fired up and sounds good.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:06:13 PM
I allowed it to cool and topped the fluids. It took two more quarts of transmission fluid to get a low stick indication and maybe 1.5 quarts of Dexi-cool to top up the cooling system. I'll work on the transmission fluid level when I have a drivetrain and I can shift it into gear.

Next up I punched two holes into the roof and pulled in 1/4" nutserts. For some strange reason, neither of them fastened well. One stood proud and one turned after crimping. I had to remove both and pull two new ones. Those worked fine
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:07:27 PM
Nice, glad to hear it fired up and sounds good.


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Yea, those 243 heads and the new vinci cam makes a whole new motor out of what was an LQ4. I guess it no longer is a LQ4, but something of a hybrid at this point.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:08:39 PM
I painted them low gloss black and allowed the paint to harden then secured everything.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:11:18 PM
I picked up a rubber mat for the cooler. I plan to affix a drain hose to it with a valve and install a couple of tie downs to secure it and call that done as well.

The inside was still cool despite my having drained it yesterday and there was actually a couple small pieces of ice remaining!! I'm just two days short of two weeks and it is still cool! That is some kind of cooler!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:12:26 PM
I haven't made all the connections, but the step retracted anyway. I like how well this one tucks into the body
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:13:55 PM
So, now it is Axle time. I started the teardown of the mongo full floater. It did not come apart easily!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:15:08 PM
But piece by piece, it did yield to the mighty wrench
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:17:04 PM
The axles are 35 spline and came out easily, held in place with 1/2" (Head size)12 point fasteners.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:19:17 PM
The hubs had no moisture inside, only 18 year old grease. They came apart easily

I'll clean them up and replace the seals, clean and paint, oh and new studs, but that will be the extent of it
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:22:12 PM
My plan for the brakes is to just reuse the stuff from the the semi-floater stock 14 bolt

To find out if I had a swap potential. I needed to tear down the stocker as well.

Initial measurements are all coming out the same as stock. Spring pad, width, and bolt hole c-c distances on the axle flanges.

The stocker also came apart easily. A lot easier than the mutant axle
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:23:43 PM
JR really likes this axle, and except for the C-Clip, I can see why. The ring gear is of a decent sixe and the axles start big, but step down, a weight savings measure, no doubt
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:25:33 PM
This flange is identical to the one on the mutant axle. That means there is a possibility of the brake swap becoming a reality
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:26:49 PM
So I slid them onto the mutant axle to see if I had something good or was off back into the invention mode
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:29:31 PM
The mutant axle tubes have a small step up in diameter. The backing plates slid over the first part, but not over the second slightly larger diameter part.

On close examination, I noticed the backing plate is bolded into the axle tube opening and reduces the diameter a little bit. I am thinking I can remove that folded part and maybe,  just maybe, make it to the next step of fitting it all up.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:31:00 PM
I dropped it onto my axle dolly where the bulk of the work will take place.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:32:04 PM
Really happy with how this is coming together
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 28, 2019, 09:34:59 PM
I need a lot of compartmented storage options. Thinking about it, I decided to build myself a post office style letter bin with various sizes of spaces. A rolled up towel in one, some plastic and paper ware in another. I will make it so that it is not intrusive but takes advantage of that deep window well.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on March 28, 2019, 11:19:59 PM
I painted them low gloss black and allowed the paint to harden then secured everything.
Unless I missed it you don’t have any gasket or sealant on that nutsert?

I would highly recommend a foam gasket or a big ugly glop of silicone....


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on March 28, 2019, 11:47:09 PM
We also would like a video or a sound clip.   This vehicle motor runs and idles.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on March 29, 2019, 05:39:18 PM
D,  late on the package drop but it went out today. Should be there mid week.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 29, 2019, 09:51:01 PM
I painted them low gloss black and allowed the paint to harden then secured everything.
Unless I missed it you don’t have any gasket or sealant on that nutsert?

I would highly recommend a foam gasket or a big ugly glop of silicone....


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I didn't write about it, but the "nut" itself is sealed with silicone, and the foot of the tube has a closed cell foam gasket I glued to it.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 29, 2019, 09:53:34 PM
We also would like a video or a sound clip.   This vehicle motor runs and idles.


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Yea, I tried, but the vid did not show up. The "Old" camera I just purchased stopped working so I had to buy another one, this time back to a Cannon EOS and I guess I don't know how to shoot video. I thought I pulled two 20 sec clips of the idle, but apparently I didn't.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on March 29, 2019, 11:28:03 PM
We also would like a video or a sound clip.   This vehicle motor runs and idles.


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Yea, I tried, but the vid did not show up. The "Old" camera I just purchased stopped working so I had to buy another one, this time back to a Cannon EOS and I guess I don't know how to shoot video. I thought I pulled two 20 sec clips of the idle, but apparently I didn't.
Get a kid to video it on a I phone and than upload to YouTube than install link


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Title: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on March 30, 2019, 12:35:26 AM
Commas and decimal points are really important. Especially in finance


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And I believe if it’s less than qty 10, you’re supposed to spell it out ;)

Four 3/8”


Edit: didn’t realize I was replying to a three day old post, otherwise I wouldn’t have brought it back up.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 30, 2019, 08:34:33 AM
Commas and decimal points are really important. Especially in finance


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And I believe if it’s less than qty 10, you’re supposed to spell it out ;)

Four 3/8”


Edit: didn’t realize I was replying to a three day old post, otherwise I wouldn’t have brought it back up.


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Yea Man

You're really on top of stuff!!!  :rolleyes: :shocked: :wink:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on March 30, 2019, 02:17:47 PM
OK, caught up now but you need to tell us a new thread is going!

Glad that is fired right up, all the parts work!

I agree on the comma and number stuff, was taught that writing reports and it just works.

That would be cool if those brakes work. I will still take a FF over the SF anytime, just the 9.5SF is not a bad rear if you have a 1/2 ton.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 30, 2019, 08:46:43 PM
OK, caught up now but you need to tell us a new thread is going!

Glad that is fired right up, all the parts work!

I agree on the comma and number stuff, was taught that writing reports and it just works.

That would be cool if those brakes work. I will still take a FF over the SF anytime, just the 9.5SF is not a bad rear if you have a 1/2 ton.

I would have used the SF stocker and I think with just a 35" tire and the stall converter I used, I might have gotten away with the 4.10 gear, but with this axle and a 4.88, I know I will be fully setup for whatever power level or tire size I go to eventually.

I do believe the truck will end up on 37's with a supercharged stroker of a D-max and either way, that mutant FF will handle it in spades.

Glad to have ya here!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on March 30, 2019, 11:34:48 PM
I'm not arguing about the upgrade. I mean a fluid change is just that,,,,,

Funny but you talking to Dave about the shackle flip vs the blocks is why I went with new springs (deavers).

For towing and heavy loads the stock hanger setup has the advantage. Stock hangers will be more stable as the load is in tension and naturally stays stable. With a flip it is twisting on the rear hangers, shackles and there is a torsional load on everything. Still not a bad setup even for the heavy Sub. No blocks either is a plus.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on March 31, 2019, 08:22:14 AM
JR, I'm trying to understand what you are getting at with the flip.  the shackle is under compression instead of tension.  Help me understand the torsional load and why its not good for heavy loads?  I'm contemplating the flip for the Bus
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 31, 2019, 02:54:10 PM
RN- I have done this before. On a Tundra. Granted I did not tow with it, but I found the handling on par with what you'd expect from a lifted truck.
I think the torsional load JR is talking about may be due to axle flex.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: dave945 on March 31, 2019, 10:11:49 PM
Found this article interesting regarding the shackle flip and towing stability. You might already know all this, but I picked up some tidbits I didn’t know.
 https://ck5.com/forums/threads/shackle-flip-stability.23402/ (https://ck5.com/forums/threads/shackle-flip-stability.23402/)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 31, 2019, 10:29:38 PM
Well, I'll be the test pilot, because at some point this Burb is going to tow.

Reading the roller coaster story, one thing I gleaned from it was the guy went cheap. Old saggy springs, poor shocks, essentially he didn't do anything right.

My setup:
Fox 2" shocks
Supplemental Air bags
Possibly, I'll be running a rear sway bar
And
Possibly I may use that track bar

I am really considering the track bar because I drove around in those vehicles in Baghdad and Kirkuk. They handled pretty well for as much as they weighed. That track bar will keep the vehicle centered over the axle as long as I get it installed flat when the truck is resting on its suspension with a load.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 31, 2019, 10:32:32 PM
So, it's Sunday and I didn't want to get into anything super serious right after Church, so I started on the storage bin cabinet thing for the right rear window recess.

I'll make in in such a way as to be completely removable and nor require any holes to be drilled in this pristine example.

I see two feet anchoring it into the storage trays.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 31, 2019, 10:33:38 PM
Starting with cardboard templates, I created the feet out of good old Kentucky hardwood (Walnut)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 31, 2019, 10:34:37 PM
Then some legs to get me up on top of the body trim
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 31, 2019, 10:35:45 PM
From there I get to the base of the first wide shelf.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 31, 2019, 10:37:06 PM
Then the same process to get me to the roof with several vertical supports
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on March 31, 2019, 10:42:01 PM
Now the idea is to create many compartments to store a myriad of things. One compartment may have paper towels, another plates and flatwear, or some cups, still another the baby wipes, mosquito candle or who knows what.

The shelves are angled down at 10 degrees toward the back to keep things from sliding all over. I'll finish it with some means of securing all the junk safely in the bins

So, next, I carried it down to the shop to start gluing and screwing. I have added the top and another vertical. Plan to see it get all boxy and house a bunch of things in a semi organized state.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on March 31, 2019, 11:25:25 PM
Any possibility to putting that set up on a sing out hinge? Like your tire carrier?  Swing it out back so you don’t have to climb inside

Is this bar doors or drop gate?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on March 31, 2019, 11:25:43 PM
Any possibility to putting that set up on a sing out hinge? Like your tire carrier?  Swing it out back so you don’t have to climb inside

Is this barn doors or drop gate?


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Title: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on April 01, 2019, 12:50:50 AM
Any possibility to putting that set up on a sing out hinge? Like your tire carrier?  Swing it out back so you don’t have to climb inside

Is this barn doors or drop gate?


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Dave, it’s a one piece vertical rising hatch... I think this is what you’re referring to. As far as I have seen that was and is the only option on his model through to today.

I believe the generation of burb before his had the rear gate options. The excursions  of
The early 2000s had different options as well.  I might be wrong in all this as it’s just from personal experience in both rigs.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 01, 2019, 07:41:05 AM
To my knowledge it was offered all the way to 06.   Rumor mill said they stopped the option because of the blind spot in the back but.... you could still do a split gate and a solid window.  Hybrid type of option

(https://uploads.tapatalk-cdn.com/20190401/5d1ce549840f510c43a21ff67b4c2f93.jpg)



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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on April 01, 2019, 10:09:19 AM
To my knowledge it was offered all the way to 06.   Rumor mill said they stopped the option because of the blind spot in the back but.... you could still do a split gate and a solid window.  Hybrid type of option

(https://uploads.tapatalk-cdn.com/20190401/5d1ce549840f510c43a21ff67b4c2f93.jpg)



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Well no surprise there, I was wrong! Learned something though.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on April 01, 2019, 10:14:16 AM
His is the hatch style. That's where the RX bag got stickied.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 01, 2019, 10:34:25 AM
Yes thinking climbing in and out of that after it’s lifted to reach the Tp might cause me to in the process.  Need a hinge on that shelve system lol


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 01, 2019, 10:43:24 AM
Any possibility to putting that set up on a sing out hinge? Like your tire carrier?  Swing it out back so you don’t have to climb inside

Is this bar doors or drop gate?


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Dave, There's like thirty six hundred pics on this thread of the back end of the truck (showing the rear hatch) Scroll backward just a few entries to where I velcroed the hatchet inside the rear hatch
Knucklehead!

And my favorite is by far the barn door. I looked for the longest time for a good clean lower mileage 8.1L barn door 2000 or 2001. I have never seen a barn door any newer, was surprised, actually, to read here that they were produced until 06.

And BTW, the competition for this Burb was a 1999 2500 with a 454 and of course, Barn doors. That one was $5000, one heck of a buy...But...Rust just coming through.
Don don't do stock, and Don don't do rust.

But to answer your question, that is an excellent idea, and with time I could probably pull that off. Maybe in the future...

For now and maybe for now on, TBD, its this bin gox separator/organizer thing.

I envision stopping at night and pulling out a few things, or unpacking for longer stays.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 01, 2019, 11:33:28 AM
https://www.4-wheelclassics.com/vehicles/236/1999-gmc-suburban


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on April 01, 2019, 12:08:44 PM
Any possibility to putting that set up on a sing out hinge? Like your tire carrier?  Swing it out back so you don’t have to climb inside

Is this bar doors or drop gate?


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Dave, There's like thirty six hundred pics on this thread of the back end of the truck (showing the rear hatch) Scroll backward just a few entries to where I velcroed the hatchet inside the rear hatch
Knucklehead!

And my favorite is by far the barn door. I looked for the longest time for a good clean lower mileage 8.1L barn door 2000 or 2001. I have never seen a barn door any newer, was surprised, actually, to read here that they were produced until 06.

And BTW, the competition for this Burb was a 1999 2500 with a 454 and of course, Barn doors. That one was $5000, one heck of a buy...But...Rust just coming through.
Don don't do stock, and Don don't do rust.

But to answer your question, that is an excellent idea, and with time I could probably pull that off. Maybe in the future...

For now and maybe for now on, TBD, its this bin gox separator/organizer thing.

I envision stopping at night and pulling out a few things, or unpacking for longer stays.

RUST!!! The nightmare of old dodge :( spent a about a month replacing the floor, and chasing rust out of this cab.... still didn’t get it all but should be good for another 40years.

(https://uploads.tapatalk-cdn.com/20190401/ead193b54930673e020bc6557e955746.jpg)

Sorry for junkin up your thread,  but wise choice on avoiding the 99 with rust... that should give you an idea of what rust is good for.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 01, 2019, 12:28:39 PM
Found this article interesting regarding the shackle flip and towing stability. You might already know all this, but I picked up some tidbits I didn’t know.
 https://ck5.com/forums/threads/shackle-flip-stability.23402/ (https://ck5.com/forums/threads/shackle-flip-stability.23402/)


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Post 11 covers what I was getting to.

I think a panhard rod would really help this issue as well as a sway with all that stuff up top!

Blind spot? They all have cameras now anyway. It was done to cut costs, one style=easier to produce.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 01, 2019, 05:47:11 PM
https://www.4-wheelclassics.com/vehicles/236/1999-gmc-suburban


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That's where i purchased mine at

See that price??
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 01, 2019, 08:04:53 PM
I see that price.... where do you think I found the website.  They offer some cool stuff


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 01, 2019, 09:04:36 PM
I see that price.... where do you think I found the website.  They offer some cool stuff


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And although that is spendy, I think we need to rethink buying vehicles.

The new trucks are just too expensive, they make no sense and a lot of the coin you are spending is on some poorly thought out exotic and expensive pollution control device.

You're literally giving thousands just so the manufacturer can make some government bureaucrat satisfied.

So whatever you spend on a good survivor vehicle, it could make sense. Keep it fitted out and running well over the years and did it really matter that you spent $5K more than you should have.

I'm thinking you should prioritize body/chassis condition over mechanical. Mechanical is easy to fix and less expensive than replacing and chasing rusty metal. Get the old 454 bruiser, then rebuild it to your specs and liking and enjoy for years and years.

The thought of spending 70K on something new is so far from anything that makes sense...I wonder how the big three plan to sustain sales of these homes on wheels?? 15-20 year financing?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 01, 2019, 09:37:15 PM
The off topic is real, but the increase of car prices, think of the cost of homes.  We have people dropping $800-1000 k on them.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on April 01, 2019, 10:42:50 PM
https://www.4-wheelclassics.com/vehicles/236/1999-gmc-suburban


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There’s paperwork in there from JiffyLube - wonder if there is any oil in the engine? ;)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 02, 2019, 07:38:00 PM
Clamped the bin box thing up overnight to allow the glue to set up after adding all the dividers

It didn't change like some of the things I weld up!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 02, 2019, 07:38:54 PM
I did some contouring to the back side, outside in this beautiful spring day
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 02, 2019, 07:39:32 PM
The fit is good so far
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 02, 2019, 07:41:31 PM
Looking at points to secure the thing, and not wanting to start drilling holes, I found this coat hook plastic piece, which I removed. Inside I found a "T" shaped opening, si I created a "T" bolt to slide in there and lock in place
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 02, 2019, 07:43:20 PM
And found a spot in the front to use as well. No drilling, that stud was the perfect size and simply screwed into the hole in the inner panel
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 02, 2019, 07:45:28 PM
To those I bent up some aluminum brackets, then pressed in some nutserts which capture a bolt coming up from the cabinet bin thing

Some finish painting and that project is in the bag
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 02, 2019, 07:48:58 PM
The trucks were not stopping today. First Brian's excellent bumpers came in

Yep, I just tossed it into the trash in the corner of her garage to allow it to rust for awhile.

Actually, studying them, I am well pleased by the design and workmanship. And they are no where near as heavy as I had thought. Using the thinner 11 gage for the wings cut down on a lot of weight, but they gave up some strength. It's a balance and I decided that the line would fall here where it did.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 02, 2019, 08:48:50 PM
Don, That shelf came out nice but I have a small suggestion. Cover the back for 2 reasons;

It will look all cluttered from the outside with all the stuff in there tinted window or not.

It will be pushed on and tested, shearing is needed to keep it solid. Even just the bases and a couple compartments will help a lot.

Going to paint it grey right :likebutton:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 02, 2019, 08:57:15 PM
Don, That shelf came out nice but I have a small suggestion. Cover the back for 2 reasons;

It will look all cluttered from the outside with all the stuff in there tinted window or not.

It will be pushed on and tested, shearing is needed to keep it solid. Even just the bases and a couple compartments will help a lot.

Going to paint it grey right :likebutton:
I could cover the back. I purchased two sheets of 1/4" so I'll look at doing that before primer.

I actually plan to spray it with bed liner to give it a durable finish. One of those compartments is for sandals, another for a towel, and some other things like that. Paint would not hold up, I am thinking. Anyway, I plan to have that done tomorrow.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 02, 2019, 08:59:18 PM
The neighbor kid and my pre-Ranger pulled up in this buggy

How cool is that!

Both of them plan on going to West Point together and making a full 20-30 year career as Army Officers

Makes you feel good to see young men like these
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 02, 2019, 09:03:02 PM
 :beercheers:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 02, 2019, 09:17:05 PM
So another truck dropped off the SmittyBilt roof rack I just ordered

I wanted to test fit the brakes and hubs to the mugo axle today, but I though I had better reduce some of the clutter by getting rid of this rack box.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 02, 2019, 09:18:44 PM
It is a three piece unit and my plan was to not install the center piece and build up a shorty rack that could be fitted along with the roof tent

After assembling which only took 4 ea bolts and a few minutes
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 02, 2019, 09:21:45 PM
The fit on the existing 80/20 roof rack system was downright perfect. The rack's 48" width fell perfectly on top of the longitudinal rails and by repositioning a lateral bar I had some great points to anchor the rack, which also strengthened up the existing roof system
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 02, 2019, 09:24:31 PM
That was it for time. Yesterday our oldest daughter delivered her forth child, a baby girl, Rory. I shopped this morning and prepared them dinner for their homecoming. It's good to serve our fellow man, and really good to serve your family...your growing family, your family which won't freakin' stop growin' your fami.... :facepalm:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 02, 2019, 09:33:26 PM
Looking at that last photo of the rig you posted.  You had better get some window tint on that big monster.   You don’t want all those expensive parts to make you a target for lazy A-holes who take things

You could maybe try some black out something or another    Maybe that cheapo spray paint that you can peel off.  Plasti dip black


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 02, 2019, 10:05:04 PM
Just have them limo out the whole thing. Sucks at night sometimes using the outside mirrors is all, never use the middle anyway.

Yep, a lightbar across the lower part would be great and the straight ones a cheaper. Just got a 46 incher for $45 on fleebay.

Congrads on another grandchild. Hope I have many years before that.
Title: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on April 02, 2019, 10:05:25 PM
Are you worried about the blind spot out that rear window now with that organizer?

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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 02, 2019, 10:09:03 PM
Are you worried about the blind spot out that rear window now with that organizer?

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Reverse camera,,,,,,,,,
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on April 02, 2019, 10:11:01 PM
Are you worried about the blind spot out that rear window now with that organizer?

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Reverse camera,,,,,,,,,

While checking his right rear blind spot when changing lanes going down the highway?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 02, 2019, 10:39:53 PM
Worried? No
Aware, yes

Everything you do is a compromise of some kind or another. Leave the window unobstructed and lose the storage space, but gain visibility. Lose the visibility but gain valuable organized storage.

Obviously, I have decided to go this way with it as I am prioritizing the overland capability aspect of the truck over not collidin' with some low rider jap car.

Thought about redneckin it out to the point people just see me and move to avoid.

You know, fishing rod hanging out of one window, double barrel out of the other one, maybe a dog leash with a collar and nothing else hooked to the bumper ;-))
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 02, 2019, 10:39:56 PM
Truck shell on c max means he doesn’t look out the blind spot. 


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 02, 2019, 10:41:32 PM
Are you going to upgrade mirrors?  They sell a good replacement on a1 auto that matches c max tow mirrors


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 02, 2019, 11:08:12 PM
Are you going to upgrade mirrors?  They sell a good replacement on a1 auto that matches c max tow mirrors


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Hmmm, hadn't thought about it.

Have to check that out

Edit: I went to the A1 Auto reference. Great mirror, I purchased them!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 02, 2019, 11:19:42 PM
Get factories if you do that. I only use my rear view to look inside, outside mirrors for outside,,,,,,,
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on April 03, 2019, 07:08:41 AM
Those bumpers take care of blind spots. Limo all but the front. 35% on the front and you can still use your side mirrors at night. And avoid legal hassles in your travels


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: longball on April 03, 2019, 07:17:08 AM
Agreed on the tint. Anything darker than 35% makes the side mirrors useless at night. Its a pain in the butt to have to roll your windows down in the rain to back a trailer.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 03, 2019, 08:09:07 AM
I know my state enforces the window tint law pretty strictly.  In my youth it was a regular hassle.  Even though your not registered here you don’t need that attention.   Legal window tint


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cruizng on April 03, 2019, 08:39:51 AM
That was it for time. Yesterday our oldest daughter delivered her forth child, a baby girl, Rory. I shopped this morning and prepared them dinner for their homecoming. It's good to serve our fellow man, and really good to serve your family...your growing family, your family which won't freakin' stop growin' your fami.... :facepalm:

Congrats on new arrival. Hoping everyone is healthy and happy.

How are your wife and son doing? She feeling better?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 08:55:05 AM
That was it for time. Yesterday our oldest daughter delivered her forth child, a baby girl, Rory. I shopped this morning and prepared them dinner for their homecoming. It's good to serve our fellow man, and really good to serve your family...your growing family, your family which won't freakin' stop growin' your fami.... :facepalm:

Congrats on new arrival. Hoping everyone is healthy and happy.

How are your wife and son doing? She feeling better?
Thanks Mike

Yea, we are doing well. We have gone forward for prayer and had elders pray over us as per instructions in the good book. Kat still gets winded sometimes, but hey, she walks the neighborhood. She was struggling just going five feet in the hospital. So something is improving.
In our past, there came a time when she tore her rotator cup and the doctors said there was no option except for surgery. She would have none of that. God created us, he can fix us. She started seeking him and getting prayer. Approaching surgery time, she was gaining mobility which the doctor could not explain. so another MRI revealed the tear was gone! Like as in it was never damaged in the first place. A few weeks later we went to Italy. I trained at the Agusta-Westland factory on the AW-139 and she stayed in the hotel with me for a few weeks on a vacation. Was a great one. When I got signed off, we "Borrowed" N139EV (Goggle it for pics) and went for a great lunch over in Bella, Italy, then a nice flight up into the Alps and down along Lago Majorie.

Oh and the not so little pre-Ranger is back to working out. Tried to go to an early pre-pre season football practice last Monday, but I put the Kibosh on that. He just likes getting out and tackling stuff.

Tangents, sorry, just brought back a cool memory. So, yea, try and repent and live a righteous life and stay connected to the spring of life and he will take care of things...Amazing!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: EL TATE on April 03, 2019, 10:36:53 AM
https://www.4-wheelclassics.com/vehicles/236/1999-gmc-suburban


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There’s paperwork in there from JiffyLube - wonder if there is any oil in the engine? ;)


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Ouch.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: longball on April 03, 2019, 01:24:33 PM
How does one “borrow” a plane that size?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wilsonphil on April 03, 2019, 03:53:17 PM
Blasphemy, never confuse an egg beater for a fixed wing!!!!!

But things like that get Borrowed all the time, as long as you don't scratch it most company/governments would never be the wiser, most of the items I have borrowed consume way too much fuel so you have to be really careful.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 06:13:41 PM
How does one “borrow” a plane that size?


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The company you work for has to own it

They need to think you are out doing some training

You do all the preflight checks just like it was training

You land at some intermediate site, like, say a parking lot

Where a very pretty girl is usually somehow involved, meets you

And you fly away on a nice adventure.

I think I have a vid of her sitting in the back lovin' life!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 06:53:38 PM
OK, so I started placing things where I envisioned they might go. The bin is obviously going to get much fuller over time, but here's the start
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 06:55:18 PM
After Playing with that, I pulled it out, and finish sanded it, then coated it with duplicolor truck bed liner. I did not like how it turned out, much too thin, laid out flat, not textured like I wanted, so tomorrow I'll redo it with something else
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 03, 2019, 06:57:06 PM
 :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 06:57:41 PM
I decided to place the CB antenna on the roof rack. I invented a friction sleeve to allow me to position it about anywhere I wanted and at any angle

Starting with a big bolt, a shock washer, a single sway bar bushing and some idle time, I created this:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 06:59:00 PM
And using a couple angle fixtures, created this sliding mount:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 07:01:59 PM
And mounted a fire-stick antenna to that

Which can be held down, Armee style with a bungee
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 03, 2019, 07:52:14 PM
After Playing with that, I pulled it out, and finish sanded it, then coated it with duplicolor truck bed liner. I did not like how it turned out, much too thin, laid out flat, not textured like I wanted, so tomorrow I'll redo it with something else
I have seen somewhere that Ship Wreck Harbor has a decent rattle can bed liner.   Try hat


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 08:24:22 PM
Got a bunch of stuff in from REI

And started figuring out where to stash it
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 08:25:28 PM
And added to the storage shelf bin thing collection
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 08:28:01 PM
Some of the paint didn't stick well to the wheels, so I removed it all

Then I tried to find a way to just clear coat the polished surface, but nothing was turning out, so I threw the Muriatic acid on them and then cleaned and painted them just like the D-Max wheels
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 08:29:47 PM
Back on the rear axle now, this is the little ridge that prevents the brake assembly from sliding onto the 4" axle tubes
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 08:30:26 PM
So I pulled the die grinder out and quickly removed it
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 08:31:45 PM
And just like that, the stock Suburban brake backing plate and caliper mount (And emergency brake) slid on the mugo axle like it was made to!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 08:34:02 PM
I slid the hub back on and snugged a single nut and started playing with rotors. First thing I discovered is that the 14 bolt semi-floater rotor will not fit overtop of the FF hub

It is maybe 1/2" or perhaps less smaller in diameter than the FF rotor
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 08:34:46 PM
Good news is that both rotors are the same large diameter
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 08:35:59 PM
Now the FF rotor is a bit deeper on the backside than the SF rotor and that will be necessary as you will see shortly
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 08:38:47 PM
Measuring from the hub meeting face inward we can see we will need 3.5" or a tad more for the emergency brake to engage into the rotor housing

So this is problem numba 1

I need to figure out which rotor will both fit the FF hub and have sufficient depth to allow the emergency brake shoes to engage the drum
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 08:43:36 PM
I would not be adverse to shimming the brake backing plate outward a little bit to give me full engagement of the parking brake shoes, but that is only an option. I want to find out which parts will make this combo work with more or less stock parts.

Following that will be the wheel stud issue. I will need to locate a 14mm X 1.5 wheel stud with a big knurl to properly engage into the hubs.

I am hoping I am not looking at some one off hybrid of a hub which will make things more difficult and costly. I suppose I could source some stock Silverado 14 bolt FF hubs which would already have the proper studs and go with those...Not sure yet what I need to do
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 03, 2019, 09:03:04 PM
So did some measuring

Stock stud has a knurl size of .612"

The mugo axle FF hub studs have a knurl size of .685"

So not all that much larger, .073" larger.

Stock stud is 2.80" long counting the head

The bolt body length is 2.555"

So it's off to the parts catalog to see if this part of the puzzle can be solved
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on April 03, 2019, 10:49:44 PM
https://www.4-wheelclassics.com/vehicles/236/1999-gmc-suburban


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There’s paperwork in there from JiffyLube - wonder if there is any oil in the engine? ;)


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Ouch.


Was wondering when/if you’d see that Tate :)

Saw this story last week.

https://www.kgw.com/mobile/article/news/investigations/oregon-man-wins-9k-court-ruling-over-disputed-jiffy-lube-oil-change/283-3a4e736c-0d67-432c-9ec6-3ba16b8148c8



Sorry Don for the DOT. Carry on.

Don Edit: Fixed it ^^^ Change "Carry on to: CM (Continue mission) ;-)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on April 04, 2019, 12:28:32 AM
I don't think I've ever seen a hub that thick before. Crazy thick from what I can see.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 04, 2019, 07:53:50 AM
I don't think I've ever seen a hub that thick before. Crazy thick from what I can see.
I've done some homework since buying this thing. It is rated as a 15,000 lb axle!!!!!!!!!

I think I figured out what to do. There are no such studs in the world that have a 14mm thread and a knurl that big, so the hubs would be a weld and machine at best.

I think it would be wisest to just pick up hubs and parts from a 2500 Silverado with a 14 bolt and install that. Keep it all GM architecture.

I just located a set of hubs, backing plates, rotors and calipers off a 2014 Silverado with a 14 bolt.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 04, 2019, 07:58:49 AM
The 2014 changed lug patterns to that 8-180 or something.  No longer the 8 -6.5

Wouldn’t you need older?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on April 04, 2019, 09:29:16 AM
Exactly∆∆∆
You need 2010 or older.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 04, 2019, 12:46:00 PM
The 2014 changed lug patterns to that 8-180 or something.  No longer the 8 -6.5

Wouldn’t you need older?


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Oh, good catch!

Hadn't realized that change affected the 14 bolt axles as well

Thanks
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 04, 2019, 01:17:47 PM
Trust but verify !! Your front axle is the 8x6.5.   The back replacement I would think you want to match.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bear9350 on April 04, 2019, 01:50:47 PM
That is what he bought wheels for and what I built the spare tire carrier for.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on April 04, 2019, 02:26:29 PM
If you really wanted to show off your talent, you could redrill all 16 holes.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cruizng on April 04, 2019, 05:07:08 PM
If you really wanted to show off your talent, you could redrill all 16 holes.

My money is on Don that he could do it!  :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 04, 2019, 05:10:29 PM
I am still stunned that Ken agreed with me!


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on April 04, 2019, 09:43:32 PM
I so want to abuse the moderation powers bestowed upon me by our great leader, but I shall try to act like an adult, for once.
Mike, can you imagine drilling through that 1-2" thick hub, 16 times, with his harbor freight drill? Lol
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 04, 2019, 09:44:33 PM
Mag drill?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on April 04, 2019, 09:48:02 PM
I thought you were talking about drilling the holes in the wheels larger for the humongo studs?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on April 04, 2019, 09:51:13 PM
I am still stunned that Ken agreed with me!


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Even more stunned that don gave you credit for the catch!


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Title: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 04, 2019, 09:52:26 PM
I thought you were talking about drilling the holes in the wheels larger for the humongo studs?


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That doesn’t actually sound like a terrible idea.  Hole should already have the acorn taper in the bottom.  Just can’t rotate tires front to back


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cruizng on April 04, 2019, 10:02:08 PM
I so want to abuse the moderation powers bestowed upon me by our great leader, but I shall try to act like an adult, for once.
Mike, can you imagine drilling through that 1-2" thick hub, 16 times, with his harbor freight drill? Lol
If he wasn’t leaving until June he could do it. Pull some all nighters.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 04, 2019, 10:24:43 PM
I so want to abuse the moderation powers bestowed upon me by our great leader, but I shall try to act like an adult, for once.
Mike, can you imagine drilling through that 1-2" thick hub, 16 times, with his harbor freight drill? Lol

I’m still waiting for the motorcycle wheelie video to surface just sayin... :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 04, 2019, 10:39:28 PM
I see you boys have been busy again!

Naw, I need to do this right. I think right means get some mo-normaller stock hubs and put the brakes back stockish.

The only way to properly prepare that mugo hub would be to (in my opinion) weld the stud holes up, then get a shop to mill half to two thirds the thickness away, then redrill.

If a man was going to do all that, he may just as well just buy the correct hub and be done with it.

So, yes, Dabe saved Don from spending $150, I was about to have the owner ship those 2017 hubs to me. Not only would I have lost the money, but the time as well.

I checked another source today and that ended up as a dry hole, so I'm still searching at this point.

But work progresses. I got the diodes in for the AMP steps and started wiring them in
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 04, 2019, 10:45:29 PM
But then I hit a snag. The instructions point to me fishing a single tan wire out of a bundle, then cutting and splicing in the diode. Problem is, there are three tan wires in the bundle.

So I called Amp technical support. The guy who took the call was of no help. Further he had no explanation as to why my harness had three tan wires. He told me, I'd have to buy an electrical tester, and see which wire went to ground when opening and closing the door. I asked him to pull the diagrams and maybe give me a pin number, but he wouldn't do it. I had the distinct feeling he just wanted me to go away.

I'll probably get the chance to rate this purchase and bet your bottom, I'm gonna tell the story.

So had to switch gears. I sprayed another coat of bed liner, the HF stuff on the shelves, and although not perfect, they turned out "Functional grade." That would not be acceptable to Tex, but for me, its ah-eite
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 04, 2019, 10:47:07 PM
I decided not to install a backing as that would decrease the depth of the cavity. I will do a limo tint, and find some netting for the front, but it's OK for now
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 04, 2019, 10:48:28 PM
Then a freight truck showed up and dropped off my tent.

I did not like reading about who assembled it
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 04, 2019, 10:50:20 PM
^^^^Fingers look like crap

Tough winter, old skin, bad habit chewing the dead stuff off...

A couple more chairs came in today. I chose them for comfort, packability and strength. This one is plenty strong
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 04, 2019, 10:51:53 PM
I started fitting out the tool box, and right away ran out of space. I'll have to switch to the next deeper L-Box to hole all this and the next pile of stuff
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 04, 2019, 10:53:59 PM
Next I tossed a couple flood lights onto the rack, positioned to illuminae the sides of the road/trail.

Nothing will be wired in at this point, just fitting and placing things. I'll do a marathon wiring thing after the automotive modifications are complete
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 04, 2019, 10:55:11 PM
In the center, I'll put a couple of old HID's that I once used on C-Max for a couple years. I freshened them up some
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 04, 2019, 10:56:52 PM
I placed some no-slip strips onto the running boards on both sides. I jumped around and climbed on them, and sure enough, they work!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 04, 2019, 10:58:34 PM
And now, its basically axle time. I started by pulling it apart again, then spent some quality time with my grinder and wire cup tool
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 04, 2019, 11:00:01 PM
^^^ That transformation right there took some time to get it to that point. Following that, I gave it a solvent bath. Next step will be the removal of the shock mounts
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:36:40 AM
Got more axle work done, but first a couple fun things

First, remember those mirrors Dave pointed me to?

Well, let's put them on!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:38:32 AM
It is a really easy and quick job to R&R the factory mirrors. Stockers easily removed...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:39:08 AM
5 minutes max to get the old stuff off. a bit longer to reassemble, just because you are dropping stuff and being really careful

But a quick reverse of the procedure and you're ready for the next challenge
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:39:49 AM
Next up, I mounted the two HID lamps on the rack. So that setup up there will have the two long range driving lights and two 120 degree floods mounted at an angle to illuminate to the sides as well
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:40:39 AM
That whole operation up there is coming around quite nicely. Some finish work and tweaking as always but I am most of the way there.

The bulk of the day was spent on the mutant axle. It got a lot more sanding and had the long stock like shock mounts removed
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:41:31 AM
I'll be reusing those shock mounts after some cleanup and shortening. Grinding and smoothing happened with a 7" 1 HP grinder with an abrasive wheel followed up with a 4.5" flap wheel with 36 grit.

You can also see that a great deal more smoothing and sanding has taken place
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:41:58 AM
The tractor was necessary to transfer the heavy thing onto a motorcycle jack which I used to drag it into place beneath the Burb
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:42:59 AM
I'll only be using one U-Bolt per side to save a little weight.  :shocked:

Yea, that's all I had, two old U-bolts and the front spring plates off of SquareD, It worked though, sucking the axle up pretty close.

I jacked it all up until it just started to lift the body, then supported the whole thing with jack stands placed beneath the axle.

Note how the shackle has moved aft. That is good, indicating that as the spring unloads the shackle will move forward, allowing for more suspension travel
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:43:54 AM
I got after those cut off shock mounts, remaking them into something I could use.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:44:26 AM
Then I tacked the shock mounts into place in a position to increase ground clearance from "wait-ah-minute" obstacles.

It turned out well
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:45:29 AM
From the passenger side:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:45:59 AM
I started putting together the panhard bar parts. I will use this bent piece of DOM that was meant to be a front panhard.

You won't believe how well that fits, wait until you see it tacked up in place. I can get the bar nearly level!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:46:41 AM
While I was digging, I literally unearthed nearly a complete solid front axle swap for our Duramax trucks. Those frame plates are used to box in a 2010 and earlier Silverado. Some of this stuff is in perfect condition
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:47:52 AM
I feel like the boss has gone and posted all of this in the complete wrong thread. This thread has all of that camping and overland equipment while all these posts are related to build part 3. 


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:48:19 AM
I feel like the boss has gone and posted all of this in the complete wrong thread. This thread has all of that camping and overland equipment while all these posts are related to build part 3. 


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You are correct!

And I was in the middle of trying to figure out how to move all these posts over to my build thread...

Anybody know how to do that?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:48:34 AM
:facepalm:
I don’t but someone does. Nate maybe...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:49:10 AM
Yea, Nate!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:49:28 AM
I will move them in morning..... :facepalm:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:49:44 AM
You are correct!

And I was in the middle of trying to figure out how to move all these posts over to my build thread...

Anybody know how to do that?

 :knucklehead:
 :laugh: :laugh: :laugh:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:50:06 AM
You are correct!

And I was in the middle of trying to figure out how to move all these posts over to my build thread...

Anybody know how to do that?

 :knucklehead:
 :laugh: :laugh: :laugh:
Not part of flyin' or building something rusty or dirty: I would know nothing about it!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:50:25 AM
LOL!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:51:36 AM
I sometimes look up word origins

I was researching "BoneHead" yesterday.

Way back in the ancient greek

I discovered the origin of that word is from the word, "Don!"
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:52:37 AM
I sometimes look up word origins

I was researching "BoneHead" yesterday.

Way back in the ancient greek

I discovered the origin of that word is from the word, "Don!"

LOL! Well, I think we've all been there in some form or fashion. Surviving boneheaded decisions is what creates experience. At least, that's been my observation of all my Armee associates.  :wink:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 09:53:17 AM
Have an appointment Wednesday to have the bumpers sprayed with etching primer, then LineX...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cj7ox on April 06, 2019, 09:54:32 AM
FOR ALL WHO SEE THESE PRESENTS, GREETINGS! LET IT BE KNOWN NOW, AND FOREVERMORE, THAT THE MODERATOR FORMERLY KNOWN AS NATE, HAS HEREBY BEEN DUBBED "THE MAN". FROM THIS DAY FORWARD, HE SHALL BE REFERRED TO AS SUCH, UNTIL THE GREAT OWNER OF THIS SITE, OTHERWISE KNOWN AS "BIG D", DECIDES HIS TRANSGRESSIONS HAVE SURPASSED THE AFFECTS OF HIS RECENT RESCUE OF SAID "BIG D" FROM EMBARRASING MIS-POSTS.
Title: 2002 Suburban 2500 build thread, Part 3
Post by: longball on April 06, 2019, 09:59:30 AM
Got more axle work done, but first a couple fun things

First, remember those mirrors Dave pointed me to?

Well, let's put them on!
We put that same set on a coworkers 2016 6.0 farm truck a few months ago. Install was a little more involved because the whole door panel had to come off and there was an optional fourth screw that required drilling another hole in the door. They seem like a good product. 


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 06, 2019, 10:01:20 AM
Don did your mirrors come with turn signal in the mirror?

Also don’t forget to remove you expensive LED bulb from the take off mirrors

Earlier you were against the idea of putting lights up High do to glare off of your hood? While I think they look cool up in that rack, what is the plan for the hood? Flat black?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on April 06, 2019, 11:04:34 AM
Am I the only one that thinks those mirrors look level, instead of tilted upwards?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 06, 2019, 11:12:49 AM
I can see that also, I wonder if aftermarket fixed GM for the better.   No more stacking washers,   


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: longball on April 06, 2019, 09:46:14 PM
Earlier you were against the idea of putting lights up High do to glare off of your hood? While I think they look cool up in that rack, what is the plan for the hood? Flat black?


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Will the glare be that bad from spot lights? Never had a set up there so I have no idea.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 06, 2019, 10:04:12 PM
Earlier you were against the idea of putting lights up High do to glare off of your hood? While I think they look cool up in that rack, what is the plan for the hood? Flat black?


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Will the glare be that bad from spot lights? Never had a set up there so I have no idea.


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He was the one with the original concern


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 10:41:59 PM
Don did your mirrors come with turn signal in the mirror?

Also don’t forget to remove you expensive LED bulb from the take off mirrors

Earlier you were against the idea of putting lights up High do to glare off of your hood? While I think they look cool up in that rack, what is the plan for the hood? Flat black?


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Man you people have been busy!

Mirrors level? Who knows?

Mirrors have turn signals...Who knows?

Hood glare, Who knows?

Future plan for the hood? Who knows?

Guess I took care of all the questions!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 10:43:37 PM
So with the panhard bar, to get everything linin' up, I had to weld the bushing sleeve to the end of the shaft then load that with the poly parts.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 10:44:52 PM
Snugging up the bolt a bit aligned the bar with the mount on the axle. That gave me a reference point to build off of on the frame.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 10:47:38 PM
That's a grade 8 wing nut right there, plenty strong for mockin' up!

So I built the frame mount a piece at a time. Starting with a WFO piece, I cut that apart and started adding pieces to box in a section of frame and to spread the lateral load out a bit
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 10:50:07 PM
I'm happy with how that panhard bar turned out. It will provide more lateral stability and help eliminate some of the tippy feel of a top heavy truck

Following that, I applied one of the door decals just to see how that would fit/look

So, like it or burn it off?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 10:51:06 PM
Oh, forgot to post the forward looking shot from the back. Note how level the panhard bar ended up being.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 10:54:19 PM
Then it was time to start cluttering up the rear wheel well and suspension.

I mocked up how the air spring will mount, function. Due to space requirements and ease of build, I located this one a bit aft of center. To place the bag at the center would require it to stretch quite a bit and I thing, possibly enough to pull the bag apart. Bu going off center the amount of movement will be less, and likely keep the thing alive much longer
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 10:55:47 PM
In the final installation, I squashed the bag a bit to allow more room to expand
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 10:57:58 PM
The mount is super simple. I simply welded 3/8" frame bolts directly to the frame and panhard mount. The upper mount simply slides onto the studs and bolts solidly.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 06, 2019, 11:00:40 PM
With that complete except for final welding, I went after the passenger side. This side is less crowded and should be easier. I got the U-bolts cut to length but drilled the holes in the mockup plate off center so I now have an alignment problem. No worries, I'll just order the permanent plates and finish the mount when they get here. Next i'll be mounting the aft sway bar
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 06, 2019, 11:41:30 PM
I like the sticker   Big one on the hood?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on April 07, 2019, 04:28:56 AM
Panhard bar looks good.  Not sure I concur on the bag placement, but keep us posted


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on April 07, 2019, 11:23:12 AM
Panhard bar looks good.  Not sure I concur on the bag placement, but keep us posted


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Ditto
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 07, 2019, 02:14:30 PM
I like the sticker   Big one on the hood?


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Naw, just blackness, I think, on the hood.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 07, 2019, 02:22:06 PM
Panhard bar looks good.  Not sure I concur on the bag placement, but keep us posted


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Ditto
OK, then, what's your thoughts on my site selection for the bag. Granted, I have never seen one placed there like that, but it would work. I just don't have thee space to place it over the spring pad like it would normally be found, so looking at all factors, I settled on the plan you see.

Look at it closely and you can see that the working center of the "pushin'" is only maybe 6" from the center of the spring pad.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 07, 2019, 02:40:31 PM
Try again on rear track bar mount or take it off altogether and put the bag where it belongs.... my 2 cents
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Sammconn on April 07, 2019, 03:07:10 PM
I hate to agree with Shawn but I think he’s right.
Bags need to be centered.
Trackbar/panhard only need a perpendicular path to frame.

I’d move bar and centre bags too.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 07, 2019, 04:07:27 PM
Reality is you put cart b4 the horse. Start with the bags, get them on and functioning then decide if you really need track bar which you know you don’t but agree it is a nice feature maybe? A sway bar back there would be more beneficial imo for the high load.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 07, 2019, 05:36:18 PM
Reality is you put cart b4 the horse. Start with the bags, get them on and functioning then decide if you really need track bar which you know you don’t but agree it is a nice feature maybe? A sway bar back there would be more beneficial imo for the high load.
I'm adding a sway bar too. That was next, after the bags

So can anyone make an argument why the bag would not work where I have them placed? I can't find a reason why not...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Sammconn on April 07, 2019, 05:44:14 PM
I don’t know if my logic is sound but I don’t like the loading of the bags occurring aft of the center.
The physics of it are above me but my gut doesn’t like it.
It will load the aft half of the spring significantly more that the front half.
The axle in the center twisting with the load centered behind the axle rotation is my issue.

Someone smarter than me might be able to physics it, I just don’t like the placement.

I’d like the bags above the axle, the panhard could be moved aft and sway bar where there is space left.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on April 07, 2019, 06:41:30 PM
I would explain it about as good as Sam.
But it would probably work to some degree.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 07, 2019, 06:53:58 PM
My logic is simple.  Grandpa W would look at something I wanted to do that wasn’t how he would do it.  Usually let me try it and it would not work, he would laugh with a heavy I told you so
I think these guys above are saying sure try it.   So they can say I told you so


However bags are easy to add later if you need them.  The sway bar might not actually be needed.   


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: OldKooT on April 07, 2019, 07:57:08 PM
In all respect.... take yr panhard bar off, maybe use it as a swinging clothing rack or something useful. Install the air bags as designed where they belong. Then add a sway bar as you intended, if you feel the need.  A sway bar is only as useful as it's end links, so make sure you use stiff poly at minimal, or better yet Delrin bushings with multiple adjustment points for tuning on the bar.

I'd likely make the sway bar links a combination of Derlin and rod ends so I had minimal movement, and adjust pre-load right off of static. FWIW

Kay's old suburban 2000 3/4ton had stock rear leafs, a small block (1.5") no sway bar at all, and it towed and drove great. It also had Bilstein 5100's on it as well. I always felt Chevy's engineers got the rear suspension about right, it was the stupid IFS in front that was usually the culprit of any issues with how the truck drove. About as useful off the hyw as a drag slick.


Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 07, 2019, 08:21:15 PM


Thanks for the responses!

OK, folks, I'll relook the air bag placement

I have a couple of ideas now that I have spent some time thinking about it

As for the panhard bar, I feel it is a good idea. GM engineers and the armcorp folks building much heavier Suburbans for government use decided they needed it. Up-armored burbs with 2" of glass and a lot of weight up higher were more in need of keeping the axle under the truck.

Now mine is no up-armored truck to be sure. I'm guessing 7K give or take when armored ones went well north of 10K. But I will have a 200 lb tent way up high on the roof. And my burb is "leveled" at 7" higher than a stocker. My burb sits on 35" tires almost 2.5" taller than stockers. Finally, my shackles point down away from the CG, which will exacerbate the rolling motion I would think.

I'll look at the air spring, panhard stays for all the reasons I mentioned, + I can't start losing build time. My window is closing soon.

As for the sway bar, I had planned to bolt it to the frame/chassis instead of the axle the way Ford designed it to fit. I always figured I would start to get pretty busy with all the stuff I was adding, and that should be easy to fit in.

So tomorrow, I'm back at it, having lost maybe 4 hours of fab time on the bags so far on the clean slate scenario.

Just ordered new stock (For a HD 2500 truck w/ff axle) hubs, seals, bearings rotors and pads. I'll be reusing the stocker calipers. That should get me home with the brake/wheel stud, fitment issue thing.

For those reasons I think the panhard will just start to come in to its own
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: OldKooT on April 07, 2019, 09:46:19 PM
The reason up armored SUV's use a track bar is the huge weight above the roll center of the truck as you mentioned.. My large 6 person roof top tent weighs 147lbs. not all that heavy honestly. It's cool with me if you keep the track bar...it's not like it will hurt anything. But because your Burb is no different than ours was....I offered it isn't needed. I offered because I already have built what you are....drove it, and evaluated it quite a while before my wife managed to swamp it, and watch it roll over headed down river.

Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: dave945 on April 08, 2019, 06:29:14 AM
So you’re saying you didn’t have one on your suburban and it rolled over?  ;)

See what I did there Don?  I justified your work.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: swbhobie16 on April 08, 2019, 07:22:38 AM
So you’re saying you didn’t have one on your suburban and it rolled over?  ;)

See what I did there Don?  I justified your work.


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that’s what you took away from all that..? hahaha
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: OldKooT on April 08, 2019, 08:12:05 AM
yah Dave,,,, she was crossing a creek on a road here with a cement pad on the creek bottom and the water pushed the truck off the pad....it got hung. She then climbed onto the roof and took a running jump and took a swim. About 30 min later the rising water rolled the truck off the pad and it headed down stream. No real loss, she got out safely and it was a Burb with IFS

We learned from this...she now owns a water proof phone and we moved LoL
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 08, 2019, 08:32:46 AM
yah Dave,,,, she was crossing a creek on a road here with a cement pad on the creek bottom and the water pushed the truck off the pad....it got hung. She then climbed onto the roof and took a running jump and took a swim. About 30 min later the rising water rolled the truck off the pad and it headed down stream. No real loss, she got out safely and it was a Burb with IFS

We learned from this...she now owns a water proof phone and we moved LoL
Man, that's a story!
I don't think a panhard or anything short of a tug boat could have prevented the "Roll over."

I am facing challenges this week...

Haircut this morning (Loss of 3 hrs work)
Sports banquet tonight (Loss of 2.5 hours work)
Talent show tomorrow evening (another 2.5 hours lost time)
Breakfast with a friend (Self inflicted 2+ hour loss)
Baby's first bath (Who knows)
...Other daughter poppin out her new baby boy...Loss of daze...
So you’re saying you didn’t have one on your suburban and it rolled over?  ;)

See what I did there Don?  I justified your work.


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;-)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on April 08, 2019, 10:32:05 AM
I call liar liar on that.  No way with as little hair as you have that a haircut will take that long


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 08, 2019, 07:34:15 PM
Panhard bar looks good.  Not sure I concur on the bag placement, but keep us posted


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Me too. Might add some variables you don't want.

That size sticker on the hood, nice but extend the clear and make it matt, no glare!

Koot, do you have pictures??
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 08, 2019, 07:38:53 PM
I call liar liar on that.  No way with as little hair as you have that a haircut will take that long


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 :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: OldKooT on April 08, 2019, 07:44:09 PM
Pics of what Kay's old burb?   We may have some, would have to dig around on some old hard drives. It looked like a standard issue mid 2000's burb with a small lift and a Warn front winch bumper. We decided in Colorado that a IFS front axle was useless off road so we never did many mods past what was required to go camping.

I have a old square body burb now (1990) that I was going to build but decided I prefer a pickup for off road exploration so I guess I should sell it LoL. Anyone need a burb project...? 

Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 08, 2019, 08:00:17 PM
Pics of her on the hood!!  :laugh:

Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 08, 2019, 09:48:05 PM
I call liar liar on that.  No way with as little hair as you have that a haircut will take that long


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OK, so I'm gonna have to prove it
Drive over to the barber shop 16 min
Had to wait 4 min for it to open
Waited almost 10 min while the ladies got their stuff together enough to call me back
Haircut, shampoo, dryin. greasin' it up with whatever that was, maybe 15 min.
From the haircut over to Subway. In and out in I'd say 20 min.
Drive back home, another 16 min

So right there 2 hours and 36 min!

Ha!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 08, 2019, 09:51:38 PM
I took all of your comments to heart and decided to can the method I was using to mount the air bag and start all over.

This is the stackup I decided to put together:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 08, 2019, 09:52:44 PM
Continued:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 08, 2019, 09:55:59 PM
Now, I had to work on the U-Bolt length and those U-bolt plates are just set up pieces, I have a new set enroute. But that setup is pretty much a doable configuration after a lot of measuring and fitting.

The Air spring poly "cups" worked perfectly, and will allow for the air spring to be attached on the top only
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 08, 2019, 09:57:52 PM
Welded up the rectangle tubing feet onto the air spring lower mount

I cut circular holes through the top to allow easy installation of the nuts
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 08, 2019, 09:59:09 PM
The daystar air bag bucket is held to the lower weight bearing mount by one 3/8" bolt
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 08, 2019, 10:01:12 PM
With the axle resting on the jack, the top mount is pushed pretty far north, so I removed the jack stand and drooped out the spring to give me ease in working the mount in the lower position
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 08, 2019, 10:03:08 PM
Having done so, when I attached the upper mount to the frame, and supported the axle once again in a loaded position, the air bag collapsed into this position. Air pressure will even things out a bit, but this is acceptable
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 08, 2019, 10:04:05 PM
And the driver's side:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 08, 2019, 10:06:04 PM
I agree that this mounting location looks much better than the off center position I had come up with first stab at it.

Thing is looking beefy!

So tomorrow should see the rear sway bar going in, along with possibly the aft battery.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on April 08, 2019, 10:25:56 PM
Looks good.  Interesting you had to fab up the lower mount.  Thought the kit would have been a plug and play.

Sway bar will be much more important than a track bar unless you are nascar racing
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: OldKooT on April 08, 2019, 10:34:17 PM
Yeah....looks, will work much better. See....one day ya got it done, AND a hair cut.


I spend 10 min getting a hair cut.... Kays quick/fast and works cheap LoL

Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on April 08, 2019, 10:44:37 PM
I call liar liar on that.  No way with as little hair as you have that a haircut will take that long


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OK, so I'm gonna have to prove it
Drive over to the barber shop 16 min
Had to wait 4 min for it to open
Waited almost 10 min while the ladies got their stuff together enough to call me back
Haircut, shampoo, dryin. greasin' it up with whatever that was, maybe 15 min.
From the haircut over to Subway. In and out in I'd say 20 min.
Drive back home, another 16 min

So right there 2 hours and 36 min!

Ha!

I was going to let this slide, but no.  I have to draw the line.

You weren't at a barber shop as evidenced by the text above.

Don was at a SALON.  Get a mani-pedi while you were there, big guy?

See you boys in a month, when my temp ban is over..... :beercheers:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 08, 2019, 10:54:09 PM
I call liar liar on that.  No way with as little hair as you have that a haircut will take that long


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OK, so I'm gonna have to prove it
Drive over to the barber shop 16 min
Had to wait 4 min for it to open
Waited almost 10 min while the ladies got their stuff together enough to call me back
Haircut, shampoo, dryin. greasin' it up with whatever that was, maybe 15 min.
From the haircut over to Subway. In and out in I'd say 20 min.
Drive back home, another 16 min

So right there 2 hours and 36 min!

Ha!

I was going to let this slide, but no.  I have to draw the line.

You weren't at a barber shop as evidenced by the text above.

Don was at a SALON.  Get a mani-pedi while you were there, big guy?

See you boys in a month, when my temp ban is over..... :beercheers:
HAHA. I’ll give ya my log in Tex,  use it all ya want after ya get fired.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on April 09, 2019, 01:03:23 AM
Tex is on a roll tonight, both seen and unseen.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 09, 2019, 08:58:53 AM
Not sure I like what's been goin' on in my absence here!

Have to give it some thought

All I know is I have a convictable offence here. Just have to decide what to do about it.

And like usual it involves a Dave.

His ways have lured a once reputable member into low places...

Pity.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 09, 2019, 08:59:47 AM
Looks good.  Interesting you had to fab up the lower mount.  Thought the kit would have been a plug and play.

Sway bar will be much more important than a track bar unless you are nascar racing
Clue: Shackle flip
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 09, 2019, 09:19:20 PM
 :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 09, 2019, 09:57:58 PM
:popcorn:
Sorry to keep you waiting JR

Pre-Ranger had a talent show. Darned kid placed! There were six acts that qualified to move on the the next step, where they will perform for the entire school.

So, today was all about the rear sway bar placement and fabbing up. It will go here in this open space behind the axle, and below the factory aux fuel tank
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 09, 2019, 10:01:23 PM
I'll be using a bar sourced from a F350 and some Addco universal sway bar mounts
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 09, 2019, 10:02:27 PM
I like how it unshrouds the rear diff cover
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 09, 2019, 10:04:31 PM
To create an endlink, I used some more Addco sway bar links, with one end cut off and the old shock mounts I took off the front LCA. Bolt that all together and point it straight up
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 09, 2019, 10:06:18 PM
Using a section of DOM tubing and some 1/4" plate, I created a crossmember to support the sway bar end link mounts
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 09, 2019, 10:08:09 PM
I then created a jig to jack the crossmember up into place on the frame and hold it there while I drilled some holes, then made up some "L" nuts to slide into the holes from above and be able to tighten without having to use a wrench in those tight quarters.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 09, 2019, 10:10:07 PM
I am actually using 3/8" Frame bolts as they are called.

The DOM will stiffen things up back there and add a layer of protection for the exposed fuel tank, and another one which is yet to be installed
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 09, 2019, 10:11:31 PM
No real welding yet, just tack welds for the most part. But clearances from other parts is all good
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 09, 2019, 10:13:45 PM
Going to be a good show from behind. I can only imagine how many folks tuck in behind the burb on the open road to get a peek at all that business in the back

Leme see:

Dana 80
Full Float Axle
7" lift
Panhard bar
Sway bar
Air bags
Flipped shackles
who knows what else...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 09, 2019, 10:17:04 PM
So, I just keep looking at the lower Panhard bar mount. A single shear affair with a long bolt. I know it's factory put together like that, but I keep wanting to make it a double shear

I even made up a quick bracket to tie the free end of the bolt into the air bag mount.

Don't know if I'm going to use it though...Thinking...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 09, 2019, 10:18:33 PM
Getting closer!!!!!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 09, 2019, 11:17:25 PM
Won't be top heavy with all that down there.

I may have to do airbags too. The deaver springs are made for flexing and have no overload. And I will be towing.

Sure will be cool to have it sitting on the wheels.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 08:54:42 AM
Won't be top heavy with all that down there.

I may have to do airbags too. The deaver springs are made for flexing and have no overload. And I will be towing.

Sure will be cool to have it sitting on the wheels.
Indeed!
I have had two of the tires mounted to put the front on the ground so I get an idea of the height of the thing
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on April 10, 2019, 09:21:39 AM
Might wanna turn the upper link mounts 90* if it's not too late. They need to flex around corners.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on April 10, 2019, 12:23:07 PM
Not a bad point.  However with all the hardware including the panhard rod, I’m not sure the axle will actually ever move


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on April 10, 2019, 12:53:20 PM
LOL
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 10, 2019, 01:07:33 PM
No pictures,,,,,,,,,,,,,,,,,,

:popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 02:22:00 PM
Top orientation is good for what I was seeing while jacking it around

Panhard isn't going to allow the axle to push in or out

Another note: Got the rear bumper dropped off at Line-X. Going with their premium UV stable glossy finish.

Have some work to do on the front bumper yet. so I'll be hanging it and doing a couple of things
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on April 10, 2019, 03:49:48 PM
Illl just leave this here
https://images.app.goo.gl/vDB3ko44UaZEufLv7


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 10, 2019, 03:58:23 PM
Don did own a hummer a time back, could it be?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 10:34:30 PM
Illl just leave this here
https://images.app.goo.gl/vDB3ko44UaZEufLv7


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That looks so retarded
How is my honest to pete build thread becoming a refuse heap once again???
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 10:42:00 PM
So, the rear bumper was dropped off at the LineX business in Erlanger, KY. More on this shop later. Good bunch of guys, and one of the owners, or prehaps, "The Owner" Brian showed me around his one year old operation. He has quite a lot going on with his operation and my first of what will likely be plenty of jobs there is about to begin. My bumper is scheduled for the booth tomorrow

While that is happening, I decided to make some changes to Brian's excellent front bumper build.

You may recall that he builds bumpers out of 7 gage steel, but for my build I had him make the core and structural pieces out of the 7 gage, but everything else out of 10 gage. I wanted to save weight, and I have to say, this front unit is a lot lighter than I envisioned.

But it gives up some strength in the wings, so I am going to create a bottom plate to tie all that together and give me more stable pushing power when i want to nudge something out of the way.

And before I settle on side mounting my winch, something Brian worked out with the SmittyBilt folks...I want to see if I can fit it in the traditional location. I'll mount it up after strengthening it and take a crack at it.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 10:43:44 PM
With that said, I disassembled the rear suspension once again and dropped the mutant axle out to do the diff change out

Here it is being torn down
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 10:45:19 PM
Just look at the size of the bolts holding that ring gear onto the carrier. That's a 15/16" head
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 10:46:49 PM
Next, I started scrubbing everything with degreaser and soaking it with purple cleaner. After some pressure washing it was getting to be pretty clean
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 10:48:13 PM
The brake backing plates were cleaned as well. They will need additional rust removal and paint before reusing, but I'll use the same 96,000 mile old brake shoes!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 10:49:23 PM
Removing the bolts, I just dropped the carrier onto the floor from maybe 3" height and the ring gear fell right off
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 10:50:50 PM
And I checked one more time

8 pinion gear teeth, and 39 ring gear teeth

= 4.8750   4.88!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 10:53:08 PM
The duragrip is Yukon Gear's limited Slip differential which I'll use this time instead of a full up locker. I don't think there was a grizzly available, only the much harsher detroit locker which would be out of character for a people carrier.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 10:54:39 PM
I cleaned that all up, then applied some assembly lube to the ring gear mating flange, then bolted it all up
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 10:57:40 PM
I was kind of on a roll up to this point, the point where I made a mistake

I did not check the factory carrier as closely as I should have. I should have noticed that the shims Tate sent were much smaller than the large spacers that fit outside of the carrier bearing races. Had I known I could have stacked that amount of shim beneath the bearing prior to pressing on the new bearings, but I didn't and now have to pay the price.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 11:01:58 PM
So when I dropped the completed carrier back into the case, it went in easily...Something wrong with that...

And I could slide the carrier from side to side a little bit. So where's the tight fitting operation that needs a case spreader?

Had I placed the shims onto the carrier, then pressed on the bearing, I would have been golden

When things didn't add up, I looked harder, then immediately discovered my bo-bo.

Using a bearing puller, I got to work pressing on the bearing backside which goobered up the factory shim pack something fierce.

No worries with all that, I only really needed to measure it and build up a new stack of shims from the new Tate supplied parts
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 10, 2019, 11:03:20 PM
On the bumper. What about adding a brace to the rear adding mucho KIA pushing ability. Same stuff I have been thinking on mine.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 11:06:02 PM
I did get a good measurement at .1520"

I was able to build up a stack that came in at .1530"

One thousandth off is GTG, but I was unable to pry off the new bearing from the new carrier.

If I tug on it, the roller cage is distorting, and will be destroyed. But the bearing seats right against the case with only two opposing slots to stick a puller into. When I pull the cage will get destroyed, but will provide the room to grab onto the small spots of bearing inside to allow me to pull it off.

Translation: I'll need to purchase another bearing.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 10, 2019, 11:06:19 PM
I thought on Danas the shims go on the outside of the race. You shim for X preload after finding backlash?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 11:07:09 PM
On the bumper. What about adding a brace to the rear adding mucho KIA pushing ability. Same stuff I have been thinking on mine.
That other piece is a leg of the engine hoist, not part of the bumper
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 11:08:59 PM
I thought on Danas the shims go on the outside of the race. You shim for X preload after finding backlash?
Not in this axle. THe outside of the race spacer is like twice the diameter of the shims Tater supplied that are clearly marked "Dana 80"
And the factory carrier was shimmed inside of the bearing...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 11:10:37 PM
Well, with useful daylight still burning, I got after painting the housing. Using that brushable KBS epoxy, I gave it a coat. Looks like a piece of glass!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 11:11:41 PM
I'm hoping the supplied neutralizer will keep the paint alive for another use or two
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 11:12:37 PM
So that's the state of the build as of closing tonight. Back after it in the morn
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 10, 2019, 11:13:39 PM
Grill on the roof is going to either get the LineX or the KBS black treatment...undecided at this point
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 11, 2019, 07:50:55 AM
Grill on the roof is going to either get the LineX or the KBS black treatment...undecided at this point
Why would you paint your grill? That will smell terrible when ya cook on it


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 11, 2019, 09:48:55 AM
You know, Norm and I were just talking the other day about that fancy clam shell puller Tate sells...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: EL TATE on April 11, 2019, 10:15:50 AM
I thought on Danas the shims go on the outside of the race. You shim for X preload after finding backlash?

The outboard "shims" are really just spacers, designed a narrower carrier some years back when races kept spinning and damaging the softer housing material. The spacers now take that abuse and really serve no adjustment purpose. All the backlash shim and preload are under the bearing as Don found out the hard way. Bummer sir, how can I help?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 11, 2019, 10:20:31 AM
Grill on the roof is going to either get the LineX or the KBS black treatment...undecided at this point
Why would you paint your grill? That will smell terrible when ya cook on it


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 :knucklehead:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: OldKooT on April 11, 2019, 10:59:04 AM
Set up bearings *cough
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: EL TATE on April 11, 2019, 11:08:18 AM
 
Set up bearings *cough
:evil: probably should have thought about those. Or that bearing puller. I don't think I've been banned yet, maybe it's my turn
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 11, 2019, 11:34:08 AM
Set up bearings *cough
:evil: probably should have thought about those. Or that bearing puller. I don't think I've been banned yet, maybe it's my turn

I second that you’re long overdue!  :tongue:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: OldKooT on April 11, 2019, 12:41:48 PM
Don I am sure tate can set ya up with a clam shell puller and set up bearings to do that job the simple way. NEW TOOLS LoL
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 11, 2019, 09:47:13 PM
OK, well, I purchased a new bearing. I destroyed the new-old one getting it back off.

This time I added the factory shim stack under the same bearing as was shimmed in the Dana factory carrier.

It was a booger to get in there. Like nearly impossible. I pounded on it with a rubber mallet for some time and finally it nested.

But while it was closing down closer to hitting home the backlash on the ring gear was going away quick. I sort of knew I had a bad setup but I torqued the caps down anyway just to take some measurements.

Well, that didn't help. with the caps loose I could rotate the thing but with zero backlash. When I tightened the caps it locked up. No way to turn it at all, so I am all the way back to starting out fresh.

And I'm not going to do that. Much like that automatic transmission dodge junk thing I messed with, when it didn't come together, I took it to the pros

I called Cincinnati Driveline, the folks who build my driveshafts. They also set up differentials. The minute I told them what had happened, they said, "I don't know why people like those Dana's so much, we hate them! Too darned hard to work on and the Gm 14 bolts are so easy."

They have a stand and all sorts of setup bearings and machines to get the thing setup properly. He did caveat that for the $300-$350 a setup normally costs and considering it is a Dana with older gears, they would take a run at it and could give me some backlash but getting it perfect is a crap shoot.

I am so regretting not buying a used 14 bolt! Would have been done and running by now. But it is what it is, I own it and I'll see it to its end, but for me, no more Dana axles...EVER. I'm sticking with the GM stuff for now on.

This could cause a problem. They have several axles in queue before me, and said it would be a struggle to get it done by the first week in May, so now I'm nervous as this will likely affect my start date. I really need to have some time driving it to iron out the bugs, and this rear axle thing may trip me up.

But, there is a lot of other things to get done, so I'll switch to them starting with the rear bumper tomorrow. Get that hung, then start on the modifications on the front bumper, then on to the secondary battery and electrical system. Hopefully, the axle will come in and I'll have everything ready to throw it in there and get going.

To that end, I spent the afternoon finishing the suspension parts I just built, and got them into paint before stopping

Here is that rear axle paint 24 hours later:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 11, 2019, 09:49:00 PM
That's some hard stuff! I was able to gouge it and deeply scratch it when rotating the axle in the rack, but normal scraping it with a tool has zero effect.

I snapped this pic just as I got the diff installed:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 11, 2019, 09:50:53 PM
Then I spent some time cleaning and derusting some more parts, then chemically cleaned them before brushing on more KBS epoxy
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 11, 2019, 09:52:21 PM
I'm disappointed that I could not finish the diff setup today, but even though I may have lost that battle, the war is still in progress, and judging from the enormous change in that truck, I may be winning still.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 11, 2019, 10:08:58 PM
Don, if you want to run that axle to Ft Wayne I know the guy who sets up the rear rear ends at Dana for testing purposes.

Seth, can put that together with his eyes closed. Let me know if you need his number? He did all our race trucks.

He may or may not have once cut a custom set of gears for a rock jock 60 housing after hours at Dana too. Didn’t like the setup he was getting so he made gears to his own specs.....  :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 11, 2019, 10:12:51 PM
Don, if you want to run that axle to Ft Wayne I know the guy who sets up the rear rear ends at Dana for testing purposes.

Seth, can put that together with his eyes closed. Let me know if you need his number? He did all our race trucks.
Too far my friend

I'll take the bird in hand. take me 90 min to drive up, drop off and ditty-mau back home.

Or are we talking an overnight deal??Drive up, grab a hotel, load the next day and come home???
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 11, 2019, 10:14:52 PM
Don, if you want to run that axle to Ft Wayne I know the guy who sets up the rear rear ends at Dana for testing purposes.

Seth, can put that together with his eyes closed. Let me know if you need his number? He did all our race trucks.
Too far my friend

I'll take the bird in hand. take me 90 min to drive up, drop off and ditty-mau back home.

Or are we talking an overnight deal??Drive up, grab a hotel, load the next day and come home???

Last I knew Seth worked third, worth a shot to call and see what his schedule is. May be able to run up in morning and have him do it then run home. He used to work out of his brothers garage but as of late when axles are in a truck he was using Branik motor sports shop with lift.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:21:59 AM
Don, if you want to run that axle to Ft Wayne I know the guy who sets up the rear rear ends at Dana for testing purposes.

Seth, can put that together with his eyes closed. Let me know if you need his number? He did all our race trucks.
Too far my friend

I'll take the bird in hand. take me 90 min to drive up, drop off and ditty-mau back home.

Or are we talking an overnight deal??Drive up, grab a hotel, load the next day and come home???

Last I knew Seth worked third, worth a shot to call and see what his schedule is. May be able to run up in morning and have him do it then run home. He used to work out of his brothers garage but as of late when axles are in a truck he was using Branik motor sports shop with lift.
Yea, I looked at the distances involved, not just a simple drive over. That's quite the drive. Thanks anyway but I'll stay with current plan.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: EL TATE on April 12, 2019, 09:42:40 AM
How far from Eastern, California, or Burlington, Wickliffe, Murray, or Louisville KY? How about Dayton, Columbus, Lucasville, Pataskala, E Palestine, Junction City, Harrison, Twinsburg, Dayton or Garfield Heights OH?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: OldKooT on April 12, 2019, 10:11:02 AM
if you didn't move the pinion depth, all you should need is some set up bearings and shims and a hour. Dana axles aren't hard to work on if you have the correct tools. YT SB80 I think is yukons part #....
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: dave945 on April 12, 2019, 01:50:19 PM
How far from Eastern, California, or Burlington, Wickliffe, Murray, or Louisville KY? How about Dayton, Columbus, Lucasville, Pataskala, E Palestine, Junction City, Harrison, Twinsburg, Dayton or Garfield Heights OH?
Burlington is just up the road probably 20 minutes from Don

Don, if you get in a real pinch, we can pull the 14 bolt from under the blazer and you can rebuild it and put disk brakes on it and use it til you get back and have time to work on the Franken-axle.  Then I’ll stick it back under the blazer. :)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bob Smith on April 12, 2019, 01:50:47 PM
Don, I know you would never abuse that trailer hitch "but" why not put a good hitch on it just in case you accidently tried. Those round factory receivers are just junk and you already have it removed.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 12, 2019, 02:32:24 PM
Don, I know you would never abuse that trailer hitch "but" why not put a good hitch on it just in case you accidently tried. Those round factory receivers are just junk and you already have it removed.


https://www.curtmfg.com/part/14080

No more junk GM hitcth.  I tried amazon but couldn’t find it


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 03:34:46 PM
OK, for the axle people: I dropped the mutant axle off at Cincinnati Driveline, the go to place in this area for all things, well, driveline. They said they would try and get to it next week. I think they liked the fact that it was all cleaned up and pretty.

Towing People: Chevy tow hitch=No good??

Didn't realize that, well can't have that business, better go and get that Curt unit you goodins recommend, because like Bob aptly pointed out, Although I am not known to abuse things, the possibility exists!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 12, 2019, 03:45:50 PM
OK, for the axle people: I dropped the mutant axle off at Cincinnati Driveline, the go to place in this area for all things, well, driveline. They said they would try and get to it next week. I think they liked the fact that it was all cleaned up and pretty.

Towing People: Chevy tow hitch=No good??

Didn't realize that, well can't have that business, better go and get that Curt unit you goodins recommend, because like Bob aptly pointed out, Although I am not known to abuse things, the possibility exists!
I am sure the tow rating and so forth matches up, but knowing that nice easy me bent my factory GM hitch we had better get you in a upgrade model!


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 03:52:22 PM
OK, for the axle people: I dropped the mutant axle off at Cincinnati Driveline, the go to place in this area for all things, well, driveline. They said they would try and get to it next week. I think they liked the fact that it was all cleaned up and pretty.

Towing People: Chevy tow hitch=No good??

Didn't realize that, well can't have that business, better go and get that Curt unit you goodins recommend, because like Bob aptly pointed out, Although I am not known to abuse things, the possibility exists!
I am sure the tow rating and so forth matches up, but knowing that nice easy me bent my factory GM hitch we had better get you in a upgrade model!


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Appreciate the advice!

Just ordered the Curt Class VI from Amazon

Be here Thursday
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 12, 2019, 05:37:18 PM
I couldn’t get my amazon to pull up anything larger than class 3 for some reason, is your frame bolt pattern same as the trucks?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bear9350 on April 12, 2019, 06:23:18 PM
I couldn’t get my amazon to pull up anything larger than class 3 for some reason, is your frame bolt pattern same as the trucks?


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My research had told me the suburban and truck bumpers were the same.  But Don just sent me an email saying the bumper wasn't bolting upright, and after looking at some of Don's pics closer I can definitely say they are not the same.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:06:48 PM
OK, dropped off the axle like I mentioned earlier, I think, and drove over to the Line-X shop in Erlanger. They are pretty new but have a pretty nice operation going on already. The showroom is well laid out and also features other truck and overland products
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:08:26 PM
The business end of their shop is focused on a large spray booth that looks like it can swallow nearly any vehicle!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:16:47 PM
The crew there were super nice, well informed about their business, and judging from the work they just did for me, very capable an d experienced as well. The two gentlemen standing behind the bumper did the work and honestly acted as though they enjoyed doing unique projects like this one.

Jimmy pictured, and Brian, who was out of the shop at the time run the place

I gravitate to businesses like this one. Young doers making it happen! That's one of the things that makes this nation great!

Contact them at:

Line-X of Northern Kentucky
3126 Dixie Highway, Bldg B
Erlanger, KY 41018 
linexnky.com
859 360-6634
859 750-6556
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:19:35 PM
The bumper coating job was terrific, and was their premium treatment with an overspraying of UV fighting clear coating which also brightens up the finish.

So getting the bumper home, the fun began

There was an immediate misalignment issue pictured here

With the holes in the bumper and the ones in the frame aligned the fit was way off
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:22:07 PM
So I had my boys lift it up as far as they could get it, but some "L" shaped protrusion which actually had the mounting holes prevented a proper alignment.

At this point it was obvious that something was amiss. I was thinking that perhaps Brian had used the wrong frame/vehicle file because had the file been correct, it should have fit.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:25:41 PM
Not only did the thing nor want to fit vertically, but laterally, the mounts are about 3" from where they need to be.

OK, mistakes are sometimes made and this was starting to feel like a lemon, but I decided to make some lemonade out of it. Brian had done a terrific job building the thing, and the Line-X was outstanding, and I need a bumper, and I just paid for this one, so I guess I'll just have to add some Kentucky engineering to get it where it needs to be.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:27:03 PM
So, I started with cutting off the "L" portion to a length I thought might work
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:28:56 PM
Then I discovered my next issue. The arm latch point would not allow the hatch to open!!! ERRRRRRR

But no worries, just another challenge and problem to solve
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:30:41 PM
So I resorted to using some of the shims Brian supplied, but Darned if they were too narrow to fit the large bolts I was using (Factory bolts and hardware). So I ended up using some large nuts to try and shim the bumper downward to start some kind of alignment
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:35:00 PM
Then the next problem surfaced. I could not close the spare tire carrier without first hitting the hatch.

So I had shimmed the bumper down, and bolted it up to the factory hitch as a reference and I couldn't open a hatch nor close the arm...hmmm???

Next I tried to angle it downward a tad bit keeping the "leading edge" in a "Normal" position, and allowing the backside to droop a bit. With that I got the arm to just close and I could open the hatch, but the clearance is a super skinny .020"!!!!!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:37:15 PM
Darned thing looks good for a bumper that won't fit!

Frustrating, but I am not done

I will also have to do something about all this room between the body and the bumper. I guess I'll create some sort of spacer or something as that is way too much room. It is not so much a bumper wing as a mud n' air scoop
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:39:28 PM
With some more adjusting I got it this far. Things are fitting, sort of, but from the side it looks like I grafted some F150 bumper onto my truck...Have to fix that!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:40:37 PM
Lotza room to close up...

Or should I just go with it as is and live with it???

What say the people?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:45:12 PM
The latch is some mini version of a real latch. I am thinking I will need to replace this with something more substantial. Holding a couple hundred pounds still is not in this little guy's skillset

And for some reason the arm sits about an inch proud of the foot beneath the mount. So much that the latch pin will not engage into its hole. So I'll either have to find a longer pin or, heck, I don't know what else to do.

I thought well, the tire weight will bring it down, but I had one of the Pre-Rangers hang on the tire rack and it just touched. He weighs 130...So maybe that and some water will in fact settle it down.

I do not view that as a mistake. Rather I see it as planning and thoughtfulness on Brian's part. He was trying to allow for droop after heavy things got installed, and I would have done the same thing...No worries!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on April 12, 2019, 08:46:59 PM
I would just go with it as it is, talk to brian and see what the issue was/is and fix/finish when you return from trip.....time is getting short.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:49:12 PM
...But that teeny latch...Nope, that's a solid fail!

So working on, this is what I am faced with currently. The frame on both sides fits well inside where the bumper arms are located. So I have to bridge that distance, while maintaining the integrity of the bumper. I think I have an idea how to do that, but more welding and grinding will be needed
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: BobbyB on April 12, 2019, 08:49:22 PM
I would just go with it as it is, talk to brian and see what the issue was/is and fix/finish when you return from trip.....time is getting short.

I agree.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:52:01 PM
I would just go with it as it is, talk to brian and see what the issue was/is and fix/finish when you return from trip.....time is getting short.
Concur.

No time to redo now, I'll make the best of it that I can and it is what it is.

There may be another problem. Brian used the same vehicle file to build the front bumper too...

If that one is cooked, I'll have to punt and do something else, and the time is like now to make that call. I'll be finishing modifying the rear bumper tomorrow and check the fit of the front one immediately thereafter.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 08:53:47 PM
Other than the fitment issues, it looks pretty good thus far, and I am close to getting it hung enough to make it useful
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 12, 2019, 09:00:49 PM
And, for the record, Brian did the best he could, and produced a great looking set of bumpers. I am not upset with him, although I'll bet he is more upset with himself than I with him.

I think he will learn from this and be better for it. We may do something to solve this or we may not. Heck if I can get it installed well enough to use and it doesn't look all goofy, then I'd be OK to run with it.

If the front bumper doesn't fit, then we have a larger issue. I can turn right around and purchase an ARB and simply bolt that on. But we aren't there yet and Brian hasn't read in either. We'll let him comment and like Bobby said, sort it out later.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 12, 2019, 09:27:43 PM
That bumper looks killer fitment or not!

The gap on the rear bumper and fenders is a little large I feel also.  But suggestion for a after trip fix.   Cut off the bottom of those rear fenders and wrap the bumper up the wheel wells.  Lots of toyota guys do it, I’ll be doing it do mine one day when the rust Finally finishes off my fenders.

I like that looks I guess
(https://uploads.tapatalk-cdn.com/20190413/0747f9b50988142f850b4bf10c4db4bb.jpg)(https://uploads.tapatalk-cdn.com/20190413/ced01eb43139fa4a071f3167ba150164.jpg)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 12, 2019, 10:07:14 PM
Can’t believe I’m admitting this but I agree with Dave. Take that lower valence off between rear wheel well and bumper. Fab a set of custom storage boxes in there while you’re at it and make use of the dead space. I like bumper as well it’s just too bad the mounts are that far off.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 12, 2019, 10:37:37 PM
Man did I just read what I think I did?   Hells gonna freeze over now


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 12, 2019, 11:24:18 PM
Bumpers are killer.

Norm, I agree that the rear should just have been shims for backlash and good. Same gears and pinion not pulled.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 13, 2019, 01:08:33 PM
Couple of corrections

First the bumper "Shims" I posted are actually the light tabs for the front bumper lights...My bad

Next, have been speaking to Brian. He thinks the front Suburban and 2500 truck are the same, so we should be good with the front fitment. Will know shortly.

I'd say that if I can get the rear to mount up, and I should, then all that remains is sorting out the spare tire/bin carrier arm. Not sure how that ends, but that should remain the only problem.

On cutting off the lower quarter, I actually thought about it earlier. I did it with my Tundra years ago and built a wrap around bumper/slider affair. Not now, but may go that route after the trip as some have suggested, actually those two brothers, Dave and his older brother, Shawn. (He-he)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on April 13, 2019, 02:04:14 PM
OUCH!!!!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on April 13, 2019, 02:04:23 PM
Couple of corrections

First the bumper "Shims" I posted are actually the light tabs for the front bumper lights...My bad

Next, have been speaking to Brian. He thinks the front Suburban and 2500 truck are the same, so we should be good with the front fitment. Will know shortly.

I'd say that if I can get the rear to mount up, and I should, then all that remains is sorting out the spare tire/bin carrier arm. Not sure how that ends, but that should remain the only problem.

On cutting off the lower quarter, I actually thought about it earlier. I did it with my Tundra years ago and built a wrap around bumper/slider affair. Not now, but may go that route after the trip as some have suggested, actually those two brothers, Dave and his older brother, Shawn. (He-he)

Shoot, you and Shawn could probably knock out that mod in a day, just crash at his shop for an overnight!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 13, 2019, 02:41:45 PM
Couple of corrections

First the bumper "Shims" I posted are actually the light tabs for the front bumper lights...My bad

Next, have been speaking to Brian. He thinks the front Suburban and 2500 truck are the same, so we should be good with the front fitment. Will know shortly.

I'd say that if I can get the rear to mount up, and I should, then all that remains is sorting out the spare tire/bin carrier arm. Not sure how that ends, but that should remain the only problem.

On cutting off the lower quarter, I actually thought about it earlier. I did it with my Tundra years ago and built a wrap around bumper/slider affair. Not now, but may go that route after the trip as some have suggested, actually those two brothers, Dave and his older brother, Shawn. (He-he)

Shoot, you and Shawn could probably knock out that mod in a day, just crash at his shop for an overnight!

Turner, he referred to Dave as my blood relation. Realize my shop is in a secured gated facility, there is a reason for that...... :tongue:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 13, 2019, 04:56:03 PM
OUCH!!!!
I like you.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on April 13, 2019, 07:11:06 PM
Couple of corrections

First the bumper "Shims" I posted are actually the light tabs for the front bumper lights...My bad

Next, have been speaking to Brian. He thinks the front Suburban and 2500 truck are the same, so we should be good with the front fitment. Will know shortly.

I'd say that if I can get the rear to mount up, and I should, then all that remains is sorting out the spare tire/bin carrier arm. Not sure how that ends, but that should remain the only problem.

On cutting off the lower quarter, I actually thought about it earlier. I did it with my Tundra years ago and built a wrap around bumper/slider affair. Not now, but may go that route after the trip as some have suggested, actually those two brothers, Dave and his older brother, Shawn. (He-he)

Shoot, you and Shawn could probably knock out that mod in a day, just crash at his shop for an overnight!

Turner, he referred to Dave as my blood relation. Realize my shop is in a secured gated facility, there is a reason for that...... :tongue:

I was tracking that, just saying you and Don could chop and add in a day, I also knew your shop is high class and require a gate.... (not sure I can say that because my house is gated)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: OldKooT on April 13, 2019, 09:15:11 PM
yah....well I have a gated ......,um well fence
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 13, 2019, 10:01:14 PM
Couple of corrections

First the bumper "Shims" I posted are actually the light tabs for the front bumper lights...My bad

Next, have been speaking to Brian. He thinks the front Suburban and 2500 truck are the same, so we should be good with the front fitment. Will know shortly.

I'd say that if I can get the rear to mount up, and I should, then all that remains is sorting out the spare tire/bin carrier arm. Not sure how that ends, but that should remain the only problem.

On cutting off the lower quarter, I actually thought about it earlier. I did it with my Tundra years ago and built a wrap around bumper/slider affair. Not now, but may go that route after the trip as some have suggested, actually those two brothers, Dave and his older brother, Shawn. (He-he)

Shoot, you and Shawn could probably knock out that mod in a day, just crash at his shop for an overnight!

Turner, he referred to Dave as my blood relation. Realize my shop is in a secured gated facility, there is a reason for that...... :tongue:
I bet I get in there! ;-)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 13, 2019, 10:03:56 PM
So, I didn't get anything done (on the truck) today. Spring time lawn cleanup. Took most of the day, then it was night. Other daughter had her new baby a couple days ago. Will be going over there after church so questionable if I can get to it tomorrow...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 15, 2019, 09:51:47 PM
So, I started the work out today with fitting the front bumper. It fit well and Brian was thoughtful enough to keep the bumper upper mount loose to allow me to make any necessary adjustments, then weld it in place. With everything fitting well, I tacked that part in place and let the thing hang on its own accord.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 15, 2019, 09:52:58 PM
I finally took the hood out of the service position, returning it to the normal day to day position it will live in
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 15, 2019, 09:54:00 PM
And checked the open/close fitment with all the new parts.

So far, so good!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 15, 2019, 09:58:15 PM
So that is looking good, next up it to pull it back off and do some welding, then fit the winch and see if that will still fit. I didn't realize it, but that bumper keeps stuff pretty close at hand and tucked in. The winch, any winch is going to be pretty tight in there. I think I may have to move my newly installed transmission fluid cooler to make more room.

So, back to the rear bumper which was not fitting so well. I decided to simply weld a piece of angle steel to the butt end and use that method to take up the space for the incorrectly located arms.

I first added some of the things that are going to stay mounted or carried by that bumper to ensure everything still fits
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 15, 2019, 09:59:39 PM
With that I drilled the holes, and tacked in the new mounts, then removed the bumper and final welded the new stuff
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 15, 2019, 10:00:56 PM
I then added a piece of square tubing to reinforce that weld and to it added a ground spot for the yet to come back up lighting
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 15, 2019, 10:02:56 PM
With the area cleaned, I undercoated everything anywhere near that bumper.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 15, 2019, 10:04:28 PM
And heavily sprayed the new steel and the damaged areas of the Line-X
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 15, 2019, 10:07:29 PM
The bumper went right back on, and I bolted it up with no fuss. I did however get it a little bit off, and it contacts the hatch, so another adjustment is forthcoming.

This time I packed the bearings with grease, installed the seal, tightened the nut and carter-keyed the assembly in place

Here are some areas I placed foam tape onto
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 15, 2019, 10:08:29 PM
And it opens and closes, and the hatch works and this thing is just about finished
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 15, 2019, 10:09:26 PM
The truck grew a little bit in length
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 15, 2019, 10:10:29 PM
Oh and the dust cap became the "busted" cap. Darned thing wouldn't fit and i ended up denting the heck out of it!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 15, 2019, 10:11:11 PM
Back at it tomorrow...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 15, 2019, 10:13:00 PM
And, don't be surprised if a hi-lift jack shows up bolted to that brush guard on the front bumper. I can't find another place to mount it, so It just may assume duties as a brush buster in addition to being a jack.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 15, 2019, 10:37:31 PM
Seen the Jeep crowd mount them to the hood, other folks mount them to the side of the luggage rack,  that bumper looks awfully nice to mess up the lines with a clunky jack

Did ya notice all the extra storage room under that rear quarter panel ?
When is the new tow hitch due?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 15, 2019, 10:59:34 PM
Seen the Jeep crowd mount them to the hood, other folks mount them to the side of the luggage rack,  that bumper looks awfully nice to mess up the lines with a clunky jack

Did ya notice all the extra storage room under that rear quarter panel ?
When is the new tow hitch due?


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Its due in Thursday

Curt Class IV

Will be going right in there when it comes in!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: OldKooT on April 16, 2019, 09:42:56 AM
it's looking heavy Don.....the burb
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 16, 2019, 09:53:36 AM
it's looking heavy Don.....the burb
its looking good!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 16, 2019, 10:05:21 AM
it's looking heavy Don.....the burb

Hey Norm, he’s coming around slowly. On those bumpers he chose a lighter gauge material on the wings versus his normal depleted uranium armor alloy throughout similar to an Abraham’s tank...  :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: OldKooT on April 16, 2019, 10:05:40 AM
yes it does look good....my project is stalled due to a Mustang and a Ariens garden tractor /tiller in my shop atm lol
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 16, 2019, 07:58:08 PM
Mounted up the spare tire. arm swings effortlessly
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 16, 2019, 07:58:50 PM
I'm satisfied with the fit, on to other things
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 16, 2019, 08:00:12 PM
Not wasting any time, I am installing everything I can fit that makes sense. Two more parts off the shelf, the rear Clevis fixtures
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 16, 2019, 08:02:46 PM
And on the cooler, here's how I plan to manage it. The thing will pretty much stay put where it is located. I will place another smaller cooler next to it, another roto-molded thing that will hold drinks so that we are not going into/out of the big guy very often

So I attached a section of hose to the drain and a simple valve to the other end. I'll just drain water every once in awhile and top over with more ice as necessary
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 16, 2019, 08:03:48 PM
Had to sand down and repaint these three wheels once again. I got too much trash in the paint last time I sprayed. Need to mount the tires, so it's go time
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 16, 2019, 08:05:58 PM
Then on to front bumper work

First up, I pulled it and welded in the top mounts

Next I made a reinforcing plate for the bumper wings. Basically I am making more of a "C" channel out of the setup Brian came up with.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 16, 2019, 08:08:11 PM
After cutting out a section of 10 gage, I shaped it like a quorkie Gurka knife, then fitted and welded it in to the bottom of each wing
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 16, 2019, 08:09:09 PM
Then I welded in the light mounts
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 16, 2019, 08:59:23 PM
Next I loosely installed the winch to the mounting plate Brian had made up and slid that onto the four studs welded to the bumper.

Looking at it I removed the allen head screws on the clutch handle end and rotated it 90 degrees, then tightened that down.

We picked it up and tried to mount it to the truck, but it won't fit

The winch or the radiator core support, that's my choices, one or the other, not both

No, I'm not very happy

After all the stuff I had to go through on the rear bumper, to find out my winch bumper cannot mount a winch is not good news.

So I guess I'll just redo things myself again. This time, I'll just send the da__ed thing in and have it coated and get it bolted up to the frame. Then I guess I'll take some of the time I was saving by not having to build the bumpers myself and fabricate up some sort of a cradle to hang the winch in the space just below the radiator and create some way of guiding the rope through the hole so that it doesn't get destroyed, or maybe I'll just go buy the ARB bumper I was going to buy in the beginning.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 16, 2019, 09:00:52 PM
So that's where it is at today. Another step forward and another big stumble backward...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 16, 2019, 09:36:21 PM
Had an idea, check your pm box boss.....
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on April 16, 2019, 10:54:04 PM
That sucks about the winch.

Any update on the third member?

What’s on the punch list to finish?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 16, 2019, 11:02:50 PM
That sucks about the winch.

Any update on the third member?

What’s on the punch list to finish?


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I'll be able to sort the winch. I'll just create a cradle for it, like Dodge does on that rock crawlin truck of theirs

No word on the axle. At the shop, in queue... Had one or two ahead of me

Punch: Get axle and build up with new parts
Install
Measure for driveshaft (hoping to get lucky)
Paint and install all the new rear suspension stuff
Run rear brake lines, bleed system
Mount remaining tires on wheels
Install wheels
Install F bumper when it is Line-X complete...Thursday???
Install aux battery
Run bat cables, switch, connect both
Build winch cradle/wire in winch
Drop roof top tent on, bolt down
Install new 2-din receiver/better speakers
Drive it, align the front end, drive some more
Pull recording for BlackBear/re-tune and install
Fix whatever i found goobered up
Install some more lighting
Load with kids and hit the road!!!!!!!!!!!!!!!!!!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 16, 2019, 11:58:51 PM
Why can’t you have the winch sit up like normal? Is it a air block issue? Trying to keep it hidden to maintain a low profile?

Cut the top of that bumper open a little wider and mount it in


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on April 17, 2019, 12:35:00 AM
Why can’t you have the winch sit up like normal? Is it a air block issue? Trying to keep it hidden to maintain a low profile?

Cut the top of that bumper open a little wider and mount it in


Sent from my iPhone using Tapatalk

Shrinkage issue during the build caused the up top winch spot to be too small, so he cut and modified and moved, hoping it would all fit. Check out post 15 in the suburban bumper build thread. Was an unaccounted for whoops.

Or atleast that’s how I understood it
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Atkinsmatt on April 17, 2019, 07:25:54 AM
Is it possible to remote locate the winch control pack and would that help?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 17, 2019, 08:03:24 AM
Why can’t you have the winch sit up like normal? Is it a air block issue? Trying to keep it hidden to maintain a low profile?

Cut the top of that bumper open a little wider and mount it in


Sent from my iPhone using Tapatalk

Shrinkage issue during the build caused the up top winch spot to be too small, so he cut and modified and moved, hoping it would all fit. Check out post 15 in the suburban bumper build thread. Was an unaccounted for whoops.

Or atleast that’s how I understood it
Copy


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cudakidd53 on April 17, 2019, 12:18:05 PM
Two steps forward and one step back - kinda what I'm going through trying to dot all the I 's and cross all the T 's with retirement matters!  I've had scabs ripped off old wounds looking for tax docs and other papers from the "practice wife" era.  God will create a path forward for us all Don - fret not!  :grin: :grin:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 17, 2019, 12:21:27 PM
Why can’t you have the winch sit up like normal? Is it a air block issue? Trying to keep it hidden to maintain a low profile?

Cut the top of that bumper open a little wider and mount it in


Sent from my iPhone using Tapatalk
It's a depth issue. The bumper does not allow enough space to place anything behind it and still clear the radiator support
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 17, 2019, 12:24:11 PM
Two steps forward and one step back - kinda what I'm going through trying to dot all the I 's and cross all the T 's with retirement matters!  I've had scabs ripped off old wounds looking for tax docs and other papers from the "practice wife" era.  God will create a path forward for us all Don - fret not!  :grin: :grin:
I'm not worried about it.

Its small potatoes, I'll figure it out.

I'm much more concerned about Andrew, the man who contacted me who is dying of cancer. He is the guy in the faith section I posted a thread on. He is in a bad way...

I feel really wrong thinking I have any problems worthy of note in view of his titanic suffering...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 17, 2019, 12:29:22 PM
Is it possible to remote locate the winch control pack and would that help?
This winch has all that built in. Its a nice design

I have only two choices. Get another bumper,
or
Build a cradle beneath the back of the bumper and make it work

I think door number two is the right approach. I think the bumper is well built, fits well for a non-winch bumper and is here. I'll use it and make the winch work, that's the decision.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on April 17, 2019, 12:35:40 PM
If this house is torn down I have a house in heaven, not built with hands.

Hopefully Andrew can find comfort


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cudakidd53 on April 17, 2019, 12:39:37 PM
Two steps forward and one step back - kinda what I'm going through trying to dot all the I 's and cross all the T 's with retirement matters!  I've had scabs ripped off old wounds looking for tax docs and other papers from the "practice wife" era.  God will create a path forward for us all Don - fret not!  :grin: :grin:
I'm not worried about it.

Its small potatoes, I'll figure it out.

I'm much more concerned about Andrew, the man who contacted me who is dying of cancer. He is the guy in the faith section I posted a thread on. He is in a bad way...

I feel really wrong thinking I have any problems worthy of note in view of his titanic suffering...
  Just posted on that - check when you can and relay it to Andrew please -
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 17, 2019, 02:32:39 PM
Two steps forward and one step back - kinda what I'm going through trying to dot all the I 's and cross all the T 's with retirement matters!  I've had scabs ripped off old wounds looking for tax docs and other papers from the "practice wife" era.  God will create a path forward for us all Don - fret not!  :grin: :grin:
I'm not worried about it.

Its small potatoes, I'll figure it out.

I'm much more concerned about Andrew, the man who contacted me who is dying of cancer. He is the guy in the faith section I posted a thread on. He is in a bad way...

I feel really wrong thinking I have any problems worthy of note in view of his titanic suffering...
  Just posted on that - check when you can and relay it to Andrew please -
I sent the link to him, but commo is spotty, he is not well...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 17, 2019, 09:43:05 PM
No actual work on the Burb today, but I did get the front bumper dropped off to have sprayed and dropped off the rest of the tires/wheels to be mounted.

Today, my favorite lawn care hobby (Not) spreading mulch. 20 yards of the stuff plus 10 bags of pine bark nuggets around some of the conifers.

The Curt hitch came in along with the new mount for the cable plug.

Moving right along!

Looking at a 270 degree awning thing, really cool!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 17, 2019, 09:45:04 PM
You should see if you can cut that cable plug into that new bumper. Keep the low hanging fruit from being so low.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 17, 2019, 11:42:13 PM
If that control box was remote would that solve the issue? A new winch might be simpler answer.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 18, 2019, 10:24:40 AM
If that control box was remote would that solve the issue? A new winch might be simpler answer.
Wait and see grasshopper...
New is not the answer we seek
Making rice paper from the seed is the solution...

I crack myself up!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 18, 2019, 10:26:08 AM
You should see if you can cut that cable plug into that new bumper. Keep the low hanging fruit from being so low.


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Patience, my son, patience...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on April 18, 2019, 11:02:23 AM
Patience, my son, patience...

I can only assume he's adopted?

I mean, we've heard you call him plenty of other things, but not that particular one. :grin:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 18, 2019, 12:08:55 PM
Patience, my son, patience...

I can only assume he's adopted?

I mean, we've heard you call him plenty of other things, but not that particular one. :grin:



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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 18, 2019, 12:38:41 PM
Patience, my son, patience...

I can only assume he's adopted?

I mean, we've heard you call him plenty of other things, but not that particular one. :grin:

Must be the red headed step child then.....  :tongue:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: OldKooT on April 18, 2019, 03:09:17 PM
LoL hey I have 4 of those....
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 18, 2019, 08:01:10 PM
The new rear hitch arrived late yesterday, so it was first up to get rid of the box.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 18, 2019, 08:03:06 PM
Curt is a Class IV with square tubing. Chevy part in background. Curt hitch weighs more for sure

Also Curt hitch is more compact. Notice how far Chevy places the hitch receptacle below the center mount
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 18, 2019, 08:05:03 PM
The Chevy hardware was of a larger diameter and was still in great condition, so I elected to reuse it, but also added two of the curt grade 8 bolts to the front points

Notice how tightly it tucks up to the bumper. That is a ground clearance/departure angle improvement that I had not bargained for.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 18, 2019, 08:05:48 PM
I picked up a new connection and mount as well
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 18, 2019, 08:08:00 PM
Knowing I'll be "Scrapin' tail" probably at Moab, I mounted the receptacle to the rear face where it could face downward for protection

I drilled holes, then used two 1/4" nutserts to complete the installation
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 18, 2019, 08:08:33 PM
I like it!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 18, 2019, 08:11:08 PM
Next up, I modified the license plate light to connect it to the LED's Brian supplied

I just taped one of the bulb sockets, minus the bulb to the main harness to limit the impact of the modification as much as I could. Then I zipped and taped the harnesses up and out of harms way
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 18, 2019, 08:12:39 PM
Looking at the rear quarter extension that everyone suggests cutting away to extend the bumper forward...Be it known that doing that will be a bit more complicated than when I did it to my Tundra truck
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 18, 2019, 08:13:37 PM
The hitch fit so tightly to the bumper that tightening the center bolts pinched and slid some of the Line-X coating uphill:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 18, 2019, 08:15:41 PM
Next up. I pulled the newly created crossmember for the sway bar and welded that all up, then went on and welded up the panhard bar frame mount. I triangulated and gusseted the living heck out of the thing. Unnecessary, but I don't want problems years from now
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 18, 2019, 08:16:43 PM
I'll clean that all up and undercoat it in the morrow and paint all the parts to be ready to go back together when the axle is completed
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 18, 2019, 08:22:01 PM
So, except for mounting the vehicle tag, the rear bumper business is now complete.

The front bumper is sprayed and will pick up tomorrow and maybe get that thing installed as well.

I also Line-X'd the grill too! Not sure what that will look like, but it won't be shiny chrome anymore. I plan to remove everything that shines except for the pretty paint. Think I'll leave that just as it is!

Oh, also had the tires all mounted, so before the clock chimes midnight Sunday, I want the truck resting on its front suspension, with bumper installed. Winch cradle will come next week...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on April 18, 2019, 08:43:22 PM
I know you had issues, but from the rear, that bumper looks uptight and out of sight. (Looks great)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Sammconn on April 18, 2019, 09:28:48 PM
Ken is right. Did I just say that. The bumper looks good for sure.
Like the hitch.

You’re gonna love the grill all line x’d up.
Seen a few and like them.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 18, 2019, 10:07:30 PM
Yep, looks good. Surprised you didn't do the combo plug for the hitch though.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 18, 2019, 10:09:34 PM
Surprised hitch wasn’t designed / built into rear bumper.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 18, 2019, 10:32:46 PM
Seen a guy from the forum we don’t speak of.  Greg
This is pretty idea
(https://uploads.tapatalk-cdn.com/20190419/d22a89e86fdcf620fcfb0b4890bc4543.jpg)(https://uploads.tapatalk-cdn.com/20190419/2f7b9cd48d3b2b3385f6e2c7504245e4.jpg)(https://uploads.tapatalk-cdn.com/20190419/bc9d28b8b095b95aeca865ba2397fdbc.jpg)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 18, 2019, 10:40:45 PM
What’s that added anchor supposed to do Dave?  :huh:

Oh wait, must be a Chevy thing I wouldn’t understand right?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 18, 2019, 10:50:33 PM
It’s for the folks in the inner city who like to follow to close.  Makes the sudden stop less on your vehicle




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Title: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on April 18, 2019, 10:51:29 PM
Rock slider if I had to guess.

^^ that works too.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 18, 2019, 11:00:57 PM
It’s for the folks in the inner city who like to follow to close.  Makes the sudden stop less on your vehicle




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Here I was guessing some sort of anti mulch bed device being you posted it on Dons thread!  :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 18, 2019, 11:17:08 PM
He’s coming to Utah, better be prepared for tailgating a holes with slow reaction times


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 18, 2019, 11:35:56 PM
He’s coming to Utah, better be prepared for tailgating a holes with slow reaction times


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Uh.... legal dopers in Colorado

Need I say more?  :rolleyes:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 18, 2019, 11:45:33 PM
We just have dopes lol


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Farmer Jon on April 19, 2019, 07:30:14 AM
Everything looks real good to me. I like to clevis tow hooks on the back. I was going to go with D rings on my truck bumper. But, I think I'm going to copy you instead.
Great idea putting the hose on the cooler.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 19, 2019, 10:54:19 AM
Surprised hitch wasn’t designed / built into rear bumper.
That was a result of a decision I made during the design process.

And if I can say

Although Brian's bumper thing seemed to turn south somewhat

He built two really nice bumpers
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 19, 2019, 10:58:10 AM
Well, morning TC complete (Thread check) off to get a freshly coated bumper.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 19, 2019, 11:07:46 PM
Well, I picked up the bumper, then did absolutely nothing the rest of the day. Had to scoot this evening. Wife threw me a gathering/party. Mexican food, was really nice. I am blessed! Grandkids ate all my ice cream desert! I didn't get a single bite!!!!!

So bumper is still in the back of the truck, guess I'll get to it tomorrow.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cudakidd53 on April 20, 2019, 09:46:36 AM
Well, I picked up the bumper, then did absolutely nothing the rest of the day. Had to scoot this evening. Wife threw me a gathering/party. Mexican food, was really nice. I am blessed! Grandkids ate all my ice cream desert! I didn't get a single bite!!!!!

So bumper is still in the back of the truck, guess I'll get to it tomorrow.

Grandkids snatched all the ICE CREAM!   :facepalm:  Glad you had a enjoyable day!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 20, 2019, 01:08:05 PM
Sounds like heaven
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 20, 2019, 08:14:51 PM
Here's the bumper when I picked it up at Northern KY Line-X. Bryan foreground is the owner, James is the general manager.

They put out a good product and on time. What more could you ask?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 20, 2019, 08:16:40 PM
The bare frontend is no more. The Line-X coated grill is sprayed on both sides
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 20, 2019, 08:18:51 PM
No sooner did I install the grill, I removed it once again to install the bumper.

It slid right on, the fit was excellent! Such a shame the winch did not fit. Had it, this bumper would have been a perfect 10! Looks spectacular regardless of having a winch or not
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 20, 2019, 08:20:05 PM
With that snugged up into place, I popped the grill back in, this time for good. Another milestone and project in the bank!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 20, 2019, 08:21:07 PM
And just like with the rear bumper, I threw the Clevis links on right away. Just getting things off the shelf and installed is a good feeling
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 20, 2019, 08:22:08 PM
Next I popped the Hawse head on and snugged its two bolts permanizing that piece
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 20, 2019, 08:26:22 PM
So that makes the front bumper sort of done. Sort of because i will still need to fabricate the winch cradle, but the next thing is the electrical system.

To review, I will have a rear battery that is connected to the vehicle charging system and battery via a switch. The idea is to disconnect the system at night while the deep cycle battery runs the camping needs. Then when driving, close the circuit and charge the system again.

And I'll be wiring up lights on the rack, the front ones to the high beam, the rear facing lamp to the BU lights, and then some independently switchable lighting for boon docking

Here I am pulling the trigger from the hot side of the high beam to switch the roof lights on.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 20, 2019, 08:29:14 PM
This cable will originate at the hotside of the battery at that nut that is tapped to supply power to various things. It crosses the front over and back to where Chevy would mount a second battery. I will mount a couple of mega fuses to connect to. One will supply the camping and non driving time needs, and one will supply power to the front winch.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 20, 2019, 08:30:10 PM
Here are the wires going in:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 20, 2019, 08:32:04 PM
From that point I will run a hot wire to several places where it will supply a fuse block that will power various things. The main cable will connect there and travel aft to where it enters the cabin to connect to the disconnect switch, then from there to battery number two

With that done, I replaced the radiator cover, freshly decaled up to finish off that part of the engine removal/modification/ reinstall
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 20, 2019, 08:34:55 PM
I'm building my own master fuse panel out of a piece of plywood. Once I get it configured, I'll spray it with bed liner and bolt it where the second battery would fit
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 20, 2019, 08:35:46 PM
Have to get busy ordering some lights to fill those holes!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on April 20, 2019, 09:04:16 PM
Don, all this electrical work, did you finish up the steps and I missed it? Or is that still a too do...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 20, 2019, 10:14:17 PM
Don, all this electrical work, did you finish up the steps and I missed it? Or is that still a too do...
You are paying attention!

I need to connect three wires. You will recall I could not find the correct wire to connect to for the front doors. I needed a multimeter. Actually, I needed a new battery for mine. With all the stuff going on, I just kept forgetting it. However today I finally picked up a new 9VDC battery and can test for the correct wire. Should have that buttoned up in a day or two.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 20, 2019, 10:52:30 PM
Bumper looks great, like to see the winch idea you have.

On the isolated battery, why not use a relay that works that energizes when the engine is running? Nothing to forget to switch on/off and maybe a little led showing it is charging?

Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on April 20, 2019, 10:59:02 PM
Bumper looks great, like to see the winch idea you have.

On the isolated battery, why not use a relay that works that energizes when the engine is running? Nothing to forget to switch on/off and maybe a little led showing it is charging?
Actually all he needs is a battery isolator.  It’s automatic.  Will allow it to charge but not drain the primary. Essentially it’s just a big diode


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 20, 2019, 11:02:37 PM
Bumper looks great, like to see the winch idea you have.

On the isolated battery, why not use a relay that works that energizes when the engine is running? Nothing to forget to switch on/off and maybe a little led showing it is charging?
Actually all he needs is a battery isolator.  It’s automatic.  Will allow it to charge but not drain the primary. Essentially it’s just a big diode


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And probably simpler,,,,,,,,,,,,,,
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on April 21, 2019, 12:33:10 AM
Definitely isolator. That's what motorhomes, ambulances, and etc use all the time. You can then install a disconnect switch that ties the batteries together in case of emergency.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on April 21, 2019, 12:34:15 AM
Don, all this electrical work, did you finish up the steps and I missed it? Or is that still a too do...
You are paying attention!

I need to connect three wires. You will recall I could not find the correct wire to connect to for the front doors. I needed a multimeter. Actually, I needed a new battery for mine. With all the stuff going on, I just kept forgetting it. However today I finally picked up a new 9VDC battery and can test for the correct wire. Should have that buttoned up in a day or two.

Good to hear! And yea as others have said, bumpers look great, even with all the hiccups, God needed you to slow down for some reason.

Saw those electric steps on an F150 today, commented on them to my OIC (wife, as I am technically the 6, few will fully understand that) because our crew cab build is much taller than anticipated. Her being a tiny thing, we will need some flavor of step. Had me thinking about never seeing yours finished.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Sammconn on April 21, 2019, 11:04:44 AM
I think the steps are ok in the fairer climates.
Everyone I know that HAD them hated them.
Between mud and ice or a combination of both they stuck down up or somewhere between.

So depending on your AO there is that tidbit.
When they worked they loved them.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 21, 2019, 07:33:03 PM
Bumper looks great, like to see the winch idea you have.

On the isolated battery, why not use a relay that works that energizes when the engine is running? Nothing to forget to switch on/off and maybe a little led showing it is charging?


Yea, not a bad idea JR, but I already purchased a BOS (Big ole switch) to handle the chores
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 21, 2019, 07:36:02 PM
I think the steps are ok in the fairer climates.
Everyone I know that HAD them hated them.
Between mud and ice or a combination of both they stuck down up or somewhere between.

So depending on your AO there is that tidbit.
When they worked they loved them.
Samm has a point. As for mine, been fine throughout the seasons, but we have far, far less snow/cold weather than he does. For a moderate zone 6 condition they are OK.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 21, 2019, 08:14:02 PM
Utah weather gums them up also.   I think a heated garage might solve some of that issue for me. 


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 21, 2019, 08:31:51 PM
OK gents, thanks for the advice. I read that a simple solenoid wired to the hot ignition will be a great solution, so I ordered one. Dirt cheap, Like $20 for a 80/150 amp unit. I'll stick that in there

Good idea...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on April 21, 2019, 08:48:52 PM
You talking a simple starter type solenoid? If so, they aren't designed for 100% duty cycle. The only solenoid designed for constant "on" is a latching solenoid, like motorhomes use.
Still be easier with an isolator.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: swbhobie16 on April 21, 2019, 09:26:37 PM
the issue with a latching solenoid (at least the one we used on the kaiser) is that it takes a 12V pulse to turn on, then a 12V pulse to turn off. so it can’t just be wired to the ignition.

i can however figure out the type used on the LS scouts my buddies built to turn their winch setups. (LED lighted switch inside to show use/not in use)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 21, 2019, 09:50:35 PM
Here it is from Amazon listing:

Mobile Audio Relay and Battery Isolator
Great for isolating a second batter making it dedicated to the stereo system
Does not create a voltage drop to the second battery like conventional isolators
80 Amps at 12V Continuous Power Handling
150 Amps Surge Power Handling
Handles 80-Amps Continuous and 150-Amp Surges
Durable Weatherproof Construction
For Switching Power Sources and Systems with Heavy Current Draw
Keeps Primary Starting Battery from being Drained
Does Not Create any Voltage Drop to the Secondary Battery
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 21, 2019, 09:51:33 PM
Boneheads!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on April 21, 2019, 11:07:01 PM

Well alrighty then
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 22, 2019, 10:46:18 PM
So more work on the electrical system, series 2.

But first, I bolted on the front wheels and set it down on its suspension for the first time. I think it's a bit taller than with the stock suspension. May even be noticeable...?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 22, 2019, 10:48:54 PM
But both wheels were severely toed outward.

So I adjusted the links all the way in and still had a toe-out condition.

.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 22, 2019, 10:50:52 PM
I ran into this with the D-max with these baseball bat tie rods. I had to cut a portion off the female end on that truck to make it all fit.

So I quickly removed the fat end and cut a about 5/8" off the thing and threaded it back on. That fixed the misalignment and allowed me to get it straight enough to think about a real alignment.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 22, 2019, 10:51:52 PM
I've had issues with the rubber failing in about a year, and although these are quality parts, I just chucked the rubber boots and installed some new poly boots
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 22, 2019, 10:52:34 PM
Bolted it all back up and I'd call that good enough
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 22, 2019, 10:53:57 PM
So, you may recognize the stainless steel battery box. It once held battery number two in SquareD.

But now it will become a part of Ravin8
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 22, 2019, 10:56:37 PM
Just forward of the rear axle location is a high and dry area where a 3.5" diameter steel tube crossmember crosses laterally

I grabbed an old 3-link bracket and cut that apart until I got a good base that would both fit the crossmember and provide for a flat to attach the battery box
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 22, 2019, 10:56:50 PM
Can’t wait to see this sitting next to your duramax see how much in size difference they have.   It looks really good sitting


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 22, 2019, 10:58:21 PM
Next I fashioned up a backing plate from some 1/4" steel, drilled holes and attached the battery box mount using 3.8" stainless hardware
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 22, 2019, 10:59:03 PM
Can’t wait to see this sitting next to your duramax see how much in size difference they have.   It looks really good sitting


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Won't be too much longer. Only need that rear axle
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 22, 2019, 11:00:17 PM
I made a few more adjustments to the base mount
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 22, 2019, 11:01:00 PM
Then tacked it into place after removing the undercoating from the crossmember
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 22, 2019, 11:02:55 PM
I didn't know it at the time, but I blocked off the upper shock bolt, so I'll have to trim off a bit of the upper portion to get the bolt out.

Backing plate assembly tacked into place and fitting nicely
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 22, 2019, 11:04:34 PM
Then I removed the stainless part, added a third mount, then welded all that in
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 22, 2019, 11:05:20 PM
I'm guessing a bit, but the driveshaft fits about where my hand is, which is quite a distance below the battery box, and offset to the outside
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 22, 2019, 11:06:53 PM
Are you still planing on replacing shocks with bilsteins


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 22, 2019, 11:07:37 PM
I noticed some of the inner fender well sticking out, so I trimmed all that on both sides to clean up that installation
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 22, 2019, 11:07:57 PM
Are you still planing on replacing shocks with bilsteins


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Fox 2.0
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 22, 2019, 11:10:38 PM
And that's where I ended the work today

Have to get the battery in so I can accurately run the cables and wires. Getting that battery into its mount is a logjam that once completed will allow me to forge ahead with everything electrical.

Oh and I ordered all the infotainment stuff today. Going to be pretty cool. CarPlay app in a pioneer head so that the unit itself or any cell phone can run things.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 22, 2019, 11:23:11 PM
Are you still planing on replacing shocks with bilsteins


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In case you haven’t bought or anyone else is in need I’m a radflo dealer now.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 22, 2019, 11:55:00 PM
Dang that looks good Don, are those 37's?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cj7ox on April 23, 2019, 03:06:25 AM
Dang that looks good Don, are those 37's?

x2! The burb's got a nice stance!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on April 23, 2019, 05:37:14 AM
Which headunit did you get? We got one that has that CarPlay feature as well, for the crew cab build.

Any word on the rear axle? Still waiting to get  on their table I’d guess...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: swbhobie16 on April 23, 2019, 07:07:21 AM
Which headunit did you get? We got one that has that CarPlay feature as well, for the crew cab build.

Any word on the rear axle? Still waiting to get  on their table I’d guess...

my table is now open.. hahaha
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 23, 2019, 08:26:07 AM
Dang that looks good Don, are those 37's?
35"
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 23, 2019, 09:05:29 AM
Clearance wise do you think you have more room for more bigger tires.  It looks like you didn’t do the inner fender mod yet which gets ya lots and lots of space


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 23, 2019, 09:20:34 AM
Which headunit did you get? We got one that has that CarPlay feature as well, for the crew cab build.

Any word on the rear axle? Still waiting to get  on their table I’d guess...
No word on axle

Components:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 23, 2019, 09:24:40 AM
Clearance wise do you think you have more room for more bigger tires.  It looks like you didn’t do the inner fender mod yet which gets ya lots and lots of space


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Well, I purchased the 35" tires way back around Christmas

Then some time later I purchased that mugo-axle

I then discovered the axle had 4.88's

Had i known I was going to run 4.88's I would have purchased 37's

When these wear out I'll likely purchase 37's

Because I'll need to cut down the rpm some and also because when I get back or maybe next winter, I'm going to turbocharge the thing up to 700-800 HP. It will have enough bottom end torque with that to pull any tire and still climb a tree.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: EL TATE on April 23, 2019, 12:03:05 PM
I made a few more adjustments to the base mount

I think Trevor would be tickled to see his brackets holding up a battery, lol
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 23, 2019, 03:21:17 PM
I made a few more adjustments to the base mount

I think Trevor would be tickled to see his brackets holding up a battery, lol
I think Beau sold them to me...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:31:34 AM
Before I post yesterdays work, I'd like to give a shout out to Tate Hudson of Randy's worldwide.

We had a little hiccup with the rear axle today. I called Tate to inform him and before I could call back, he had called Cincy Driveline and coordinated with them and solved the problem.

Having a good product gets you in the race. Having competent people like Tate wins it!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:32:40 AM
So a bunch of more stuff showed up today

I try and see what I can install every time this happens

I did manage to get some on, but mostly not
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:34:12 AM
I got in and finished welding in the battery box mount and the suspension/frame stuff

I learned that the heat of molten steel exceeds the ability of cotton to resist the heat

The first hole in the shirt was caused by fire. The rip from me moving out like a man on fire and snagging my shirt
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:36:31 AM
So I did some smoothing on the frame, then cleaned it thoroughly, then sprayed it
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:37:38 AM
After some dry time, I bolted up the base of the sliding battery box and lubed it up
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:38:44 AM
Then practicing my close grip bench, pressed the new battery up into its cozy home
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:40:21 AM
The tray has two positions, a lower, "Maintenance" position, and a upper position where it rides normally
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:41:00 AM
Then on with a new ground cable
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:41:44 AM
And some new positive 2 gage copper cable to connect to the front
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:43:26 AM
So, I didn't want the cable to chaff on anything, so I decided to just slide a stick of conduit up through the frame recesses, fasten that, then slip the new cable into that
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:44:51 AM
Then I heated that business up and bent it into the general shape of the frame rail. It did not bend pretty!

But the cable is WELL protected!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:45:45 AM
The infotainment system showed up from Crutchfield

It will have to wait to get installed...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:46:23 AM
A whole bunch of lights came in...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:47:46 AM
The light bar is like 200,000 lumens and will be a back up light.

Thought being the vehicle is backing in unfamiliar terrain at night, I want things well illuminated
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:50:32 AM
I assembled it with some longer than provided 5/16" bolts and drilled two holes into the aft roof rack support.

I may need to upgrade this 1" section to a 2" piece...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:52:39 AM
The porta-potty unit will work its way down through the crossbars of the cargo rack, so I decided to lay in a sheep of plywood to give it a floor, but leave the aft open for things I may want to have more depth.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:55:02 AM
I drilled a few holes through which to use some zip-ties to secure it, then waterproofed the bottom side

This plywood is OSB (Outside Board)

The brushable rubber stuff is really thick, brushes on like tar
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:56:40 AM
And that's about as far as I got yestertag!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:15:45 PM
That rubber coating cured very nicely:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:16:28 PM
So first thing I coated the opposite side
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:17:38 PM
Allowing that 6-7 hours to cure, i dusted some rubberized undercoating on top of the fresh rubber to add a little texture
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:18:38 PM
Then after some dry time I installed it into the cargo rack and zip-tied it securing it
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:21:53 PM
I picked up some lights for the bumper cutouts, but to my surprise, I could not get them in there. There is simply not enough space between the back of the bumper and the grill/radiator to slip the lights in. I'll have to remove the bumper if I want to mount the lights in there.

I may have to come with a plan "B"
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:24:24 PM
Back to wiring, I finished the fuse/switching panel

The wire from the main battery will attach to the open terminal on the solenoid, then a wire will connect to the bus end of the fuses and attach to the second battery
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:25:32 PM
With everything attached, I encapsulated the whole thing in liquid rubber
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:27:29 PM
I started getting a little crazy with the rubber stuff. The top of the center console is hard plastic and stuff does not stay there while bouncing around on the highway, so I masked it off and laid down a coating there as well
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:29:39 PM
Next I terminaled all the various cables to get them ready to attach
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:31:23 PM
Then created two new ground cables

One attaches to the engine cylinder head, the other to the body

Both will then attach to the fuse block to the single stud. I will then ground other things to it as well
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:33:39 PM
In the wiring game, you really have to sort out and mount the components first, the you can figure out how to run the wiring. Since all of it is sort of happening at the same time, I mounted the kicker sub woofer amp. THis thing is 150 watts and fit perfectly under the single seat in the back
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:35:20 PM
I then mounted the ground and started to lay out the wire to see how is best to run it.

Some will bo beneath the floor pan, but the majority should find a home just under the carpet
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:37:37 PM
So, the Driveline shop is currently working on the mutant axle and should be done tomorrow.

To get ready for its arrival back home. I cleaned and painted a lot of the rear suspension and rear axle related parts
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:39:12 PM
I threw a little paint on the exhaust pipe as well. I had previously painted it with a dull silver by mistake, so I corrected that.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 25, 2019, 10:40:52 PM
It may not look like much but that was 8 solid hours of work!

But I also had to install a new mirror onto C-Max, since I managed to crack the old one backing into an immovable object
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on April 25, 2019, 10:55:54 PM
I have that same subwoofer in the sissy denali gasser I have.  It compliments the Bose system nicely.  not nearly as clear and bright as the Mark Levinson system in the wifes suv, but pretty nice.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on April 25, 2019, 11:49:04 PM
Back to wiring, I finished the fuse/switching panel

The wire from the main battery will attach to the open terminal on the solenoid, then a wire will connect to the bus end of the fuses and attach to the second battery

I know you’re fond of wood tables for welding and all but am I the only one raising an eye brow at this wooden rubber covered mount? I realize it’s a long shot but it something shorts out and that gets hot you don’t think a fire with extra kindling might be a concern?  :huh:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 25, 2019, 11:55:52 PM
Oh come on now.... I have never seen a zip tie in the sun last a year. 


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 26, 2019, 11:01:00 AM
Back to wiring, I finished the fuse/switching panel

The wire from the main battery will attach to the open terminal on the solenoid, then a wire will connect to the bus end of the fuses and attach to the second battery

I know you’re fond of wood tables for welding and all but am I the only one raising an eye brow at this wooden rubber covered mount? I realize it’s a long shot but it something shorts out and that gets hot you don’t think a fire with extra kindling might be a concern?  :huh:
Man that would make for a great YouTube vid!

Burb driving down the road, occupants obvious to the roof on fire!

Cool!

Edit: Just figured out, you were talking about the fuse panel. I was thinkin' the roof rack plywood...

Yea, I guess It could catch fire, but all that plastic normally used in the engine compartment is combustible as well ...

Oh and the gasoline, that's combustible

Ooh, and the various oils, they burn

What about the anti-freeze, that burn? Naw, probably not, so I'll give ya that one

But the insulation on all those wires...What is that stuff? Not fireproof, me is thinkin'

Knucklehead!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 26, 2019, 11:01:46 AM
Oh come on now.... I have never seen a zip tie in the sun last a year. 


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I'll have to put some stuff on top to shield them from the deadly solar rays...

Bonehead!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 27, 2019, 12:03:24 AM
The mutant axle is finished

Got a call from them today reporting it is alive and well and they even got a good pattern ou the gears.

Larry over there said there was a lot of unusual custom work done on that thing and will show me what he found when i show to pick it up.

The KBS paint goobered up, so I had to sand (grind) most of it off and start new. It was raining yesterday when I painted it, and in the past when I have painted in the rain, it rose up and gave the same reaction. Repainting the parts during today's sunshine seems to have healed the old wounds
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 27, 2019, 12:04:02 AM
With the fuse block dried, I mounted it
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 27, 2019, 12:05:21 AM
Then connected the main cables. Note that the either side of the cable is not currently (get it: Current-ly) connected to a battery.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 27, 2019, 12:06:46 AM
I thought I'd get the relay to the overhead lights wired in, so in a jiffy, I had that done, except for running the hot supply cable to the actual lights
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 27, 2019, 12:11:24 AM
The small LED cubes on the overhead were replaced with two HIDs which were purchased for the bumper
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 27, 2019, 12:12:16 AM
That rubber stuff did a good job of creating a no slip surface for the console
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 27, 2019, 12:14:09 AM
I needed a good spot to bring wiring in from the front of the vehicle.

To do so. I punched a 1.25" hole in the floorboard, then sealed around the edges with a grommet and some RTV
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 27, 2019, 12:15:53 AM
I then traced down the trigger wires for the folding steps on the passenger side and wired in the supplied diodes. Afterward I retapped the harness
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 27, 2019, 12:16:36 AM
And now those steps work as advertised
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 27, 2019, 12:18:06 AM
It took a bit of searching but I discovered the switched hot wire to splice into which now also powers the second battery solenoid connector
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 27, 2019, 12:19:03 AM
The tailpipe turned out looking like glass. Bad pic, but beautiful paint effect on that pipe
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 27, 2019, 12:20:41 AM
So the plan is to bring in a power lead from the back battery side of things to a position beneath the console. I hope to mount a fuse panel, and the stereo amplifier in there and run the wiring beneath the front passenger carpet in the footwell.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 27, 2019, 02:15:20 AM
Good progress, I want to see that rear!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 27, 2019, 03:33:23 PM
Good progress, I want to see that rear!
Axle...You want to see that AXLE!!!

Bonehead...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: longball on April 27, 2019, 09:48:19 PM
He’s been in California a long time Chief.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on April 28, 2019, 03:09:11 AM
Jez, a little slang and you guys go nuts.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 28, 2019, 01:03:51 PM
He’s been in California a long time Chief.


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Copy!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 28, 2019, 01:04:28 PM
Jez, a little slang and you guys go nuts.
;-)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 28, 2019, 01:08:02 PM
So looking at the tracking, when I ordered that 270 degree sunshade thing, it originated in the China. Took a couple daze to get to Shanghai, then over to the Alaska, then all over the place down to Louisville then out to a station near me. I should have it in the morrow.
Good thing as part of the day will be wasted while I go to pick up mutant axle.

Come home, unload axle, (as Norm sez) Toss on the sunshade, then maybe scoot MA under the springs and start boltin' it all up...YIPPEE!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 28, 2019, 02:05:26 PM
What’s the punch list loot like now? Axle install, tent, sun shade, fluids
Drive line?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on April 28, 2019, 07:20:09 PM
What’s the punch list loot like now? Axle install, tent, sun shade, fluids
Drive line?


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Add to that infotainment, alignment, sorting/troubleshooting and its done...for now
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on April 28, 2019, 07:43:22 PM
What’s the punch list loot like now? Axle install, tent, sun shade, fluids
Drive line?


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You calling Don a thief? Pretty sure he aquired all those parts legally.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on April 28, 2019, 08:20:12 PM
What’s the punch list loot like now? Axle install, tent, sun shade, fluids
Drive line?


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You calling Don a thief? Pretty sure he aquired all those parts legally.
Oh please. 


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cj7ox on April 30, 2019, 09:03:48 AM
What’s the punch list loot like now? Axle install, tent, sun shade, fluids
Drive line?


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You calling Don a thief? Pretty sure he aquired all those parts legally.

LOL!  :facepalm: :beercheers:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 09:48:59 AM
So, picked up the axle this morning, and decided to add some fresh mulch to the gears while off loading it! Should quiet things down a little bit
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 09:50:48 AM
The gears patterned out well and the backlash is set at .012"

Note the nice Forged Steel caps. These are not stock. Dana creates cast steel caps, but someone decided these needed forged steel

Randy's Yukon brand limited slip carrier is looking right at home!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 09:55:08 AM
And a certain member of this august group provided one of his quality (Over the top) diff covers to tighten things up and keep it all squared away in the rocky stuff.

He also sent a stud kit to secure the cover where it belongs.

Great Lakes Offroad kills it yet again. Heck his diff covers have been on every build I have done in the past ten years!
(Thanks Shawn!)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 09:56:19 AM
His decals now say KMI along with Great Lakes OffRoad. Perhaps he can take a minute to explain...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 09:57:39 AM
I installed the stud kit which has the coarse threads on the axle end and finishes with nice fine threads to secure the cover
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 09:58:38 AM
After two coats of the KBS silver epoxy:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 10:00:01 AM
Not installed here, rather just slid down over the studs to keep bugs out from nesting in the mulch

I need to do a tad bit more painting on the gasket surface
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 10:01:08 AM
Here is the sway bar crossmember painted and installed
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 10:04:27 AM
And then I ran into a snag

Somehow the U-Bolts came up missing...as in gone!

I suspect the boys tossed them in the trash which was already collected because no amount of searching produced any result whatsoever. We even uncovered Jimmy Hoffa's shoe, but no U-bolts!

So no wasting of time if you may, So I grabbed the freshly arrived awning and decided to "toss" it up there.

Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 10:05:31 AM
First up, measuring it told me the CB antenna needed to move forward to clear the required 100"
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 10:06:13 AM
So that got done
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 10:07:58 AM
Nice working with that 80/20 stuff. Just loosen and reposition

Unzipping the cover reveals the stuff inside
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 10:09:34 AM
The manner of attachment is via another extruded aluminum section which captures the hex head of a 5/16" SAE bolt nicely, but the original metric stuff a little better.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 10:11:39 AM
I used the supplied two "L" brackets along with a few sections of aluminum Angle to secure it to the 80/20 rail
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 10:16:42 AM
So I was "Finishing" this last night when the chicken was showing up, so it remained installed in the current configuration, however, there was some interference issues with opening and closing the door, so I'll have to flip it upward to clear.

As you unzip the bag, the actual awning is exposed, secured by three straps. Releasing them allows the panels to drape. Following that you simply walk the poles, four each, around until the thing is open. I did that, but could not fully open the cover because of clearance issues with the garage door.

I did see that the hub was flexing far too much and will need to be solidly supported and the height of the vehicle will require additional length be added to the expanding poles
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 01, 2019, 10:55:13 AM
Bummer on the bolts.

Doesn't the tent flip out this same side?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 01, 2019, 10:58:44 AM
His decals now say KMI along with Great Lakes OffRoad. Perhaps he can take a minute to explain...

You’re welcome Don, that cover also has an integrated drain machined into it by the way. Need to make sure you put some thread sealant on the pipe plug.

So the KMI, long story short is the parent company of greatlakeoffroad.com.

I sold Great Lake Off Road LLC in Jan of 15, that guy ran that company into the ground after 13 successful years by Tonya and I running it. During the reacquisition process I hired an attorney who deals in business transactions and bankruptcy to write the contract to purchase the GLO assets (what little remained) back. In business and law by my basic understanding there are degrees of separation. Having my new company KMI make the purchase of those assets was one degree of separation. I won’t bore you with the rest but the more degrees the better I am protected from their delinquency.

I could have bought the assets and started a new brand out of the ashes. However, reflecting back now I guess my ego wouldn’t allow that so here we find ourselves.  :wink:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 01, 2019, 11:43:40 AM
You didn’t paint it that tractor orange?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 02:09:10 PM
Bummer on the bolts.

Doesn't the tent flip out this same side?
No, tent goes the other way
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on May 01, 2019, 02:18:35 PM
Everyone knows suspension parts are higher performing when painted red....


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 01, 2019, 05:48:54 PM
And here I thought the red was only for braking components....
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 01, 2019, 06:13:07 PM
 :rolleyes:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on May 01, 2019, 10:32:57 PM
Wait, so now I’m confused, I thought it was red cars that went fastest... but now you’re telling me it’s red suspension that compress and extends best?

Or red stoppers that slow the best???

Sounds as if ALL THINGS on a vehicle should be red!

Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 10:54:00 PM
Are we done???

Ok, continuing...

I went over to the local truck repair shop. For those who don't know, truck repair stations will bend new U-bolts from stock of various lengths. This time they used some really good looking grade 8 material and fashioned the new hardware.

I coated them with the cosmoline based preservative.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 10:55:05 PM
Axle in and hanging!

Finally!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 10:55:38 PM
Panhard bar bolted in
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 10:56:45 PM
I bolted it up with the axle jacked up until it lifted the truck.

Pics show it compressed and hanging
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 10:57:57 PM
Lube locker gasket is rubber encased steel with a full perimeter seal of a raised material. Quality gaskets!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 10:59:38 PM
I decided to just paint the flange.

After drying, I "tossed" on the LL gasket.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 11:00:35 PM
I placed a magnet onto the cover double securing it with some RTV along with sticky magnetism!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 11:01:25 PM
Cover fit perfectly...Looks good too!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 01, 2019, 11:02:28 PM
I hung the sway bar, but before permanizing it, I'll need to find some bine thread bolts to bolt up to the arms
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: longball on May 01, 2019, 11:56:57 PM
Axle in and hanging!

Finally!
This may be a dumb question but I’m gonna ask it anyway. With the u-bolt flipped, is there any chance of those nuts backing off and causing trouble on a remote trail somewhere? With the exception of welding tables everything you build looks heck for stout has built in fail safes. I guess my real question is, for Murphy’s sake, would another nut torqued down on top of those u-bolts hurt anything?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 02, 2019, 12:41:58 AM
I never had torqued U bolts come loose. Plus you need to retorque a few mile later, could add lock tight them.

Good to see it on there. Hope that posi is nice, I got one from Tate today for the DMax.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 02, 2019, 07:47:40 AM
Axle in and hanging!

Finally!
This may be a dumb question but I’m gonna ask it anyway. With the u-bolt flipped, is there any chance of those nuts backing off and causing trouble on a remote trail somewhere? With the exception of welding tables everything you build looks heck for stout has built in fail safes. I guess my real question is, for Murphy’s sake, would another nut torqued down on top of those u-bolts hurt anything?


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No, that is not necessary at all.
Thinking about it, with the "U" bolts in a factory configuration with the nuts and threaded end hanging down and banging into things and reducing your ability to clear obstacles, the factory configuration would be more prone to that kind of disaster.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on May 02, 2019, 10:04:38 AM
Since u bolts aren’t supposed to be reused it couldn’t hurt to put a little tack weld on them


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 02, 2019, 10:40:35 AM
Since u bolts aren’t supposed to be reused it couldn’t hurt to put a little tack weld on them


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I think I've stated this before but the trick on reusing u-bolts is to have them made in course threads. The fine threads are more susceptible to stretch and distortion. I have a friend who sells truck tractor stacking equipment and they use all course thread u-bolts on that equipment and reuse them over and over again.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 02, 2019, 11:55:52 AM
And to add to Shawn's commentary

I saw stretchin' happenin' all over that bolt when I put the electric "twister" on those nutz.

And

Talking to Tater just now, I have a disconnect on my axles fitting

Stock 14 bolt chevy axles are 30 spline 1.5" diameter

Mutant axle axles are 35 spline 1.5"

I have installed a 35 spline Yukon Duragrip

The mutant axles were made to fit the mutant sized hubs with a 5" diameter "hub"

Stock Chevy 14 bolt hubs are 4.482" in diameter

So, my mutant axles are going to have to have their hubs cut down and redrilled to work

Another hurtle!
Title: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on May 02, 2019, 12:01:37 PM
At least when you swap an LB7 in there you won’t have to redo the rear.....

So do the wheels fit over that hub?



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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 02, 2019, 12:10:43 PM
And to add to Shawn's commentary

I saw stretchin' happenin' all over that bolt when I put the electric "twister" on those nutz.

And

Talking to Tater just now, I have a disconnect on my axles fitting

Stock 14 bolt chevy axles are 30 spline 1.5" diameter

Mutant axle axles are 35 spline 1.5"

I have installed a 35 spline Yukon Duragrip

The mutant axles were made to fit the mutant sized hubs with a 5" diameter "hub"

Stock Chevy 14 bolt hubs are 4.482" in diameter

So, my mutant axles are going to have to have their hubs cut down and redrilled to work

Another hurtle!

Stan or Brandon at Branik..... or upgrade to their 300M double ended & splined setup  :shocked:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 03, 2019, 08:52:10 AM
At least when you swap an LB7 in there you won’t have to redo the rear.....

So do the wheels fit over that hub?



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They fit over both hubs, but not over the huge studs in the militarized stuff. And the geometry of the mugo stuff is all wrong
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 03, 2019, 08:54:31 AM
I'm off to Cincinnati driveline this morning to try and figure out these axles and driveshaft. You'll see about that in a little bit.

But

With springtime, the explosive growth of nature is slowing down things. Lawn care, and now maintenance on the Scag mower and concerts and birthdays and...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 03, 2019, 08:55:32 AM
So first up, I created the lower links of the sway bar from sections of the old stuff that once had a different end on it
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 03, 2019, 08:56:58 AM
Using a forstner bit, I drilled out the end link bushings to 9/16" and assembled the sway bar links to the frame, then to the bar and tightened all that business in place
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 03, 2019, 08:59:36 AM
Shocks next. First install the bushings, then bolt them inplace

But

They are too long

Having moved the shock mounts to a ground clearance friendly spot took away inches which these particular shocks badly need.

Guess who is buying two new Fox shocks???
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 03, 2019, 09:01:06 AM
I performed some maintenance on the parking brake system. Had those things working as smooth as warm butter.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 03, 2019, 09:02:18 AM
Yep, driveshaft is too long...Leaving for the driveshaft shop in 30 min...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 03, 2019, 09:03:05 AM
Air bags are in!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 03, 2019, 09:04:20 AM
Worked until 2100, then threw the other towel in. (First one caught fire while welding the bolts near it)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on May 03, 2019, 09:40:11 AM
Great progress! That sure is a good lookin rig.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on May 03, 2019, 11:52:32 AM
Don, what are the specs on the shocks? Wonder if they’d fit my truck?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 03, 2019, 12:59:18 PM
Don, what are the specs on the shocks? Wonder if they’d fit my truck?


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Ryan, They are the shocks supplied by BDS for their 7" lift for my year Suburban. Need a part numba?
If your truck is lifted more than 4", they would likely work, but if stock height, no way.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 03, 2019, 01:03:18 PM
Driveshaft is dropped off at Cincinnati Drivelines and will be completed in a few days.

We looked at the axles and they ended sending me to chat with Charlie, a Biker guy who owns a machine shop. He was a pretty cool fella, and as we warmed up to the prospect of him machining the things he started measuring and testing hardness with a file and thinking out loud.

He told me to get him a hub, (which I did not bring along) and he would take a stab at it.

They will end up having 16 holes drilled into the flange, but given the strength inherent in the design and in this particular product, we should be fine.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: longball on May 03, 2019, 02:49:21 PM
Co-worker of mine has a 6.5” BDS lift on a Duramax. If they don’t fit for Ryan you can pm me a price and I’ll see if he wants them. He was talking about replacing shocks last week.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 03, 2019, 04:46:57 PM
Co-worker of mine has a 6.5” BDS lift on a Duramax. If they don’t fit for Ryan you can pm me a price and I’ll see if he wants them. He was talking about replacing shocks last week.


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Wow! How fortunate for me!
I think I paid $125 ea for them, maybe $100 ea since they're new. If anyone really needs them, I'll work with ya...Not focused on the money...But I do have to order another set now :-(

Another subject: I cleaned up the driveshaft really well then took it to the driveline shop where the manager commented on just how clean and rust free it was (And it is!). It had a tag on it showing a proud Chinese company had given birth to the thing. He said, yea, those guys paint the driveshaft whereas Dana leaves the shafts plain steel and allows them to rust.

Don't know about you, but I think I like the Chinaman's way of building a little better than the Dana philosophy.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 03, 2019, 05:11:13 PM
No time remaining to get in to getting my hands dirty on Ravin8. Concert tonight with one of the prerangers playin' the guitar. Heck both of them do, and the smallest one sings and plays (Where is this comin' from??)

Gotta do DD (Dad Duty) and get him there early which means I can't show up looking like a chimney sweep on overtime.

Gooder news is I struck a deal with my son in law. He gets to borrow the zero turn anytime he needs it. In exchange, he pulls the maintenance on it! Last two days, he pull dismantled, cleaned and reinstalled the carb. Pulled both air filters and blew them out. Swapped out the fuel filter. Sharpened all three blades. Greased the movin' parts. Cleaned all the grass caked underneath the deck. Cleaned up the top side. Installed new spark plugs and overall has it running like it was new again.

I figure the thing has like 360 hours on it. Those Scag mowers with the big block engine (Mine) last a couple thousand. With that kind of lifespan and the little bit we use it, it should serve both of us for many years and still not be taxed.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 03, 2019, 05:50:49 PM
Great work so far,you won't hurt those hubs.

Bet they didn't get the singing from you, I can't sing either.

Think I going to put a CV on my front shaft, no spacer. They don't drive over 45 too.

Isn't that a lot  of grease on those breaks? Get warm and drip?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on May 03, 2019, 07:42:37 PM
Looks great Cap'n! ;)
Title: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on May 03, 2019, 08:30:12 PM
Don, what are the specs on the shocks? Wonder if they’d fit my truck?


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Ryan, They are the shocks supplied by BDS for their 7" lift for my year Suburban. Need a part numba?
If your truck is lifted more than 4", they would likely work, but if stock height, no way.

Oh yeah, those would be way too much. I want a lift, but seeing as I have a 1-ton, the back is already pretty high so I just want about a 4” to bring the front up level, leaving the rear at or slightly higher than it is now.

So that’s a pass for me - longball you’re up!


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on May 03, 2019, 10:34:17 PM
Chief. I’ll take second position after longball


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: longball on May 04, 2019, 08:44:21 AM
Go ahead Tex. My buddy already bought a set.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 04, 2019, 09:04:30 AM
OK, all that's fine, the shocks will take up a hangin' position somewhere in the shop where they will get in my way, so no worries

And on shocks...Wouldn't normally mention this, but my record of getting shocks shipped to a new owner is not stellar. So regarding the shocks that came off or SquareD. I decided to give them to a member here. we talked and I shipped those shocks out in the very boxes that the Fox shocks had just arrived in. I just shipped them snail mail because I was saving a dime. On that day I also sent Tex some greasy parts and some stuff to Norm.

Well Norm said the box was all buggered up, I think Tex got his stuff all well and good, but those shocks??? They never arrived. I waited a bit too long to do a trace with a shipping label that I tossed in the trash the next moment after it was given to me. So, yea, even properly packaged shocks are a so-so coming out of my post office it would seem.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 04, 2019, 09:27:14 AM
Don, not complaining but when you retire GLO won’t be hiring & putting you in charge of packaging / shipping. That box I got the other day appeared to have been in combat and dropped out of one of them aircraft you used to fly on final approach. After examining it I have a present to send along with you when you visit the shop this summer.....  :tongue:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 07:51:28 PM
Don, not complaining but when you retire GLO won’t be hiring & putting you in charge of packaging / shipping. That box I got the other day appeared to have been in combat and dropped out of one of them aircraft you used to fly on final approach. After examining it I have a present to send along with you when you visit the shop this summer.....  :tongue:
Hmmm. Needin' some trainin' hugh?

You can't teach an old warrant officer new tricks ya know. He won't show up for training, wouldn't pay attention if he did, and seem to only be interested in the always present quoffee cup he constantly regarded (In lieu of everything you were teachin')
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 07:53:44 PM
Doing some punchout to roll into the day, a dreary/rainy one

Added three quarts and some friction modifier to the mutant diff. More to come, just wanted to immerse and coat everything waiting on the axles
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 07:56:37 PM
BTW, I had planned to build up the hubs, installing bearing races, but I guess I didn't order the larger bearings. Or maybe I did, and they went to the same place as "T's" shocks. So instead of losing any time I immediately got on some punch-out items.

Next up, I relocated the fold-out awning to a high mount position which immediately got the thing out of the way of the doors and body
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 07:58:32 PM
Testing it out last time, I could see that the corner supporting the four "Arms" was way to flimsy, so I reinforced it with aluminum angle and affixed a brace to the rack system
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 07:59:16 PM
And, yes it all clears the hatch
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 05, 2019, 08:01:27 PM
 :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 08:06:03 PM
I gathered up all the stuff that the roof rack is supposed to carry and arranged it up there.

That includes:
2 ea folding chairs
1 ea, folding "Basket" chair
Folding commode
Folding dinner table
Shower tent

Then I stretched a grid pattern of bungee straps over the pile of stuff, then tied them together with zip-ties.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 08:07:47 PM
Then I finalized the air bag air line, "T"ing the two sides together for now.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 08:09:01 PM
Just waiting for a tent...It's sitting in the next garage.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 08:11:19 PM
So time to try and fit a winch into my winch bumper

First thing I rotated the free wheeling release once more to the top position
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 08:16:46 PM
There isn't enough room up there for much,so I got creative with creating space. Bottom line is I NEED a winch and the bumper/radiator/frame clearance is insufficient.

I started by hoisting the winch up and seeing what interfered and did something about that, then repeated the process many times.

First up this frame bracketry was made to fit the factory bumper and is not used any more, so I removed it
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 08:19:06 PM
With each evolution, the winch moved up a bit, gathered a couple more scratches and caused the removal of something else
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 08:20:26 PM
Removal or adjustment of the things previously shown in red got me this far:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 08:22:19 PM
Finally I completely removed the studs that Brian had welded in there to mount his winch plate to, and that paid dividends
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 08:24:50 PM
Because the bumper is built so close to the body, everything on the radiator like the transmission cooler is now an interference issue. So I moved hoses, nudged hard lines and spoke in tongue and got a bit more
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 08:27:25 PM
I'll be using the plate (I think) that Brian supplied, but since its only 7 gage, I'll be reinforcing it.

So the plan is to get the winch as far up in there as I can get it, then build the mount into the frame and connecting it to the bumper. Then cut out part of the inside of the bumper which will rub and cot the winch line and with all that I just may have saved this thing.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 08:29:18 PM
To start the mount, I wanted to catch two bolts in the frame that are actual bumper mounts. To do so, I fashioned up this crossbar out of thick DOM, sleeved at the ends.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 08:30:04 PM
Here it is hanging from the bolts and tacked together
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 08:31:20 PM
There wasn't even enough room up there for the big clunky hook, so I chopped it off and will use a bobbin instead
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 08:33:00 PM
Jacked the winch up in there once again and checked. I'll need to suspend the winch from a couple of straps, then slide the initial mount beneath the winch plate and see what I'm looking at.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 05, 2019, 08:34:29 PM
First thing up tomorrow will be getting the axles and a hub over to Charlie's machine shop to get that going, then back to this. I would like to wrap this up by COB tomorrow to try and stay on schedule.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cruizng on May 06, 2019, 08:13:11 AM
Don, You mentioned leaving in May a while back. When do you plan to head out? Are we going to have  a NORAD like Santa Claus tracking enabled?   :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 06, 2019, 08:24:12 AM
Don, You mentioned leaving in May a while back. When do you plan to head out? Are we going to have  a NORAD like Santa Claus tracking enabled?   :popcorn:
Shooting for the end of the month.
I'll stay in touch
I should have an "Adventure Blog" going by then. Have some plans to expand the scope and breath of the Real-Man thing, but for now all that is still close hold pending some more work...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:22:06 AM
A couple of straps supports the theng, now hanging while I work on the underside
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:23:51 AM
So first of all I unbolted the BDS bash plate and realigned it to now mount to the lower winch crossmember

I tacked on a couple angle tabs through which to bolt to the plate
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:25:03 AM
Then set a section of 1" X 3" between the lower winch plate and the cross member
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:26:17 AM
Then I tied in the old bash plate crossmember to the new mount
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:28:44 AM
Next I stiffened up the winch plate and added forward bumper mount supports
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:32:41 AM
The two bumper mounts will use 4 ea. 3/8" bolts

This structure ties in the front suspension crossmember to the lower radiator crossmember to the new crossmember catching both frame rails all to the front bumper. The mount ties all that together and bolts in at eight different places. I don't know and will not know until having done some testing, but I think that will do.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:33:54 AM
Then it was removed, disassembled and welded up
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:35:23 AM
I removed the remainder of the scale then chemically cleaned it before applying a coat of that KBS black chassis paint
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:36:32 AM
The truck has become heavily damaged by dust

I am hoping a simple blowing it off with an air gun will restore it, but I'm not sure... ;-)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 07, 2019, 08:38:23 AM
What is the total weight of this little addition. That thing looks small in photo but maybe not in actuality?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 09:05:25 AM
What is the total weight of this little addition. That thing looks small in photo but maybe not in actuality?


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Surprisingly light, maybe 20-25 pounds
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on May 07, 2019, 10:23:51 AM
Looks like a solid winch plate! Should do the job well.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on May 07, 2019, 11:07:19 AM
Guess I won't be a camp host in Idaho for you if you're leaving that late. I'm leaving next Friday.

I would rethink teeing those air springs together. Your anti-roll bar will be working overtime.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 07, 2019, 12:06:34 PM
I think we should find a spot to hang the burb from the winch one complete


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 12:20:01 PM
I think we should find a spot to hang the burb from the winch one complete


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Should lift it with ease. 13K winch, 7K ish Burb
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 12:22:23 PM
Guess I won't be a camp host in Idaho for you if you're leaving that late. I'm leaving next Friday.

I would rethink teeing those air springs together. Your anti-roll bar will be working overtime.
Well, I could redo pretty easily I suppose

Have had my Silverado airbags "T'd" for a couple years now. But it never had a rear sway bar. Come to think of it, neither did this 2500 burb.

Unlike Shawn, I tend to listen when Ken speaks. (Creatin' mischief right there) ;-)

Others??
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 07, 2019, 12:28:14 PM
This is interesting being we know Kens affiliation with H. So you’re sliding liberal in your old age now huh?  :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:29:53 PM
This is interesting being we know Kens affiliation with H. So you’re sliding liberal in your old age now huh?  :popcorn:
No idea what you just said, so I'll just move on...

The mount dried and I bolted it to the winch
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:33:08 PM
That whole assembly doesn't weigh as much as you may think. I didn't weigh it, but I was moving it around pretty easily.

Before mounting the winch in the bumper, I had to cut some ribbing out of the front of the thing. Without removing this rib, the rope would ride up and over the ridge pinching it. I guess there was a whole different thought about how that was all going to work, but no matter, it's gone now.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:34:59 PM
The bash plate was held in place from the factory with a self tapping 15mm head bolt. I did not like that, so I through drilled the cross member and ran a 3/8" bolt from the top to the bottom. This will bolt to the mount when installed
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:36:37 PM
With some wiggling, the mount/winch combo slid right into place and I bolted it in securely
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:37:53 PM
Have to get that radio mounted!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:39:21 PM
The bobbin goes on super easy and makes for a pretty clean front end
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:40:53 PM
The cable access is perfect, somewhat shielded, but easy to get to quickly
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:42:28 PM
I have a problem I need to chase down. The battery keeps going dead, and it was new just a little while ago.

The battery charger cannot pump in more that 63% charge

I don't know what's causing this...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:44:12 PM
So since I lifted the truck, when I deploy the awning, the poles are too short. So, I lengthened them 6.5" and created a carrying tube to store them in along with a couple of other things
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 07, 2019, 08:47:05 PM
The sleeves, 1" PVC pipe is slid well up on the aluminum tube then affixed to the tube with a single #10 screw and lock not.

The tube will get a mount and painted and I'll add a lanyard to the cap. I think it will mount about where you see it. I have some temporary clamps holding it there for now
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on May 07, 2019, 09:09:42 PM
I have to disagree with Ken. There is not enough cross section in that little fill line to transfer air from one bag to the other fast enough to change spring rate on each side. That is unless you are taking the long left hand sweeping turn at Sebring or Road America at high sustained speed...nah. Thought not.

Proof point. My dually had a custom air manifold with remote control Fed from the main air tank and tees to both bags. Had more than 5,000 lbs in the bed on many occasions. No sway bar. No problem.

You should be GTG


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on May 07, 2019, 10:28:20 PM
Charles, try not to compare your 1 ton with a 18k gvw rear end to a top heavy burb, that will take a few mountainous sweeping turns on his trip, but with the bar, probably wouldn't notice...almost as good as having 2 extra tires.

 Standing firm, maybe slightly hunched over,  on this one.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 07, 2019, 10:42:07 PM
Ken, Charles, what the heck are you two arguing about exactly? The air line to the bags has X pressure. If it’s enough pressure (more than the leaves) then the spring rate won’t allow body roll. The axle can’t shift side to side due to the track bar. Anti roll bar really isn’t a factor, more overkill....

Even with the high center of gravity & weight I don’t see an issue. The reality is the front corners will squat and become a steering issue before a rear tire lifts and induces a roll. Driving speed will be dictated by front end stability not the rear.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 07, 2019, 10:53:11 PM
Did you buy those gussets? Sure are clean. Thinking about continuing the skid all the way to the front bumper?

Come on guys, 8K, 6 inch lift, monster bumpers, lots of drag up top and Dons driving. What could go wrong?

 :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on May 08, 2019, 06:31:53 AM
Shawn, ever squeeze a balloon?  Two bags connects by a line. Cornering would exert pressure on one bag and compress it little squeezing a balloon.

Ken asserts, ( not arguing) that it will induce instability.  I assert that the small long air line won’t allow the transfer of air rapidly enough to make it make a difference


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 08, 2019, 07:39:23 AM
I don’t agree with Ken, no surprise there..... :tongue:

But I don’t agree with you either really. Put enough air in them to keep the ride stabilized and move on.  :knucklehead:  :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 08, 2019, 08:35:57 AM
Knowing something of fluid dynamics, the size of the air line is an inhibiting factor given the volume of the bags and consequently, the amount of air that would need to transfer and the time it would have to do so...Juxtaposed around the inherent anti-roll characteristics of this particular suspension configuration.

Ultimately, Ken's configuration would be best, but by a teeny-weeny amount. The bigger and more overriding concern would be getting the pressure correct in each bag. Having had the independently plumbed bags in the past, I have found it difficult to get both bags equal, although perhaps a tad bit more pressure in the left bag might be beneficial (Considering the weight of the fuel tank and my big carcass).

So, I'll leave it be for now, since I have big, smokin hot issues to contend with before I launch, and this is more of an ankle biter.

So my judgement is to award both Ken and Tex a gold star for engaging in a logical and intelligent conversation.

JR gets a pass (With a C-)

and
To demote Shawn (again) for causin' strife and discord on my website!

So let it be written, so let it be done ;-)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on May 08, 2019, 08:57:04 AM
….
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 08, 2019, 11:03:20 AM
C- ?, was its the Dons driving :cool:

When will it be on its wheels?

Nate, is it always about food!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cudakidd53 on May 08, 2019, 12:54:11 PM
I don’t agree with Ken, no surprise there..... :tongue:

But I don’t agree with you either really. Put enough air in them to keep the ride stabilized and move on.  :knucklehead:  :popcorn:

OK - the fact that there's a compression on one side and a lift on the other, the compression will squeeze the air to the other, non- compressed side, then when one of them pops the whole thing deflates and Don heads for the ditch on that side of the road, ass end first rolling on top of the TacTopper2 and trapping the Pre-ranger sleeping in the back under spare parts, tools and a heavy wooden drawer unit.  I'd go with isolated fill lines......even if Hillary is Ken's girlfriend......consider the "Rule of Don" who's known to roll 4x4 vehicles on tank courses, injure oneself using too much throttle on a motorcycle and injure himself do to candy bar wrapper fires.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cudakidd53 on May 08, 2019, 12:58:03 PM
I have a problem I need to chase down. The battery keeps going dead, and it was new just a little while ago.

The battery charger cannot pump in more that 63% charge

I don't know what's causing this...

I vote leaking from your aux battery isolation get-up - don't know how or why, but that's my vote......
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 08, 2019, 01:33:36 PM
Here’s another thought, maybe Don should drive within limits of suspension.  :rolleyes:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: EL TATE on May 08, 2019, 02:23:14 PM
I have a problem I need to chase down. The battery keeps going dead, and it was new just a little while ago.

The battery charger cannot pump in more that 63% charge

I don't know what's causing this...

I vote leaking from your aux battery isolation get-up - don't know how or why, but that's my vote......

Not picking on you Chief, but I agree. is the isolation config grounded well? is the batter disconnected from the vehicle with the charger connected? isolate the battery from the truck and charge it. if it still won't go further than mid 60's then you know what's up. if it charges, you've got a steady drain somewhere.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on May 08, 2019, 03:45:12 PM
Here’s another thought, maybe Don should drive within limits of suspension.  :rolleyes:

 :facepalm: That has to be the funniest thing you've ever said. You remember who Don is, right?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 08, 2019, 04:35:29 PM
Here’s another thought, maybe Don should drive within limits of suspension.  :rolleyes:

 :facepalm: That has to be the funniest thing you've ever said. You remember who Don is, right?

Well, at least while he’s on asphalt!  :facepalm:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 08, 2019, 04:38:57 PM
https://www.instagram.com/p/BxNh79jhqSY/?utm_source=ig_share_sheet&igshid=c4qkvbfbivg2
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on May 08, 2019, 04:46:57 PM
Nate, is it always about food!

that's just a bigger version of this one... :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 08, 2019, 04:54:43 PM
Here’s another thought, maybe Don should drive within limits of suspension.  :rolleyes:

Oh, I think the suspension will handle it just fine. Even with deep mulch beds.

I also think the airbags are a moot point with as little that will transfer unless it a LONG turn and the sway bar helps that too.

Nate, we are the BIGGER versions,,,,,
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on May 08, 2019, 07:01:09 PM
Nate, we are the BIGGER versions,,,,,

 :beercheers:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 08, 2019, 08:16:28 PM
I have a problem I need to chase down. The battery keeps going dead, and it was new just a little while ago.

The battery charger cannot pump in more that 63% charge

I don't know what's causing this...

I vote leaking from your aux battery isolation get-up - don't know how or why, but that's my vote......

Not picking on you Chief, but I agree. is the isolation config grounded well? is the batter disconnected from the vehicle with the charger connected? isolate the battery from the truck and charge it. if it still won't go further than mid 60's then you know what's up. if it charges, you've got a steady drain somewhere.
Naw, wasn't that

The battery main terminal wasn't hooked up to the thing until yesterday. And the wire supplying voltage to switch it is switched on with ignition. But after investigating some yesterday, that darned thing isn't working. I can't hear it clicking when I turn on the switch, but then again, I can't hear anyway, so it may be playing the ballad of the green berets and I'd still be in my happy space.

But I have bigger fish to fry all of a sudden.

I started the morning off doing a quick check of the bearings before installing them into the hubs

and

guess what?

They don't fit!

Full one ton chevy stuff is too small for the spindle ends of the axle tubes!

Just like that I took a pretty big step backward

I called Charlie, the machinist right away and at least heard he had not milled the axles yet, so those got saved.

What this means is that I have to machine the mugo hubs to fit the 14mm wheel studs and run those bearings.

OK that isn't so very bad, but the stock brake setup just got tossed out the window. I don't think there is anyway to run that setup with a standard parking brake with the backing plates I will now have to switch back to.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: EL TATE on May 09, 2019, 09:35:09 AM
So does the fella that built the axle have any part numbers for the brakes he put on there?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on May 09, 2019, 11:35:05 AM
So does the fella that built the axle have any part numbers for the brakes he put on there?

Axle wasn’t built by a guy per se... they were built in large quantities to stick under up armored suburban and the like in Iraq and Afghanistan. So possibly built by a company for OshKosh or some such.

Of course I may be VERY wrong but that’s what I understood, and have seen the up armored people movers over there.

But I too was wondering, some where there ought to be a parts list on these. Because they’d have to be serviced at some point. Unless they were designed and built for one time use, which the way the gooberment spends money, that would not surprise me.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 09, 2019, 12:22:02 PM
OK, sorry for the delayed response gents, a lot started happening last night when I started this entry...

So the bottom line is I think I have it handled. I will be using the original mungo hubs. I took them to the biker machine shop where Charlie said he could bore new stud holes in between the old ones, and counter sink for the heads of the stock studs. So, with all that done I will be able to get a wheel on the truck.

But the backing plates will not allow the use of the stock emergency brakes...I think, so I'll be back to something else...What? I don't know at the moment.

The start of the good news is I picked up the shortened drive shaft with new U-joints, and I suppose that is good news
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 09, 2019, 12:25:58 PM
The driveshaft was "bent" according to Cincinnati driveline. They define bent as having in excess of .030" runout. They strive to achieve .003" runout for a true vibration free unit, which I now own, so again, that is good news.

Getting ready to install it I ran a tap down the holes of the yoke. They are 5/16" X 24 fine thread SAE. It actually took some time and a great deal of resistance to power through all the corrosion and rust in those threaded channels. But in the end, I now have four well lubricated and protected bores, ready for bolts
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 09, 2019, 12:31:41 PM
I am really liking that Summit assembly lube for lubing bolts, holding parts in place during assembly, slipping parts together and buttering the nose of my sleeping mutt. It produces some interesting effects when used as a buttering agent and can also add to the humor level of a room!

So here's the next problem I ran into.

I have never encountered this before, but apparently U-joints of a family have different lengths.

The joint they placed in the shaft (I think they are 1350 joints) obviously fit the end of the driveshaft just fine but was too short to fit the yoke in the pinion gear.

I am reading a length of something over 4", perhaps 4 1/8" between the stops in each saddle of the yoke, and the U-Joint is only something like 3 3/4" wide (Long).

Now what in the heck is that???

Tate...??
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 09, 2019, 12:35:56 PM
So, now I need to solve for the odd sized U-joint. I have no idea what the driveshaft looked like that came off the up-armored Suburbans, so I have nothing to go on. I have no source to go to, since all this stuff was produced under some military contract for a program which has long since been handed over to the Iraqis who had ISIS subsequently steal it from them and was finally bombed into oblivion by the US military.

Seems that things do travel in a circle...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 09, 2019, 12:57:25 PM
1410 same cap size as 1350 but wider
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 09, 2019, 01:20:14 PM
Napa should have conversion universals in stock. Pretty common really.

On the air bag issue, just add a shut off valve in line? Open and adjust as needed, close and bags are isolated.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 09, 2019, 01:29:20 PM
Sorry didn’t see the ds was different than the yoke. Buy a yoke from Tate and swap it out.....

Or those conversion ujoints, 1350-1410 is probably one you need.

My personal belief is the 1350 is a stronger setup, the 1410 normally give you more articulation angle though.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 09, 2019, 05:30:44 PM
I think Tate is all over this.

He said they have something like what I need...We will sort it out.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 09, 2019, 05:36:59 PM
So, I'm thinking through the emergency brake system

I could splice into the existing line and run it into the cab and place a simple on/off valve. That way, I could step on the brake, close the valve and release, trapping the pressure to the rear and setting the parking brake.

I may yet be able to figure out some way to rig up the factory drum brake thing

But I was thinking of something else too.

Remember that the brake caliper plate was designed for two calipers on each wheel...???

Well I was thinking that if I could use the existing parking brake pedal to drive the stock cable, then at the end of that cable, mount some sort of hydraulic ram which would exert force on a piston when pulled, then I could route a separate set of lines to the second set of brake calipers and make them function as parking brakes.

I know, sounds funky, but it just may work. Looking at parts to make this function...

Decision is not made at this point.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 09, 2019, 05:41:49 PM
I believe an emergency bake must be a separate system, line lock doesn't work. Brakes fail, you need to stop you still don't have brakes, most are mech vs hydro.

Title: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on May 09, 2019, 07:06:18 PM
Drive shaft e brake? Wilwood has one, it’s mechanical I’m pretty sure.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 09, 2019, 07:10:57 PM
That driveline brake would be bad A!!


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 09, 2019, 08:04:43 PM
And legal (like it would be checked)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 09, 2019, 08:05:01 PM
I believe an emergency bake must be a separate system, line lock doesn't work. Brakes fail, you need to stop you still don't have brakes, most are mech vs hydro.

JR, only for inspections. Don doesn’t have to in the tuck.

Don, what is mount spacing on that bracket?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 09, 2019, 08:14:40 PM
Actually I bet that is a federal DOT rule, tuck or not.

But like I said, who would check. We do want the prerangers safe, right?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on May 09, 2019, 09:40:01 PM
Trying to understand why the backing plate won't work.  Can't you just trim the center hole? Or was the offset different?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 09, 2019, 11:09:55 PM
Don, I may have a solution sitting in my shop.....

I have a Dana 80 with disc brakes out of a superduty (yes I know the pattern is wrong) that is 8 on 170 but I have a template to drill rotors from 8x170 to 8 on 6.5

I can take pics and measure and even drill the rotors for you. Thinking this might work on your mutant axle. I bought it for $50 minus axle shafts and gears are fubar. Wanted it for center chunk which I’m hoping bearing pockets are still good and I can do a front 80 steer axle build.

Will be in shop in morning for awhile if you want to tackle this.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 09, 2019, 11:22:14 PM
Trying to understand why the backing plate won't work.  Can't you just trim the center hole? Or was the offset different?
It's spacing and offset between both the backing plate (which locates the caliper, and where the hub puts the wheel face. Along with that, this axle has had a larger diameter tube end (Part where the hub is affixed to) grafted on.

It looks like someone (company) just threw out the rules and bought the biggest stuff that would fit, as in big time overkill, overkill.

It will have to be the original mil setup or swap out to a factory 14 bolt FF which I'll bet is less than half as wicked strong as this thing I have here.

I'll sort it out. Maybe look at that wilwood part T is suggesting...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 09, 2019, 11:24:29 PM
Don, I may have a solution sitting in my shop.....

I have a Dana 80 with disc brakes out of a superduty (yes I know the pattern is wrong) that is 8 on 170 but I have a template to drill rotors from 8x170 to 8 on 6.5

I can take pics and measure and even drill the rotors for you. Thinking this might work on your mutant axle. I bought it for $50 minus axle shafts and gears are fubar. Wanted it for center chunk which I’m hoping bearing pockets are still good and I can do a front 80 steer axle build.

Will be in shop in morning for awhile if you want to tackle this.
Thanks Shawn, really kind offer

But let me scratch around on this for awhile. This Biker guy Charlie could machine a new axle out of a chewing gum wrapper if I needed, and it looks like some custom touches will be needed to bring it all home. But what a setup when I finally do!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 09, 2019, 11:35:39 PM
Well, I’m less expensive than the satan worshipping biker...... probably equal part pia though so it maybe money well spent dealing with biker.  :tongue: With that stated I guess you have my number if you want me to take some quick measurements and compare.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:18:53 PM
Update on the rear drive train stuff.

First, the 1350/1410 U-joint just came in. Tate sent it to me moments after a phone call to him, so that will fix the driveshaft problem

The rear hubs are still not modified, but add to that, I will either have to turn down the OD of the hub part or enlarge the rotors to fit over the 5" hole these hubs have. I plan to visit the machine shop tomorrow to figure that out
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:22:03 PM
So while I am waiting on that stuff, I dove into the installation of the stereo components. That little affair has now taken me a few days with loads of disassembly of interior and body panels to fit everything.

Started out with the Polk Audio speakers. They were direct replacements for the factory stuff. THose polk units with their larger magnets weighed nearly twice what the stockers did.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:24:12 PM
Crutchfield tries to make things easy for the installer by providing all sorts of adapter harnesses along with comprehensive directions
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:25:18 PM
Pages of stuff like this keeps you oriented and on your toes!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:26:23 PM
The rear doors were easier to do than the fronts
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:27:58 PM
I greased up all the linkages while they were exposed, and finished the installation off with some stick on Polk placards to make it look professional
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:29:19 PM
Speaking of stick-on things, I don't think I showed the cool RMTWS decals I placed on each wheel.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:31:23 PM
Then I started to remove trim panels and hardware
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:32:05 PM
This stock trim piece will not be reused
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:34:48 PM
The radio is easily removed by squeezing some clips in to release it.

I tell you, Chevy really builds a nice fitting and well put together vehicle. You get one of these classics in good condition, and I'd have to challenge you to justify paying 6-10 times the price to get a new one.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:35:51 PM
The amplifier and sirius radio will fit inside the center console below the drink cup holder
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:37:22 PM
And while I was organizing my space in there, I velcroed my sunglass case to the overhead and the remote for the rear DVD player to the bottom of the screen
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:39:03 PM
THis Burb had a factory Cassette player which will not be reused, so I'll use this spot to mount the CB radio
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:41:49 PM
And it fits!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:43:57 PM
I slightly enlarged the interior cavity to clear the radio
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:45:42 PM
And that is fitting pretty well
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:47:36 PM
The shelf on top is a catch all so I wanted to match it to the rubber poured into the center console tray. I did and placed the rubber drawer liner on top of the wet rubber.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:49:20 PM
Then the small Sirius receiver and antenna was wired in
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:51:23 PM
After 12 hours of drying the rubber had cured and the assembly is almost ready to replace.

I plan to bed the radio in some spray foam when reassembling to lock it into place and strengthen everything
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:52:45 PM
In this pic the rear Sub-Woofer is all but wired in, lacking only the RCA cables which also require an adapter harness which I did not receive. It is due to come in tomorrow
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:54:29 PM
I used a large properly sized inline fuse for the unit to protect the circuit and woofer
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:56:02 PM
I ran an 8 gage wire into the cabin, then soldered on several branches to which I can later attach and power future items, along with powering the things I need to power up right now.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 09:58:14 PM
The sirius radio and wiring bundle was velcroed out of the way in the CB radio compartment
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 10:01:22 PM
Infinity supplied the four channel amplifier. I purchased a nifty 9-wire cable that keeps the wires for the four speakers tightly bundled and provides a blue wire to remotely power up your amps, sub woofers, or whatever when the radio is turned on
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 10:02:41 PM
I ran two ground wires just to be sure.

Then the RCA cables get figured out and routed all over creation then plugged in the receiver head and the amplifier
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 10:03:59 PM
At this point a lot of stuff is either removed or disconnected...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 10:04:45 PM
And this aux electrical panel is starting to get busy
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 10:06:21 PM
To install the remote microphone for voice commands, I removed the A-pillar trim and ran the wire uphill
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 10:07:33 PM
About ready to reassemble.The amount of disassembly is epic!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 15, 2019, 10:09:24 PM
The initial test power up was not successful. Although everything is getting power and seems to function correctly, there is no sound coming from the speakers!!!!

After all the scraped knuckles and torn fingers, I threw in the towel and gave up for the evening.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on May 16, 2019, 06:24:12 AM
Don, is theOEM radio double DIN?  My biggest problem with the 2001 is the 1 1/2 DIN and having to replace the bezel and shoehorn a double DIN in there.

Also, a tip.  Move that microphone to the inside of the upper roof console just to the drivers right. Less noise from the window area to interfere with the commands and it will make it easier for the system to recognize the commands..


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 16, 2019, 08:51:41 AM
Don, is theOEM radio double DIN?  My biggest problem with the 2001 is the 1 1/2 DIN and having to replace the bezel and shoehorn a double DIN in there.

Also, a tip.  Move that microphone to the inside of the upper roof console just to the drivers right. Less noise from the window area to interfere with the commands and it will make it easier for the system to recognize the commands..


Sent from my iPad using Tapatalk
Factory radio is 1 1/2 DIN

Pioneer head unit is double DIN

And I have a new dash bezel to fit it

Mic, hmmm. Wires already run. It's close to the factory location. Directions from Pioneer did not say to shroud it in...

Let me check with Crutchfield on this particular mic.

Thanks
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on May 16, 2019, 08:54:09 AM
Not shroud. Just further away from the window. Over the years before Bluetooth when you had to have a separate, phone specific hands free kit, I had several installed and they always placed the microphone closer to the middle of the vehicle for that reason.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 16, 2019, 09:00:31 AM
(https://uploads.tapatalk-cdn.com/20190516/4d1af77720483a0f92ef60a43ebbd0f7.jpg)

Right here is where we found the best results at the stereo shop,

My favorite location is here
(https://uploads.tapatalk-cdn.com/20190516/25b78b6f8efeae96eb5cec949b070c16.jpg)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on May 16, 2019, 10:58:28 AM
Ours from the factory (although Toyota) is in the center. Between the map lights.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 09:49:53 AM
I went up to the machine shop to discuss the rear brake situation.

My job is next in queue. We will machine for the factory 2500 studs like planned. But we also have to cut the center hole of the disc brake rotors to fit the mugo hubs. With all that done, I will be able to bolt something up to the axle and start to figure out where to go.

First and foremost I want to see if there is anyway to use the stock emer brake system. There may be a way of harvesting the parts from the stock backing plate and grafting onto the steel plate that is designed for dual calipers. Dunno, have to have the parts to see if anything lines up.

So that's it on that subject

Regarding the rear shocks, I spoke with a SME at the FOX off road factory. Given the factors of the heavier than stock Burb and the limitations of driving a longer vehicle on extreme trails (Ain't gonna happen!) he thought I needed a reservoir shock with 30/70 valving and 8.5" of travel.

So I purchased those shocks and get a note this morning that the things have shipped.

So, have the drive shaft and shocks sorted, brakes pending

And

Finally, after talking to the Crutchfield technicians, my problem with the audio lies in the fact that my Burb has a factory Amplifier which I will have to jump around since it is essentially not used. They sent me a schematic which will help me get that done today. So with any luck, I may be able to close out the audio mod today.

All that leaves very little on the punchout list.

Concurrently with this wiring, today I plan to attach the overhead lights and get those operating, leaving only some fog/flood lights to be added to the bumper.

All in all I am tracking but may be slightly delayed from a departure 10 days away. I think realistically, I'm looking at sometime early to mid June which still works out great for a summer jaunt.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 08:37:52 PM
Man, this stereo/electronics/wiring project almost took on a life of its own. I am on top of the curve but after 10+ hours today on it, I'm ready to put this thing to bed.

So I figured out that the reason it wasn't pushing any sound to the speakers was because I was pushing through a dead stock amp. To get around that, I needed to pull the factory Amp, and its plugs and rewire them. I did so over the morning hours

Crutchfield supplied me with a schematic which I distilled down to the essentials
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 08:39:53 PM
The amp sits behind the glove box and was bolted in from the backside! Now how or why would the factory have done that. It turned out to be a bugger getting out, but like all things facing persistence, it yielded in the end
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 08:43:15 PM
I think I may have crossed the 50% threshold, meaning I have touched more than half the bolts, wires, fasteners and what not on this vehicle. I have literally been almost everywhere!

The process here was to find and connect the input and output right front positive, then the negative then on to the other 3 speakers until all were simply crimped together bypassing the amp
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 08:45:27 PM
A quick check of the radio, and I was blessed with a beautiful sound. Man WHAT A DIFFERENCE! It is clear, powerful, and full to an extent I have seldom seen. It sounds great!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 08:46:11 PM
So I taped off the rewired harness and secured it out of the way and reinstalled the glove box stuff
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 08:47:48 PM
The rear sub woofer/amp RCA adapter cable showed up, so after installing that, I secured those wires, and tucked everything away. Lacking reinstallation of the sill plate, that part is also done.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 08:50:15 PM
And because the overhead lights bone is connected to the interior trim panels bone, I wired those aux lights in

With this 80/20 stuff, you can tuck the wires into a cavity and push in their trim strips which were designed to do exactly that. The result is pretty neat and organized
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 08:52:47 PM
Yea, I know...I'm not thrilled about that light power wire hiding in plain view, but on this truck, I just don't want to drill any unnecessary holes. I'll cover that with a vinyl patch before I get motoring.

TO find room for a double DIN head, some minor surgery is required to remove a factory shelf.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 08:54:07 PM
Then the brackets are secured to the sides of the Pioneer head unit

And the ECU is reinstalled
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 08:55:28 PM
I sorted and placed wires all over but ran into no unusual binding. The radio unit slid right in and locked in place just like a factory unit
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Mrwoody on May 17, 2019, 08:57:02 PM
Big D,
what kind of sub did you use?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 08:57:15 PM
Next came the new trim bezel in a color listed as "Limestone" which is a pretty good match. Notice there is no black accent painting. I may get that later on, but time is short and there are some bigger fish to fry.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 08:57:51 PM
Big D,
what kind of sub did you use?
A self contained unit by "Kicker"
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 08:59:51 PM
Next up, the CB radio was secured in place. I heard someone talking on one of the channels, but this thing will need some tuning and adjusting to get it right
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 09:01:13 PM
There is a remote control included so following the theme of the build, I found a spot and velcroed it in place. It is easily removable and it works well
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 09:02:11 PM
...And I moved the microphone in toward the center and close to the factory mic
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 09:04:49 PM
Here is the overhead light switch going in.

Those lights, all four of them are wired to the high beams through an independent relay. What this switch does is allow me to turn that circuit off if I don't want all that light out there.

I may reorganize how the aux lighting works later, but for now this is how we will likely depart
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 09:06:31 PM
The unused pod beside that switch will soon mount this USB port for direct connection to the receiver/control head.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 09:07:40 PM
The small rheostat on the side of the lower console is a remote sub-woofer bass level controller
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 09:08:45 PM
This was only a mockup to see if I liked my cell phone/GPS sitting on the dash

I did not!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 09:09:56 PM
And to my surprise the Fox shocks showed up

They are a bunch shorter than the way-way too long BDS supplied units
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 17, 2019, 09:10:55 PM
And this is what it is looking like at the moment:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 17, 2019, 11:20:55 PM
My cell sits right where that new switch is on yours. Doesn't block the view and I can see it fine.

Like the new head unit, thought off and on about doing that in mine. I also have XM and rarely play CDs.

In retro do you wish a 10.5 had found its way to you?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 17, 2019, 11:50:35 PM
Are you going to put some other color on that white pipe?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 10:22:06 AM
My cell sits right where that new switch is on yours. Doesn't block the view and I can see it fine.

Like the new head unit, thought off and on about doing that in mine. I also have XM and rarely play CDs.

In retro do you wish a 10.5 had found its way to you?
If I could have located a FF 14 bolt I would have been much better off, of that there is no question.

But, if/when I sort out this Dana 80 4.88 setup, I will own something truly unique with strong bones. I think it is one of the things that will in the end make this truck a standout and capable of anything a vehicle of this size is capable of doing.

It is a current stressor, but a future point of pride and joy (I think/hope)

On the larger canvas, this was one really massive project to get done in 5 months. I have likely put a year's worth of work in it since I purchased it last winter. I can bring it home and I want to think the true value in all this sacrifice will show up in the trip next year, and the year after and so forth as this thing writes indelibly onto the memories of my family..."Remember the day in MOAB when dad was driving that old suburban and he..."
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 10:22:56 AM
Are you going to put some other color on that white pipe?


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Confederate flag...



Edit: Confederate flag displayed proudly parked on your lawn! ;-)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on May 18, 2019, 10:53:47 AM
You can fly that flag at my place.  Remember the “War of Northern Aggression” !!


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 11:05:47 AM
You can fly that flag at my place.  Remember the “War of Northern Aggression” !!


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Here-Here!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 18, 2019, 11:10:55 AM
Are you going to put some other color on that white pipe?


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Confederate flag...



Edit: Confederate flag displayed proudly parked on your lawn! ;-)
I was leaning more towards a black color or a undercoat paint is all.    The white pvc sticks out like a sore thumb to me.
As for a flag.  Fly what ever ya want.  Rainbows and all


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 01:48:36 PM
Are you going to put some other color on that white pipe?


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Confederate flag...



Edit: Confederate flag displayed proudly parked on your lawn! ;-)
I was leaning more towards a black color or a undercoat paint is all.    The white pvc sticks out like a sore thumb to me.
As for a flag.  Fly what ever ya want.  Rainbows and all


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I was just planning to paint it gray or black to blend in to the scheme

BTW was over at TSC of all places picking up some hardware and this guy rounds the corner with rainbow suspenders on. I couldn't help but laugh. Wonder what he was trying to prove???
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 18, 2019, 04:44:29 PM
Mork impression?

I bought a set of those once, they’re called clown suspenders. They hired a new production manager at my old shop. He was near retirement, great resume but guy wasn’t worth two nickels. I had his number by the second day. He had a nervous habit of always pulling up his pants. So I bought him a set and stuck them in his desk drawer a couple weeks into his job at about 4 am on my way to one of our other plants. Guess he came out of his office with them and asked if anyone knew who these suspenders belonged to......  :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 09:43:03 PM
Ah, clown...Didn't know

So today went a long way toward closing the project out.

I finished the audio installation (for now) and tied up the wiring bundle. and reinstalled the wheel well liner
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 09:43:54 PM
Then I finished off the aux electrical accessories area under the hood.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 09:44:58 PM
Following that, I connected the rear battery to the system and slid the battery box up into the travel position.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on May 18, 2019, 09:46:09 PM
Did you figure out the parasitic draw issue (or did I miss that)?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 09:46:44 PM
On the inside I sealed up the hole in the floor pan and reinstalled all interior panels. Nice to have a complete truck interior once again.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 09:48:08 PM
Did you figure out the parasitic draw issue (or did I miss that)?


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Did you figure out the parasitic draw issue (or did I miss that)?


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Ryan, I am not sure I have one. But no, I haven't discovered anything that is remaining powered on of any consequence. At least nothing that wasn't designed to remain on by Chevy.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on May 18, 2019, 09:49:20 PM
Thought there was a battery not remaining charged?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 09:49:31 PM
I gave all the panel clips a touch of assembly grease to make them slide back in easily and make disassembly easier in the future.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 09:50:36 PM
Thought there was a battery not remaining charged?


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It isn't

I'm thinking it may be a bad battery, or I charged it for too long initially and cooked it. Not sure, but before I leave, that thing is going back to the store for replacement.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 09:52:21 PM
Here is the USB panel. After cutting a hole to fit the USB into, I taped it all off, then poured some epoxy into the cavity. once hardened it will hold the plug securely and be a neat way of accessing the control head
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 09:54:36 PM
Next I finished the wiring to the overhead lights. I wired them to automatically come on with the high beams when pulling the dash switch is switched on. With it off the low/high beams operate normally.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 09:55:58 PM
And this is the last time the way-too-long shocks are to be seen on the truck!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 09:57:16 PM
Because, now some correctly sized reservoir shocks have been installed
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 09:59:19 PM
I had to jockey the reservoir cans a tad bit to keep the lines free of anything they might vibrate against and chaff on. My helo days has "learned" me to watch out for stuff like that.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 10:01:02 PM
Although they appear to be pretty close to some things, they clear all suspension components with the suspension in any position I could place it in with the jack.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 10:03:40 PM
Oh, and I finished the electric steps wiring, traced down two leaks and ran out of time before final tightening of the front suspension/chassis bolts which have remained loose on purpose. I wanted to give everything a little time resting on the suspension before tightening.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: BobbyB on May 18, 2019, 10:07:19 PM
With all that dust on it, you might as well give the Burb to me so you don't have to look at the destroyed hulk of what could've been.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 18, 2019, 10:12:25 PM
With all that dust on it, you might as well give the Burb to me so you don't have to look at the destroyed hulk of what could've been.
Yea that's probably a good idea (On Third street in Crazy Town!)

It was sprayed off last winter some time, but not since. Sure is needing it though!

I'm afraid to look at the scratches I may have added to its patina. Good side of that deal is that I'd get motivated to paint it when i get back.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 19, 2019, 12:41:30 AM
It's getting there, lots of good stuff.

That 80 will be sweet when done.

But afraid, Dana 80=tach topper.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 19, 2019, 12:59:52 AM
Found your hood design Don

(https://uploads.tapatalk-cdn.com/20190519/8cb7e990a9deb3cf6ca1f9cd4b1f7ebe.jpg)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on May 19, 2019, 07:27:10 AM
Good progress Don.  Getting closer.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 19, 2019, 08:17:27 AM
Found your hood design Don

(https://uploads.tapatalk-cdn.com/20190519/8cb7e990a9deb3cf6ca1f9cd4b1f7ebe.jpg)


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On an old guy Buick no less.....  :rolleyes:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 19, 2019, 03:09:32 PM
Found your hood design Don

(https://uploads.tapatalk-cdn.com/20190519/8cb7e990a9deb3cf6ca1f9cd4b1f7ebe.jpg)


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Looks like the arms of this Biker guy who I'm working with on the hubs.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 19, 2019, 03:12:41 PM
It's getting there, lots of good stuff.

That 80 will be sweet when done.

But afraid, Dana 80=tach topper.
Don't speak that into my life. ;-))

The 80 will (Have to) live!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: dave945 on May 19, 2019, 04:05:14 PM
You can use my 14 bolt if you need it Don. Would need to be cleaned up and built, but I don’t think you’d have much trouble with that. And then I’ll have a nice rear axle when you get back. ;)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 19, 2019, 06:19:56 PM
You can use my 14 bolt if you need it Don. Would need to be cleaned up and built, but I don’t think you’d have much trouble with that. And then I’ll have a nice rear axle when you get back. ;)


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I'm good, thanks
You all of so little faith!
We haven't even gotten into this thing yet to see what can be made of it
I can get it going, Its just a question of what the emergency brake system will look like and how things will ultimately fit together. Could be a golden goose or a rotten egg

Won't know until I get the parts back and do some fittin' !!!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 19, 2019, 07:24:46 PM
I think we can jerry rig the brake, hand lever, bike cable, pulley system and a large rubber pad that pushes agains the rear tires.   Think horse drawn wagon


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 19, 2019, 07:28:00 PM
Flintstone foot brake?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cudakidd53 on May 19, 2019, 07:39:54 PM
Emergency Brake = 2 4x4 timbers about 12" each and you're golden - bigger incline, double the timbers!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 19, 2019, 08:27:41 PM
Could we maybe think of a anchor.  Toss it out the window and attach to a pillar


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: dave945 on May 19, 2019, 09:21:54 PM
Don, it’s not that I don’t have faith in your ability to pul it off. I just giving you viable options Incase you need to make a tactical retreat for the time being on the big axle. Heck, you’re getting things done that I wouldn’t have even considered.

And what’s with the need for an emergency brake, you didn’t have one on your whirlybird.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 20, 2019, 08:07:13 AM
Don, it’s not that I don’t have faith in your ability to pul it off. I just giving you viable options Incase you need to make a tactical retreat for the time being on the big axle. Heck, you’re getting things done that I wouldn’t have even considered.

And what’s with the need for an emergency brake, you didn’t have one on your whirlybird.


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Rotor brake...


HMMM


Hadn't considered that


What's the number over at Agusta-Westland Helicopters?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on May 20, 2019, 09:20:34 AM
Realizing this is a stupid question, I stand prepared for a dressing down.

In its intended application, was there a provision for e brake and why can you not source original parts?


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Title: 2002 Suburban 2500 build thread, Part 3
Post by: longball on May 20, 2019, 09:26:19 AM
Realizing this is a stupid question, I stand prepared for a dressing down.

In its intended application, was there a provision for e brake and why can you not source original parts?


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I’ve thought the same, but didn’t ask because I wasn’t sure if the question was ingeniously simple or my would only further reveal my ignorance on the matter.

I’ve also wondered if a phone call to Dana would be of any help.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 20, 2019, 11:25:08 AM
Don, got another idea. What’s the hole spacing center to center on those fancy dual caliper mounts?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 20, 2019, 10:05:30 PM
Realizing this is a stupid question, I stand prepared for a dressing down.

In its intended application, was there a provision for e brake and why can you not source original parts?


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Simply put, there are no "Original parts" as it were for this axle.

THis thing was made in a limited quantity for a government program to quickly get about a hundred Up-Armored Suburbans into the hands of the State department and DOD in Iraq.

The vendor who built the trucks built all custom axles. These things were created from scratch, so the fit is unique to this one and only application. This axle never came out in any civilian application.

Starting with a Dana80 center section, it was milled to accept 14 bolt axle tubes meant for a 1 ton Chevy. THat way it would bolt up quickly and easily into the Suburban platform. The idea here was to reduce build time and get these trucks deployed ASAP.

But the axle tubes were actually modified as I later discovered. Through a complex process the ends are partially milled off and a larger diameter end is pressed then welded onto the old tube. THis larger spindle end supports the next size up bearings. The bearings in the ends of this axle dwarf the 14 bolt FF stuff found in 1 ton chevys. I mean the ID of the bearings is like 3/4" larger in diameter.

Starting to get the picture??

So to run these larger bearings these guys sourced some hubs from an industrial application. THe Cincy driveline guys said they were thinking the bearings belonged on some forklift or something and they would rate that single axle at 15,000 lbs.

So the hubs were machined to 5" diameter and in lieu of a chevy spec 3/4" flange, mine have flanges 2" thick, and mount some gigantic 7/8" studs which dwarf the 14mm stock Chevy stuff.

So I am forced to use the giant hubs or just back out of the axle and start over, which I am not going to do. Now the geometry of this giant hub drives the position of the caliper which is nowhere near anything ever produced other than another armored Suburban from government service.

So I must use the dual caliper mounts and I am hoping stock rotors which have had their ID machined out to fit the huge rotors. So when fitting the rotors over the hubs, the emergency brake shoes mounted to the stock backing plates are spaced too far inboard to allow them to work.

I have to go at this one step at a time. First can I get the hubs to work. THe answer is yes, but I need to bore 8 new holes to fit the 14mm studs, and then counter bore the holes so the studs present at about the correct height. That is queue and should be done any day. Next I needed to bore out the center hole of the rotor so it would slide over the hubs. That can be done and is nearly complete.

The backing plates are cleaned up and painted as are the calipers. So the next step will be to get the hubs remounted to the axle tubes and slide the rotors over that business. That will be the first time I will know where the caliper falls in relation to the rotor, but looking at the rotors vs the ones that came off the axle, I think I am good.

So after all that checks out will be the first time I can see if I can somehow remove the emergency brake shoes and backing plate from the stock Suburban mount.

If I can do that then maybe there is a way to mount it onto the hybrid caliper plate in such a way that it fits into the rotor. If I am lucky enough to make that fit, then I'll be in business with a stock setup adapted to the military axle.

Long answer, but I feel as though no one here has any real idea about what I am working around/with. Most of your suggestions have made no sense, but none of you had a clear understanding about this hybrid one-off setup.

So, make sense now??
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 20, 2019, 10:06:57 PM
Don, got another idea. What’s the hole spacing center to center on those fancy dual caliper mounts?
Factory Chevy caliper spacing, need me to measure?

You thinking of adapting one of those mechanical calipers to the bracket? I have thought about that too.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 20, 2019, 10:10:28 PM
So you all guessed it, I have been cipherin' on this brake geometry problem. I have zero doubt I can solve it, but it is taking a toll in time spent.

Today I cleaned the brake components to prepare them for reinstallation, likely tomorrow. But first, I had to pull the dash bezel back off to fit the two switches, so I masked it off and sprayed it
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 20, 2019, 10:11:47 PM
Rust removal removed the remaining bristles from my rotary wire cup grinder, but I got them pretty clean
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 20, 2019, 10:13:03 PM
Same-same with the axles. Cleaned up and painted. I painted the area IVO the hubs since there will be some oil in there and I'd like it to clear off the axle easily
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 20, 2019, 10:15:11 PM
I cleaned the living heck out of the brake calipers after disassembling them. Looking at their condition I think they are fairly new. Having spoken to the previous owner, he told me he had replaced the rear brakes and that story checks out

Red KBS engine epoxy paint
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 20, 2019, 10:16:11 PM
I won't be reusing these pads, but I could. Still in nice shape:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 20, 2019, 10:51:20 PM
Don, got another idea. What’s the hole spacing center to center on those fancy dual caliper mounts?
Factory Chevy caliper spacing, need me to measure?

You thinking of adapting one of those mechanical calipers to the bracket? I have thought about that too.

Couple options there but yeah, center to center should be like 7.125 I’m thinking. I have several versions of 3/8” caliper stands with that spacing to take the 3/4 ton truck calipers and or the 76-78 eldorado ebrake calipers and have the actuation kits for those calipers in stock too.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on May 20, 2019, 11:17:18 PM
Will Ford f450 brake hardware stuff work?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 20, 2019, 11:25:02 PM
Will Ford f450 brake hardware stuff work?

Metric
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on May 21, 2019, 06:07:57 AM
Thanks for the explanation Don. Still not clear on what was used for e brake when that axle was made. I also have to believe someone somewhere has service manuals or other detailed info on the original configuration.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 21, 2019, 08:07:24 AM
They may have used separate spot calipers for parking brake was my thinking. Two separate systems, one for parking and one for stopping. Granted parking can always be used for stopping in emergency.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: dave945 on May 21, 2019, 08:10:05 AM
For some reason when I was looking at the auctions the auctions this morning, this axle made me think of Don.  It would look really good under that suburban.
(https://uploads.tapatalk-cdn.com/20190521/f789dfd665626b02af6afc3a97637e2c.jpg)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 21, 2019, 08:50:51 AM
Thanks for the explanation Don. Still not clear on what was used for e brake when that axle was made. I also have to believe someone somewhere has service manuals or other detailed info on the original configuration.


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Oh, sorry I missed your point.

It had a hydraulic trap like most aircraft do. Press on the brake, pull a handle or rotate a valve trapping the pressure and you're all set.

That is what i will go to in the event I cannot get this factory E-brake (primary system) to work
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 21, 2019, 08:54:27 AM
They may have used separate spot calipers for parking brake was my thinking. Two separate systems, one for parking and one for stopping. Granted parking can always be used for stopping in emergency.
That seems logical, but the calipers were teed together as in working off of a single pressure source. I have thought of doing that, but with twice the piston volume...master cyl sizing...added weight...Burb doesn't need that much brake...and other reasons, I want to stay as close to stock as I can.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on May 21, 2019, 10:11:28 AM
You wouldn't need to run fluid to the caddy caliper once it was pressurized.  I believe those pistons don't retract after closing the pad gap. ..they have a threaded ratchet type mechanism and iirc the ebrake lever is adjustable..a splines shaft. Been a while since I dealt with those...same as vette.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 21, 2019, 07:29:31 PM
You wouldn't need to run fluid to the caddy caliper once it was pressurized.  I believe those pistons don't retract after closing the pad gap. ..they have a threaded ratchet type mechanism and iirc the ebrake lever is adjustable..a splines shaft. Been a while since I dealt with those...same as vette.

I believe that is correct.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 21, 2019, 07:31:47 PM
You wouldn't need to run fluid to the caddy caliper once it was pressurized.  I believe those pistons don't retract after closing the pad gap. ..they have a threaded ratchet type mechanism and iirc the ebrake lever is adjustable..a splines shaft. Been a while since I dealt with those...same as vette.

I believe that is correct.

True, did them on a 9.5 axle, worked great. Not sure if they are rated for the 8k sub though!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 21, 2019, 07:35:01 PM
You wouldn't need to run fluid to the caddy caliper once it was pressurized.  I believe those pistons don't retract after closing the pad gap. ..they have a threaded ratchet type mechanism and iirc the ebrake lever is adjustable..a splines shaft. Been a while since I dealt with those...same as vette.

I believe that is correct.

True, did them on a 9.5 axle, worked great. Not sure if they are rated for the 8k sub though!

They are a 3/4 ton front truck caliper essentially, same piston size just has built in ebrake capability
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 21, 2019, 08:51:57 PM
Being they are from an 70-80 el dorado front (not a light car) they might be fine for the rear then.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 21, 2019, 09:51:05 PM
I'll have to look at this setup Shawn.

Perhaps if the stock stuff won't fit are we thinking of just running another caliper on the same rotor with the bolt spacing I currently have?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 21, 2019, 09:53:45 PM
So have the dash bezel reinstalled, and the interior cleaned after accumulating a bunch of junk

But when I went to find the floor mats, the weather tech things, I couldn't find them

They were next to some stuff I told the pre-rangers to throw away last Sunday night

Yep

Guess I'll be purchasing some new floor mats!!!!!!!!

Suggestions??
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 21, 2019, 09:54:59 PM
The caliper parts turned out OK, but when i worked on them today I buggered up the paint a little bit, so they got touched up. This is before that happened
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 21, 2019, 09:56:14 PM
New hardware
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 21, 2019, 09:57:46 PM
The stainless brake pad guide bars were cleaned up and reinstalled along with assembly grease

Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 21, 2019, 09:58:49 PM
The pads came with the rotors, so good enough, I don't have to figure out which compound to run.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 21, 2019, 09:59:37 PM
A wear comparison. New on the left "Old" on the right
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 21, 2019, 09:59:53 PM
I'll have to look at this setup Shawn.

Perhaps if the stock stuff won't fit are we thinking of just running another caliper on the same rotor with the bolt spacing I currently have?

Might be an option, but need to go over some dimensions of things when you’re near it probably.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 21, 2019, 10:00:41 PM
Two renewed calipers ready to go back on...Now where are those hubs??
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 21, 2019, 10:01:35 PM
I'll have to look at this setup Shawn.

Perhaps if the stock stuff won't fit are we thinking of just running another caliper on the same rotor with the bolt spacing I currently have?

Might be an option, but need to go over some dimensions of things when you’re near it probably.
If I do this, do you have the calipers and kit stuff or just the stuff minus the calipers??
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 21, 2019, 10:02:10 PM
The mounting plates are now rust proofed.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 21, 2019, 10:03:51 PM
I'll still need to figure out how I want to mount the brake line hardware. I am hoping I can just drill and tap a couple of holes to mount the brackets. That is first up tomorrow.

And, yes, I have all new brake hoses.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 21, 2019, 10:05:48 PM
I'll have to look at this setup Shawn.

Perhaps if the stock stuff won't fit are we thinking of just running another caliper on the same rotor with the bolt spacing I currently have?

Might be an option, but need to go over some dimensions of things when you’re near it probably.
If I do this, do you have the calipers and kit stuff or just the stuff minus the calipers??

I can supply all or partial let’s talk and we’ll figure best course. Maybe tomorrow?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 21, 2019, 10:10:10 PM
I'll have to look at this setup Shawn.

Perhaps if the stock stuff won't fit are we thinking of just running another caliper on the same rotor with the bolt spacing I currently have?

Might be an option, but need to go over some dimensions of things when you’re near it probably.
If I do this, do you have the calipers and kit stuff or just the stuff minus the calipers??

I can supply all or partial let’s talk and we’ll figure best course. Maybe tomorrow?
Sure, sounds like a plan
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 21, 2019, 10:23:34 PM
And genemens that's all I got done today. Ran around more than half a day chasing after this misfire in my mower. I have that Briggs Vanguard big block 32 HP engine which had this weird miss and backfire. The miss would change from the left to the right, disappear, then come back.

We rebuilt the carb, twice. Replaced a coil, adjusted the valves, twice, changed out spark plugs, twice and no tomato!

We did compression tests wet and dry. 120 psi dry on both sides, not much more wet so all that is good. I was about to start pulling down the motor when today I discovered two diodes that are wired between each coil and the kill switch. Two tiny diodes. They fit in a wire harness consisting of three wires and maybe 18" in length. So no worries, I thought I'd just replace that harness.

Well I run off to one small engine shop and they are no longer selling Briggs stuff. I call another one. They need the motor serial number. I drive to my son in law's place to get the numbers. We share the thing. I get the wrong numbers and drive 20 miles to a scag dealer. He says he can order it and it would cost $54 + $9 in shipping.

Over $60 for two dollars worth of diodes and wire. No freakin way, so I drive home and really start researching the reason they are there in the first place. They are used to ground out the coils to kill the motor. But wait, this motor has a fuel solenoid valve as well.

So I get the idea to just remove the diodes and tape off the wire ends and that's what I did. When we fired it up, it ran, but ran funny. So one more time we checked the spark plugs with a tester and the right coil seemed weak. So on a bet we swapped the old coil out for the other old coil and just like that we had a whole bunch of power and one sweet running engine.

Then I cut my 8" tall grass and with all that time blown. I had very little remaining to work on Ravin8
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on May 21, 2019, 10:30:15 PM
So have the dash bezel reinstalled, and the interior cleaned after accumulating a bunch of junk

But when I went to find the floor mats, the weather tech things, I couldn't find them

They were next to some stuff I told the pre-rangers to throw away last Sunday night

Yep

Guess I'll be purchasing some new floor mats!!!!!!!!

Suggestions??

Not weather tech. Try the Husky liners.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 21, 2019, 10:31:08 PM
So have the dash bezel reinstalled, and the interior cleaned after accumulating a bunch of junk

But when I went to find the floor mats, the weather tech things, I couldn't find them

They were next to some stuff I told the pre-rangers to throw away last Sunday night

Yep

Guess I'll be purchasing some new floor mats!!!!!!!!

Suggestions??

Not weather tech. Try the Husky liners.


Sent from my iPhone using Tapatalk
off to look at them...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on May 21, 2019, 10:36:39 PM
The big thing about weathertech that drives me absolutely nuts is they don’t have the nubs on the bottom to keep them from sliding around. That, and their “laser fit” tends to pull away from the trim and not fit as tight as they did when new.


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Title: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 21, 2019, 11:34:55 PM
So have the dash bezel reinstalled, and the interior cleaned after accumulating a bunch of junk

But when I went to find the floor mats, the weather tech things, I couldn't find them

They were next to some stuff I told the pre-rangers to throw away last Sunday night

Yep

Guess I'll be purchasing some new floor mats!!!!!!!!

Suggestions??

Not weather tech. Try the Husky liners.


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I’d like to see a review on these also.  My weather junks are a mess in the mommobile


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 22, 2019, 12:11:02 AM
I got a set of huskies for the burb, they were crap. Paper thin and had like a 2 inch lip along the door.

Maybe that was because this thing is 30 years old, but they went back.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Dfarm01 on May 22, 2019, 12:36:53 AM
I have a set of weather tech mats in my burb. They are all warped and fit like crap now.

I wish someone would make a set of floor trays like the factory accessory floor trays from Volvo. They are a thick, heavy soft rubber. They were awesome.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 09:32:59 AM
I have weather tech in my Silverado. They are crap. The sides have all folded inward and they will shift around on the floor easily. They do, however hold the dirt, but are very thin and when you fold them to remove, oftentimes you will spill a percentage of the dirt during the procedure.

The ones I threw away inadvertently were Huskie standard mats. They were an ugly gray and did not fit all that well. Were thin and hard and those spikes on the bottom were always punching holes in my hands. Can't say I like them much either. I would prefer some heavy rubber matt that fit well. Such a thing exist?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:06:28 AM
So, I just ordered a set of custom made heavy rubber floor mats from a company the cuts specific patterns from industrial rubber mat. Let's see what these look like.

and a bit of foreshadowing, but when I return from the trip, there will be a new addition to the Real man thing. it will offer products that are custom made for Real Man, stuff that works that will be available only through the site. That and a ton of T's and other clothing that carries the kind of message we all wish to promote.

I don't want to get too deeply into this but, I have long wanted to create something Christian men could sink their teeth into with no PC apology to the plastic sheeple crowd. I am going to launch that. Believe it or not, floor mats were one of the thing I was looking at to be made for us!

Oh and with the money I make??? Going to provide scholarships for men/women who want to spread the gospel. Pay for people I identify who are the real deal and in need. Pay for a bunch of things which supports those who are a part and the community of believers in Christ.

Nuff for now...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 22, 2019, 11:04:37 AM
Thought I smelled a business opportunity with those matts.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: longball on May 22, 2019, 12:23:53 PM
Outstanding Chief. Excited to see this take off.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:19:35 PM
Outstanding Chief. Excited to see this take off.


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I'll take good care of everyone here, and build the community too.

So worked on that business plan some today, but mostly had good wrench turning time spent on the Burb. I can see light at the end of the tunnel. As long as these brakes sort and there is no reason they won't then it will be on to alignment, some driving, some sorting, some tuning, then packing and I'll light this candle on both ends.

Right now I have to go watch my youngest get promoted into high school and maybe eat a little chinaman's food
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:24:38 PM
I went cheap on the seat covers. I like the minimalist/military style of these covers by Smittybilt. They are made to fit a Jeep, so I needed to do a bit of tweaking to get them in my cab
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:25:17 PM
Built pretty well IMHO
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:26:04 PM
The underside is rubberized
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 22, 2019, 10:27:32 PM
I like em!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:29:21 PM
And it fits
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:31:01 PM
I didn't add a bunch of pouches although each seat cover comes with seven of them. I like the large pouch to store a hoodie for those chilly mornings
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:32:17 PM
And that fit rather nicely with the folded seat and cooler arrangement
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:33:11 PM
Still plenty of room for a medium sized pre-ranger to bed down
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:34:02 PM
Pouch minimum on the other side as well
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:35:09 PM
just enough to get the job done me thinks
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:35:59 PM
And with two pre-rangers installed:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:37:25 PM
A bit more finish work, covering the unused channels in the 80/20 runs.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:38:24 PM
Then I pulled the ugly white torpedo thing off and made Dave happy:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:39:38 PM
Oh, I velcroed my rusty lock blade into my door panel
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:40:55 PM
With some press work I had the hybrid U-joint Tate supplied swapped into the driveshaft and then bolted that in
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:41:59 PM
But, I am not liking how the U-joint saddles do not bolt down flush to the saddle in the diff yoke. Going to have to do something about that
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:44:34 PM
So for the heck of it, I tossed an axle into the housing, started it up and threw it in gear.

I almost got a nasty surprise because it was in 4WD and when I tapped the gas, it wanted to climb off the rear supports powered along by the front tires. Switching into 2WD I functioned checked it and everything seems to be operating as it should
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 22, 2019, 10:45:42 PM
Still waiting on the machined out hubs, but getting closer with every day.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 22, 2019, 10:47:07 PM
And with two pre-rangers installed:
That front seat “pre ranger” looks more like take the front seat out and give him the back seat type of ranger.  Or strap that boy with them long legs on the roof!!! 


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 22, 2019, 10:53:23 PM
But, I am not liking how the U-joint saddles do not bolt down flush to the saddle in the diff yoke. Going to have to do something about that

Bet I have a set of girdles for that yoke..... :wink:

(http://i.imgur.com/wjSnozS.jpg)

(http://i.imgur.com/1s9OlFb.jpg)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on May 23, 2019, 01:41:48 AM
Doesn't help him much, that you have those,  if he doesn't.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 23, 2019, 07:57:23 AM
Doesn't help him much, that you have those,  if he doesn't.

To quote GI Joe, knowing is half the battle....  :tongue:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 23, 2019, 10:20:54 AM
And with two pre-rangers installed:
That front seat “pre ranger” looks more like take the front seat out and give him the back seat type of ranger.  Or strap that boy with them long legs on the roof!!! 


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Copy that!

Youngest one said he was just going to craw in the back and ride in the horizontal.

Front one agrees, frees him up to slide that seat all the way back.

These burbs are big vehicles, but amazingly they do not have expansive inside dimensions. I think chevy makes all the trim and seats "Thick" which takes away from the available leg room. Look at a land rover, then at a chevy and you'll see what I mean. I mean, for me, give me the chevy any day, but I think a slightly more european interior could push the big SUV over the top.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 23, 2019, 10:23:58 AM
Doesn't help him much, that you have those,  if he doesn't.
Yea, that's right, forgot GLO had those things. Shawn sent me a set for SquareD

I'd be up to PURCHASE a set if you have them Shawn.

Oh and you'll like this. I put one of the GLO decals on the hub in the middle of the spare tire hub. Looks right at home there!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 23, 2019, 10:32:14 AM
Figured out that I will need a step ladder to strap on this rig somewhere. Not easy to get to the roof basket. I winder where I'll strap that thing on????

Speaking of strapping things on, still have that hi-lift jack to put somewhere

Hmmm just had an idea

Strap it to the right front fender parallel with the ground and pointing forward like the air refuelling probe on that MH-47 Chinook I used to fly. I could practice my pre-contact to contact position flying in unsuspecting jap kars with COEXIST stickers.

Wouldn't that be fun

"He dude, you just get all jacked up??"  (Get it, "jacked" up???)  ;-)
Title: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on May 23, 2019, 10:58:50 AM
That Gerber folder is my every day pocket knife...er tool. If you didn’t know, you can mail that thing back to gerber they’ll either clean and sharpen or replace. All for the cost of shipping!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 23, 2019, 11:46:31 AM
And with two pre-rangers installed:
That front seat “pre ranger” looks more like take the front seat out and give him the back seat type of ranger.  Or strap that boy with them long legs on the roof!!! 


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Copy that!

Youngest one said he was just going to craw in the back and ride in the horizontal.

Front one agrees, frees him up to slide that seat all the way back.

These burbs are big vehicles, but amazingly they do not have expansive inside dimensions. I think chevy makes all the trim and seats "Thick" which takes away from the available leg room. Look at a land rover, then at a chevy and you'll see what I mean. I mean, for me, give me the chevy any day, but I think a slightly more european interior could push the big SUV over the top.
I sure like my big couch like seats in GM vehicles for sure!!


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on May 23, 2019, 02:46:33 PM
The Gerber folder is my every day pocket knife...er tool. If you didn’t know, you can mail that thing back to gerber they’ll either clean and sharpen or replace. All for the cost of shipping!

did you get lost.....?
Title: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on May 23, 2019, 03:24:07 PM
That Gerber folder is my every day pocket knife...er tool. If you didn’t know, you can mail that thing back to gerber they’ll either clean and sharpen or replace. All for the cost of shipping!

did you get lost.....?

Nope! Had my daily ration of color this morning :) post 898, the knife he velcroed into his door handle. Probably should have quoted it.

(https://uploads.tapatalk-cdn.com/20190523/bb872f9b903dcf68fbec0ba624171a31.jpg)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 23, 2019, 03:26:20 PM
Doesn't help him much, that you have those,  if he doesn't.
Yea, that's right, forgot GLO had those things. Shawn sent me a set for SquareD

I'd be up to PURCHASE a set if you have them Shawn.

Oh and you'll like this. I put one of the GLO decals on the hub in the middle of the spare tire hub. Looks right at home there!

No speaka englash!

Good deal on decal location......

Confirm a couple things Don, does the yoke have spicer cast into it? Is that u-joint cap in that yoke 1350 or 1410 and if you measure across the cap it should measure 1.8125 roughly. If so I’m good to sell you a set, but they’re pricey fair warning!  :tongue:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: EL TATE on May 23, 2019, 05:10:43 PM
he's got the 1410 series yoke, 1350 on the driveline side. sent him the DS U-1435
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 23, 2019, 07:07:22 PM
That Gerber folder is my every day pocket knife...er tool. If you didn’t know, you can mail that thing back to gerber they’ll either clean and sharpen or replace. All for the cost of shipping!

Heck, had flashbacks of baby food,,,,,,,,,,,,,,,,,,
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on May 23, 2019, 07:40:25 PM
That Gerber folder is my every day pocket knife...er tool. If you didn’t know, you can mail that thing back to gerber they’ll either clean and sharpen or replace. All for the cost of shipping!

did you get lost.....?

Nope! Had my daily ration of color this morning :) post 898, the knife he velcroed into his door handle. Probably should have quoted it.

(https://uploads.tapatalk-cdn.com/20190523/bb872f9b903dcf68fbec0ba624171a31.jpg)

Touche brother, touche
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 23, 2019, 08:55:05 PM
That Gerber folder is my every day pocket knife...er tool. If you didn’t know, you can mail that thing back to gerber they’ll either clean and sharpen or replace. All for the cost of shipping!
Didn't know that

It is quite aged. Rode around in my flight vest all over Iraq and Afghanistan, then in my BOB in the back of the Chevy. Maybe after this trip, I'll do that.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 23, 2019, 08:57:52 PM
Doesn't help him much, that you have those,  if he doesn't.
Yea, that's right, forgot GLO had those things. Shawn sent me a set for SquareD

I'd be up to PURCHASE a set if you have them Shawn.

Oh and you'll like this. I put one of the GLO decals on the hub in the middle of the spare tire hub. Looks right at home there!

No speaka englash!

Good deal on decal location......

Confirm a couple things Don, does the yoke have spicer cast into it? Is that u-joint cap in that yoke 1350 or 1410 and if you measure across the cap it should measure 1.8125 roughly. If so I’m good to sell you a set, but they’re pricey fair warning!  :tongue:
I'll have to take a look in the morning S, let you know
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 23, 2019, 08:59:25 PM
So got the hubs and the rotors back from Charlie. I'll know sometime tomorrow if I am a hurry up and done or back to flight idle.

Charlie glass beaded the things and cleaned them up a bit. That should help with the repainting.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 23, 2019, 09:00:35 PM
He had a bunch of hours in all this, but treated me very fairly on price. You can see the counter-bored holes alongside the old larger stud ones
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 23, 2019, 09:01:28 PM
He set them up for proper set when pulling in a knurled stud
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 23, 2019, 09:03:26 PM
Look closely and you will see a chamfer on every hole, both sides...attention to detail!

Same-same with the rotors. He opened the hole up to fit the step on the hubs, so the rotors should have zero run-out
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 23, 2019, 09:04:13 PM
Fit and alignment is perfect from what I can see and feel
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 23, 2019, 09:05:42 PM
So, this is going to be the trick, getting the emergency brake shoes to locate inside this drum. If that happens with the caliper in the correct position over the rotor, I'm doing my hap-pee dance
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 23, 2019, 09:06:48 PM
Quite a bit of difference between the 1 ton Chevy stuff and this military stuff
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 23, 2019, 09:09:40 PM
ID, OD, bearing size, axle flange and height all different between these two parts

I will have a very strong lifetime axle capable of anything I put under the hood and whatever conditions I would subject it to when completed.

This has been an interesting walk and this is very likely the only axle of its kind, converted in this manner in existence.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 23, 2019, 09:17:43 PM
But, does it fit and the dance must be recorded!!!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 23, 2019, 10:45:24 PM
Before I read all of this,  you now need to have your disc brakes custom made to fit your rear axle?  Do I understand this right?  Are you going to have the same person machine some ASAP so you have the right stuff on the shelf in a case of emergancy ?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: akcooper9 on May 24, 2019, 08:24:14 AM
Before I read all of this,  you now need to have your disc brakes custom made to fit your rear axle?  Do I understand this right?  Are you going to have the same person machine some ASAP so you have the right stuff on the shelf in a case of emergancy ?

Pretty much what I was thinking. I like over kill / over built but this just doesnt make sense. A 14 bolt FF out of HD truck or even the diesel 11.5 would have made more sense to me.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 24, 2019, 08:46:31 AM
I understand the cool factor but the min you can’t drive to s Napa and get a replacement rotor? 


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on May 24, 2019, 09:35:13 AM
As I tell my friends. When you write the check, you are the only one that has to be happy.

Spares on hand would be smart.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 24, 2019, 10:38:15 AM
The only part I might ever need is a rotor. I use stock rotors and have the center bore milled larger to fit over the big hub. That's it, easy peasy.
Hubs do not go bad (ever) Sometimes the bearings do, but just pull the number off your bearing and buy one at NAPA or Oreillys or... Seal you ask? I pried the old ones off, drove to Oreillys and walked out with two new ones in five minutes. So not as difficult as you might think.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 24, 2019, 10:42:03 AM
Before I read all of this,  you now need to have your disc brakes custom made to fit your rear axle?  Do I understand this right?  Are you going to have the same person machine some ASAP so you have the right stuff on the shelf in a case of emergancy ?

Pretty much what I was thinking. I like over kill / over built but this just doesnt make sense. A 14 bolt FF out of HD truck or even the diesel 11.5 would have made more sense to me.
...For sure!
But
None around the A.O. at the time, and this was.
Personally I prefer this mutant thing, I mean who has a Dana 80 in a suburban? Personally, I like the uniqueness. I like the fact that this particular axle was created to be used as an instrument of war. I remember driving around in those Suburbans in Baghdad. And, really, should I get to hating this thing, well, just pull it out, sell it for what I have in it and go buy the 11.5 AAM and motor on.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: dave945 on May 24, 2019, 10:54:01 AM
Not to mention, with the extra weight under the suburban, should lower his center of gravity. :)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on May 24, 2019, 11:50:11 AM
I’d run it in a heart beat! Even though it weighs as much as a Kia, it’ll be extremely tough! Look forward to seeing it in ravin8
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 24, 2019, 02:13:00 PM
Not to mention, with the extra weight under the suburban, should lower his center of gravity. :)


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Let’s put the glycol stuff in the tires too lol


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 24, 2019, 09:46:26 PM
Pressed some studs into the new/old hubs

Second pic is stock left vs mugo, right.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 24, 2019, 09:47:56 PM
These are the original bearings which were cleaned with solvent, then purged of the remaining goo and pumped full of new grease
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 24, 2019, 09:49:17 PM
Bearings dropped into the remanufactured hubs and retained with a brandly new National grease seal
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 24, 2019, 09:50:51 PM
And then came mock-up time. Using the factory backing plate and caliper mount, i assembled the parts to see where I was
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 24, 2019, 09:52:20 PM
As you can see, this setup is a No-Go. THe emergency brake shoes are only about 50% into the rotor, and the caliper alignment is way off
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 24, 2019, 09:53:54 PM
So that is that and constitutes a dead end for using the stock Suburban stuff. So, decision was made for me, that stock stuff was removed and I started again with the backing plates that came with this axle.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 24, 2019, 09:55:27 PM
And reinstalled both hubs.

This time was for the record. I snugged up the retaining "nut" installed the locking assembly, and then the second "nut" which finished this portion of the reassembly
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 24, 2019, 09:56:43 PM
After another solvent cleaning I painted the bare steel hubs with semi gloss black enamel.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 24, 2019, 09:59:22 PM
I slid on the brake rotors and checked caliper alignment and I'm happy to say, that looks good.

I did run into a strange problem though. Those new brake pads seem to be thicker than the set in the old rotors and the set that came off. And I simply cannot get those calipers to slide on. So, I threw in the towel at that point and will sort that out tomorrow. THis thing kicked my butt today!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 24, 2019, 10:00:12 PM
I tossed on the towing pintle and secured that thing. At one point it was installed in the rear bumper of SquareD
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 24, 2019, 10:00:57 PM
So, that's where I left it tonight, back to it in the morrow...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on May 24, 2019, 10:05:41 PM
I hate to ask this now... but is it possible to move the mount that holds the backing plate outwards? Just like I had to do with my caliper bracket on my 70....
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 24, 2019, 10:29:28 PM
Diameter if current rotor and hat height?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 24, 2019, 10:29:54 PM
Just needs a spacer, right!
Title: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on May 25, 2019, 06:17:05 AM
Moving the backing plate won’t work as the e brake will hit the back of the hub.  It’s the thickness of the hub face that is keeping the hat from sitting back far enough to engage the e brake.

Shawn may be on to something if he could source some other rotor with a deeper hat but that may be a big task to find the ID of the e brake, OD of the rotor, stud spacing and depth of hat.

In hindsight the solution may have been/may be to have the biker dude mill the face of the rotor to make it the thickness of the factory hub.  But now that the backside of the hub has been recessed for the studs that may not be possible.

However, BDDQ, he’ll figure it out.
(Big Don Don’t Quit)
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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 25, 2019, 08:43:30 AM


However, BDDQ, he’ll figure it out.
(Big Don Don’t Quit)
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[/quote]
 BDDQEOSqD

Fixed it for ya


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 25, 2019, 08:52:34 AM
I hate to ask this now... but is it possible to move the mount that holds the backing plate outwards? Just like I had to do with my caliper bracket on my 70....
Well, I tried some experimentation and nothing worked. The factory bracket has studs which seem to be welded in place so spacing the thing outward with washers is only good for maybe 1/2" then you run the risk of not getting enough material for the nuts to torque down on. I even got to the point of sawing the factory thing apart and after an hour of cutting bits off of it to try and get it on there, I had a mess which I would not have been happy with so I tossed the whole thing.

Nossir, the setup I currently have is the setup I will be leaving with.

Time is short.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 25, 2019, 08:58:53 AM
Diameter if current rotor and hat height?
What cha thinkin'?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 25, 2019, 11:33:09 AM
Diameter if current rotor and hat height?
What cha thinkin'?

2005 Chevy express van rotor is about 12” and has deeper than normal hat offset.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 25, 2019, 11:57:56 AM
Yep, if you can't space it or mill the hub a deeper rotor could be the answer. There goes the nice slotted/dimpled rotors though.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: dave945 on May 25, 2019, 12:13:58 PM

2005 Chevy express van rotor is about 12” and has deeper than normal hat offset.
Would the 04 be the same?  I’ll check the garage and see if I have one left from my last brake change so he could check for fit.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on May 25, 2019, 12:32:21 PM
Chief, are you going to start a travel thread soon, as the launch date id think is nearing? Waiting until it’s ready for the road?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 25, 2019, 03:12:54 PM
Chief, are you going to start a travel thread soon, as the launch date id think is nearing? Waiting until it’s ready for the road?
I think original plan was beginning of May.   Wasn’t it? 


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on May 25, 2019, 04:31:37 PM
Chief, are you going to start a travel thread soon, as the launch date id think is nearing? Waiting until it’s ready for the road?
I think original plan was beginning of May.   Wasn’t it? 


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I had always figured when the pre-rangers finished up with school for the year. But recall he had to adjust for fire with the mutant axle problem solving.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 25, 2019, 04:59:17 PM

2005 Chevy express van rotor is about 12” and has deeper than normal hat offset.
Would the 04 be the same?  I’ll check the garage and see if I have one left from my last brake change so he could check for fit.


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That I can’t say, just pulled this from my notes....
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 25, 2019, 11:51:15 PM
Chief, are you going to start a travel thread soon, as the launch date id think is nearing? Waiting until it’s ready for the road?
I think original plan was beginning of May.   Wasn’t it? 


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I had always figured when the pre-rangers finished up with school for the year. But recall he had to adjust for fire with the mutant axle problem solving.
OK, to answer the questions surrounding the trip, I was originally planning on leaving Tuesday, day after memorial day. But with this mutant axle delay, I am in a floating mode right now. As you will see, a lot of the issues are now solved, but there is still some sorting, alignment, driving, fixing what doesn't work, recording engine data, retune, drive a bit then launch. I'd say that will take two weeks and I may end up uploading the tune on the road somewhere.

Travel thread, well yes, sort of. So I dodn't want to let on too much but the Real Man concept is going to grow. We are going to go a bunch more public with a social media site like a facebook page and a link to here and another separate web site called the garage, which will look like it is a part of this web site where some interesting things are going to happen.

On a side note, if any of you want to sell stuff through that venue, its approved. Just coordinate everything with me and we'll light you up. T makes patches, so does that crazy couple in Texas who goes around adopting Ukrainian kids. Some of the rest of you do things. That part will be our commercial outlet where eventually everything under the sun related to what we do is sold. That's complicated and is a project that I've handed off to a close friend and brother in Christ.

We are going to do some cool things with the money we make there. Hmmm, just had a funny thought...What if some of you actually did get paid here! Wouldn't that be a kick! Well all for the better, I see it as sowing into the kingdom and that is always going to be job one here.

But yes, I plan to write a travel blog somewhere on something, copy it here and send it out over the interweb. I also was hoping to get enough to write a book meant for fathers about experiencing their children, but we'll have to wait and see on that.

I have set my sights high on all this, but I feel a tug in that direction, and it's time to blow this place up and get the cool word and the way real men of Christ can have a snappin' good time while leaning on each other and walking the straight and narrow.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 25, 2019, 11:53:48 PM
I started the day drinkin quoffee with my pre-ranger son, then cut the grass, then finally got on the Burb. I painted stuff I'd need later on. Bolts and the brake pads.

Here's what I decided to do. I took the pads I just took off of the burb, and in the ones that came on it and sanded the wear surfaces and the backsides. I cleaned them thoroughly, then painted them with stove-brite, paint meant for wood burning stoves.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 25, 2019, 11:55:13 PM
I smeared a coat of permatex onto the axle mounting flange, then allowed that to set up in the sun for a couple hours. I wanted it more like a gasket and less like a goopy mess when I tightened down the axle bolts
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 25, 2019, 11:55:52 PM
They dried really pretty!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 25, 2019, 11:56:48 PM
Oh, and Shawn, here is the decal of GLO proudly displayed on the back of Ravin8
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 25, 2019, 11:57:42 PM
The axles went right in, 12 pt bolts looking like they belong there
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 25, 2019, 11:59:22 PM
With the used pads, the calipers slid on about like they normally do with new pads. For some reason those supplied pads are a bit too thick. I can't say I have ever seen that before
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 12:01:01 AM
Then I finally finish tightening all the lower bolts from the lift kit crossmembers. The instructions wanted you to wait until the vehicle was resting on the suspension before doing it, so I waited until the thing had set for a couple months.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 12:03:39 AM
I had a very dense piece of Walnut which practically mills like metal that I used to fashion up the overhead storage tube mounts, 3 ea.

I cut reliefs in the top and bottom of each to act as a guide for the stainless clamp
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 12:04:37 AM
A single 1/4" attaches the mount to the 80/20 side rail
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 12:05:41 AM
It's walnut (Read rot resistant)

But I painted the pieces for some protection and to help them blend in
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 12:06:20 AM
Attached to the side rail:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 12:08:08 AM
And with the tube attached. Seems as though this is the only shot I took of the thing up there, I'll get another shot tomorrow after church...

I also constructed a lanyard for the plug end so it doesn't get left behind like all those unforgiven after the rapture.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 12:09:41 AM
Some pics around Casa-Don so you can see what has been occupying a lot of my time (Landscaping)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 12:10:43 AM
Yes, I like green!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cj7ox on May 26, 2019, 07:13:18 AM
Looking good, Don! I can't wait to get back CONUS and see some actual green!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 26, 2019, 09:28:47 AM
How many acres is the house on?

How have you resisted bringing home some of those awesome stones from your farm and adding them in the house.  I picture a stacked stone arch over the driveway

Have you seen the water heater tubes that look almost identical to what you have built to store rent posts.   Black pvc, hose and a shower attachment and warm water from the sun to shower in while on the road?
https://youtu.be/dG2HK9JsAjw


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 08:55:40 PM
How many acres is the house on?

How have you resisted bringing home some of those awesome stones from your farm and adding them in the house.  I picture a stacked stone arch over the driveway

Have you seen the water heater tubes that look almost identical to what you have built to store rent posts.   Black pvc, hose and a shower attachment and warm water from the sun to shower in while on the road?
https://youtu.be/dG2HK9JsAjw


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My big house sits on 2.5 acres in some equestrian neighborhood. Nice place, but I'm a little out of my element here.
I work on stuff in the garage, no one else does. They hire everything out.

Have seen the black pvc shower things. In my case no realestate left on the roof at all...None!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 08:57:05 PM
I have a new flex hose so I popped the factory lines off. They had zero corrosion so I decided to reuse them
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 08:57:56 PM
I stripped off the brake cables as they will no longer be used
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 08:59:34 PM
Using the factory bracket, I welded it to one of the U-bolts that hold the air bag to the spring pack. That placed the hose and line in about the stock position
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 09:01:10 PM
Then right in the middle of my work day my wife and pre-ranger decided to go for a hike. Look what they brought home:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 09:07:56 PM
That took its toll in time. Had to clean it up, try and comfort it, which was easy, heck it curls right up in your lap and goes to sleep!
No other son was back in the forest yesterday and came upon it not long after it was born. He said it was laying next to a pile of afterbirth. He walked up to it, and it walked over to him and started rubbing his leg. Trooper was trying to get at it, so the boy came home to tell us about the encounter.

Today, my wife the proverbial mother couldn't let it go, and it turns out the hike was actually a search. well, it worked out, as they went straight to it maybe a mile away. It immediately walked over to them and did the same thing. They decided to bring it home. We contacted a vet who said if mom has twins, she will observe them for an hour, then leave with the stronger one, abandoning the weaker to fend for itself.

This vet runs a rescue and Kat made some arrangement with her for her to look after it for 6 weeks, then return it to us. We are to nurture it for 6 more weeks, then either release it or keep it here. Dunno what we are going to do with another long legged dog, but here we go!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 09:09:29 PM
I made up a couple supports to mount the flex line "T" to and secure a section of line above the axle
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 09:11:11 PM
The other side worked out well. Using the factory line to chassis mount, I simply threaded it onto a U-bolt threaded end and anchored the left side line
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 09:12:21 PM
I hooked up the axle breather line, routing it along the new overhead cross member
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 09:14:03 PM
Left side line, main mount for the "T" and the right side support
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 09:15:34 PM
Picked up a four foot step ladder that will be strapped to the roof and be going along on the trip
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 09:16:12 PM
As promised, a pic of the overhead fishing rod storage tube:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 26, 2019, 09:18:15 PM
Next up, I'll connect the brake line and bleed the brakes. If all that goes OK, I'll mount the rear wheels and set it on its own tires for the very first time.

Starting the motor and placing it in gear happily spins all that business in the back. It seems like it wants to work!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: dave945 on May 26, 2019, 11:17:02 PM
For your shakedown trip, head on down here to williamstown. At least that way I get some attention from your cross country jaunt. ;)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 27, 2019, 12:49:27 AM
Ok, I am a tad confused I guess. Your hooking up the rear brakes but there is still an issue with them rotor spacing?

I mean it looks great and coming together wonderful.

I do think the brake line is a tad long/exposed though.

I like that hot water idea too!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on May 27, 2019, 09:13:38 AM
Jr, i believe everything for the brakes was working/figured out except the parking brake or the lack there of.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 27, 2019, 09:36:19 AM
You all forgot Don is a Pilut and he has two ground crew with him at all times on this trip!  :popcorn:

(http://i.imgur.com/aebBWjy.jpg)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 27, 2019, 09:43:09 AM
(https://uploads.tapatalk-cdn.com/20190527/440967ddf9a2c88d96918ab3986893da.jpg)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 27, 2019, 10:03:49 AM
For your shakedown trip, head on down here to williamstown. At least that way I get some attention from your cross country jaunt. ;)


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ok
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 27, 2019, 10:07:58 AM
Jr, i believe everything for the brakes was working/figured out except the parking brake or the lack there of.
Correct Nate

I am going to mount a trapped pressure shutoff valve, one for the front brakes, one for the rear. That way I'll have the option to set the brakes for all four wheels for situations like winching.

JR, no brake shoes, that is all gone. Trash guy just hauled those things off. That system won't work. When I get back, I may cobble on a second mechanical caliper and hook the emer cables back up, but for now, I'm going hydraulic. Hecked worked on my Chinook, worked on the jets I flew, works on my tractors...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on May 27, 2019, 11:36:27 AM
You all forgot Don is a Pilut and he has two ground crew with him at all times on this trip!  :popcorn:

(http://i.imgur.com/aebBWjy.jpg)

that's actually funny!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on May 27, 2019, 02:14:44 PM
Agree with Nate, that's pretty darn funny.
..and Don rolls right on past it. Lol
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 27, 2019, 03:09:36 PM
Without an emergency brake, he just might!!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: longball on May 27, 2019, 03:29:13 PM
You all forgot Don is a Pilut and he has two ground crew with him at all times on this trip!  :popcorn:

(http://i.imgur.com/aebBWjy.jpg)

that's actually funny!
We have to use those as backup to the air brakes on the fire trucks. If it works for a 60k lb engine surely it’ll work for Ravin8.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 27, 2019, 10:24:47 PM
^^^ All that: static... :wink:

So today, I got that darned brake line in the back hooked up. Anyone ever replace the rear rubber line in this vintage chevy?

It's one bugger to get to. Plan on spending some quality time sitting up between the axle, fuel tank and whatever else can possibly be in the way.

Add to that, I mounted some nifty magnets, the strong neodymium type in the console. I hang keys and things from them and another one installed on the dash. I epoxied a steel washer onto the back of the mic for the CB and just like that, just touch it to the dash and it sticks!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 27, 2019, 10:27:14 PM
So I tore into the brake system to sort exactly how I am going to set all that up. After arranging it in my mind, I removed the lower dash trim panel and then located a place to make a hole, then cut a 1 3/4" hole into the firewall.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 27, 2019, 10:29:23 PM
^^^ All that: static... :wink:

Maybe, but you gotta admit it was creative.... :tongue:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 27, 2019, 10:31:02 PM
I removed the master cylinder to accurately determine the fitting size which is 1/2" X 20 inverted flare.

I sourced some AN-4 fittings to adapt to that flare so that I can plumb some -4 line from the master cylinder back into the drivers compartment.

I had planned to provide an isolation valve for both the front and the rear brakes, but after pricing that stuff, I opted for just one circuit for now. I'll get the other one later, after the trip.

I noticed the back of the MC and the front of the hydro boost was wet. Can't tell if its hydraulic or brake fluid...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 27, 2019, 10:31:24 PM
^^^ All that: static... :wink:

Maybe, but you gotta admit it was creative.... :tongue:
Yes it was...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 27, 2019, 10:33:05 PM
With the rear lines all bolted and snugged in, I felt it was time to fit the rear wheels for the first time ever

And here it is, Ravin8 resting on its own suspension:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 27, 2019, 10:34:18 PM
You can really see all that work in the back:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 27, 2019, 10:35:29 PM
I was looking for a place to carry the step ladder, so I tried this spot. Not sure if that dog will hunt
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 27, 2019, 10:36:41 PM
...And, I feel the tire is a tad too close to the air bag, so I ordered some 1/2" thick spacers to push it out a bit more
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 27, 2019, 10:37:35 PM
Just from a visual perspective, it sure needs some 37's
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on May 27, 2019, 10:43:11 PM
Holy Toledo Batman!!! That thing looks great. 37s would be neat but I feel you’ll end up having to open up the fenders.

Also, while it ain’t mine, I really don’t like the ladder bungeed on the tire.

Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 27, 2019, 10:44:32 PM
That ladder looks retarded.   How about a land rover ish mounted ladder up the side of the rig. 


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 27, 2019, 10:47:54 PM
Drill some holes in that passenger side fender.  Tune right to the frame, pass through that fender and build a ladder that is close to the body

Like this but on the passenger side to avoid the fuel door (https://uploads.tapatalk-cdn.com/20190528/b7ba8e6034b11ee967c6f5d5c300dadb.jpg)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 27, 2019, 11:04:24 PM
Put the ladder up on top right above rear wheel well. Step up on wheel to pull ladder down..... :facepalm:

Stance looks great btw
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: dave945 on May 27, 2019, 11:22:14 PM
Truck looks good!  I look forward to seeing it in person.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 27, 2019, 11:26:50 PM
Yep, 37s are called for. Bet that RPM will be way over 2.2 just cruzing. Think they will clear with a 6in lift. I get very little rubbing with 35s on 3in, with the fender mod.

Yep, the ladder looks hokey. Can you use a collapsible or does it need to stand? A collapsible with hooks on top might work. Or a foldup ladder like many RVs have.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 27, 2019, 11:35:54 PM
WolfWise 8.5FT EN131 Aluminum Telescopic Extension Ladder - One-Button Retraction System, Upgraded Extendable Telescoping Ladder with Spring Loaded Locking Mechanism Multi-Position https://www.amazon.com/dp/B07LFB6X5D/ref=cm_sw_r_cp_api_i_uUk7CbP9RP2VP
STROMBER 0139.1999Stromberg Carlson LA-401BA Universal Outdoor RV Ladder - Black https://www.amazon.com/dp/B012ZZEGO8/ref=cm_sw_r_cp_api_i_SVk7CbWA0BKPC
Surco 103H Hook Over Ladder https://www.amazon.com/dp/B000CCBMDU/ref=cm_sw_r_cp_api_i_hYk7Cb5YD463S


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on May 27, 2019, 11:46:27 PM
Looks good Don.  Ready for a shakedown video.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cruizng on May 28, 2019, 09:32:10 AM
Just from a visual perspective, it sure needs some 37's

I think Don put this up as DOT bait... LOL

Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 28, 2019, 10:31:29 AM
Just from a visual perspective, it sure needs some 37's

I think Don put this up as DOT bait... LOL


No Mikey, thats PBD (Pure Big Don)
I guess my hillbilly roots need some coverin'

OK, I'll move the ladder

I guess I could strap it on top. It wouldn't make sense to do a permanent mounted one on the vehicle side, as we need it mostly to get to the front basket, then I envision propping open tent flaps and then maybe in packing stuff up on the exfil.

I do actually own a collapsing ladder...Remember the Tac-Topper project ladder...???

But would that be as good as a step ladder???

OK, so game plan is:

I have ordered all the stuff to build in a parking/emergency brake. It will be here tomorrow I'd guess. So, that will go on the same day. Today is lubing and topping off of fluids. After the brake system is completed, then bleeding of that thing and doing something with the driveshaft yoke. Shawn is trying to help me, but I get involved in doing what I'm doing and forget all about getting him measurements.

But I could probably get it to alignment the way it is and get that done. After that, start driving it, then pull some data from the motor and get Justin at Black Bear to do his thing. By then (Next week??) I should have it sorted and leak checked and secondary repairs and ready to launch.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 28, 2019, 10:33:02 AM
WolfWise 8.5FT EN131 Aluminum Telescopic Extension Ladder - One-Button Retraction System, Upgraded Extendable Telescoping Ladder with Spring Loaded Locking Mechanism Multi-Position https://www.amazon.com/dp/B07LFB6X5D/ref=cm_sw_r_cp_api_i_uUk7CbP9RP2VP
STROMBER 0139.1999Stromberg Carlson LA-401BA Universal Outdoor RV Ladder - Black https://www.amazon.com/dp/B012ZZEGO8/ref=cm_sw_r_cp_api_i_SVk7CbWA0BKPC
Surco 103H Hook Over Ladder https://www.amazon.com/dp/B000CCBMDU/ref=cm_sw_r_cp_api_i_hYk7Cb5YD463S


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Dave, that is the exact ladder that I already own!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 28, 2019, 11:25:17 AM
Don, I'm sending you the parts. If they don't work send em back or drop them off on your way through..... :beercheers:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 28, 2019, 12:00:24 PM
WolfWise 8.5FT EN131 Aluminum Telescopic Extension Ladder - One-Button Retraction System, Upgraded Extendable Telescoping Ladder with Spring Loaded Locking Mechanism Multi-Position https://www.amazon.com/dp/B07LFB6X5D/ref=cm_sw_r_cp_api_i_uUk7CbP9RP2VP
STROMBER 0139.1999Stromberg Carlson LA-401BA Universal Outdoor RV Ladder - Black https://www.amazon.com/dp/B012ZZEGO8/ref=cm_sw_r_cp_api_i_SVk7CbWA0BKPC
Surco 103H Hook Over Ladder https://www.amazon.com/dp/B000CCBMDU/ref=cm_sw_r_cp_api_i_hYk7Cb5YD463S


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Dave, that is the exact ladder that I already own!
Perfect!  Great minds think alike


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on May 28, 2019, 04:55:19 PM
So, strap the ladder to the top,  then need a ladder to get to the ladder.  Makes perfect sense.

Taste the leaking fluid..if its acidic,  it's brake fluid.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: swbhobie16 on May 28, 2019, 04:57:52 PM
Just from a visual perspective, it sure needs 6.6L of forced induction

FIFY
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 28, 2019, 06:30:58 PM
So, strap the ladder to the top,  then need a ladder to get to the ladder.  Makes perfect sense.


Boss is like six foot three, don’t think he has t-rex arms he should be ok.... :rolleyes:

Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: oklawall on May 28, 2019, 09:09:10 PM
Don,

The truck looks great. For the ladder could it go on the back of the roof rack (behind your lights) after the tent is installed and use the cut out for your tag as a step?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 28, 2019, 09:21:46 PM
Don, I'm sending you the parts. If they don't work send em back or drop them off on your way through..... :beercheers:
Thanks Shawn!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 28, 2019, 09:22:52 PM
Just from a visual perspective, it sure needs 6.6L of forced induction

FIFY
Could happen...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 28, 2019, 09:34:50 PM
So, strap the ladder to the top,  then need a ladder to get to the ladder.  Makes perfect sense.


Boss is like six foot three, don’t think he has t-rex arms he should be ok.... :rolleyes:


Actually for the initial grab, I could stand up on the power steps. I've been working off those since I bolted them on!

So today was a one over the world examination of everything. I ended up doing all sorts of things. I topped up the rear diff fluid, then repositioned the rear Fox shock reservoirs. I found one hose touching the frame. I found an area where the positive battery cable could vibrate against another part of the frame so I wrapped the cable with a ribbed anti-chaff sleeve. I found the transfer case breather not connected, then secured some loose cables. I started and this time warmed up the engine. I did so to top up the transmission fluid. I did, it was three quarts low! I added a quart of dexicool to the cooling system and zip tied some cables up. I secured the Amp steps control module while I was there. I drilled two water drain holes, one into the muffler, and another into the low point of the exhaust pipe. I got water out of that one.

I greased some of the front end that I think I overlooked and discovered a missing bolt mating the transfer case to the transmission. I found a loose drain plug in the front diff, tightened that, then topped that fluid up. I mounted another flashlight to some velcro inside the cab, and cleaned and taped off the rubber no-slip pads on the steps. I will glue them in place tomorrow.

I checked to see if any lines or hoses were chafing, checked all brake lines, all cooling hoses, and air bag lines.

I painted a couple of spots that had a touch of rust on them and wiped down excess grease. With all that done I have only to complete the brake installation, wire in the reverse light, and install the fog lights in the bumper.

I hope to get the brakes done by tomorrow, maybe the lights as well. With the brakes operational, I'll pull it out and mount the tent on top. After that its alignment time and continued sorting...

May seem like alot, but after all I and this burb have been through since October, its not much work remaining.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: dave945 on May 28, 2019, 09:59:40 PM
Dang don, all I managed to get done this evening was keep myself from killing the kids and keep the kids from killing each other. You make me feel like I’m slacking.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 28, 2019, 10:12:37 PM
If you let the kids kill each other you could be way more productive tomorrow Dave


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: dave945 on May 28, 2019, 11:22:14 PM
Don’t tempt me, I just wanna  get a few things done around the place.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 28, 2019, 11:23:41 PM
Mine tried to ride bikes in the back yard and follow me in the skidd.    Once I noticed it was hell to pay with momma.   


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 28, 2019, 11:27:24 PM
I shipped my three to grandmas house in east tn. Amazing what you can get done....  :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on May 28, 2019, 11:33:52 PM
I shipped my three to grandmas house in east tn. Amazing what you can get done....  :popcorn:

just don't make it a 4th......
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 28, 2019, 11:36:42 PM
Greatest form of birth control is a tv in the bed room. 


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on May 29, 2019, 12:33:30 AM
Greatest form of birth control is a tv in the bed room. 


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I’m not so sure about that one.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 29, 2019, 08:21:11 AM
What happened to ma' thread!!!!????????? :shocked:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 29, 2019, 08:21:34 AM
I shipped my three to grandmas house in east tn. Amazing what you can get done....  :popcorn:

just don't make it a 4th......


Nah, we kept the golden retriever she’s still here....  :tongue:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 29, 2019, 08:22:28 AM
What happened to ma' thread!!!!????????? :shocked:

It got “DAVE’D”
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on May 29, 2019, 09:02:18 AM
Now that’s funny.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cj7ox on May 29, 2019, 09:31:41 AM
It got “DAVE’D”

ROFLMAO!
 :beercheers:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on May 29, 2019, 09:44:47 AM
(https://uploads.tapatalk-cdn.com/20190529/7acd7b358a134ed49fedfc11d3dfc380.jpg)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 29, 2019, 09:50:10 AM
How does one go from reading about transmission fluid to birth control?

If this is any indication of how SOME people's mind works  :facepalm:...I'd be concerned about travelling through that area...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: dave945 on May 29, 2019, 09:59:54 AM
Just keep in mind Don, you drive past my house every time you go south on 75. 

Of course that might explain why you are heading west for your road trip and not south.....

You can return to building your all terrain cross country grocery getter now.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 30, 2019, 09:09:40 AM
^^^ Copy

So, no brake parts came in yesterday, and had some drama to attend to. Hoping the stuff will come in today and I can get this thing moving...We'll see.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on May 30, 2019, 09:29:00 AM
Did these new floor liners come in yet?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 30, 2019, 09:41:09 PM
Did these new floor liners come in yet?
No, and I was just thinking about that today. I haven't had a peep out of them!

Please, I hope there is not some funny business going on here

I'll call them in the morning
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 30, 2019, 09:45:56 PM
So, I have the brake lines in progress along with some other stuff. Should, with any blessing from above at all, have brakes on it tomorrow and able to back it out of the garage, first time since, when?? October?

Just a few things left

Finish brakes
Drive shaft rear bolts (I think Shawn has me covered on that)
Wire up back up lights
Throw in the fog lights, although I could depart without them
Mount the roof top tent
Align the front end
Drive and record data
Send that off to Justin...reload his tune, then I'm ready to go

I have two of those things in progress at the moment...

Pics tomorrow

Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 30, 2019, 09:48:05 PM
And...we have been working on the new website(s)

I'll start a new topic in the message from the owner section to explain a bit about the changes which are coming.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on May 30, 2019, 10:16:05 PM
So, I have the brake lines in progress along with some other stuff. Should, with any blessing from above at all, have brakes on it tomorrow and able to back it out of the garage, first time since, when?? October?

Just a few things left

Finish brakes
Drive shaft rear bolts (I think Shawn has me covered on that)
Wire up back up lights
Throw in the fog lights, although I could depart without them
Mount the roof top tent
Align the front end
Drive and record data
Send that off to Justin...reload his tune, then I'm ready to go

I have two of those things in progress at the moment...

Pics tomorrow

Those girdles showed delivered
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on May 30, 2019, 10:20:02 PM
Oh no, a Ranger took out the trash again.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on May 30, 2019, 10:21:07 PM
All this good stuff as the farm gets forgotten.

Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 31, 2019, 08:15:05 AM
So, I have the brake lines in progress along with some other stuff. Should, with any blessing from above at all, have brakes on it tomorrow and able to back it out of the garage, first time since, when?? October?

Just a few things left

Finish brakes
Drive shaft rear bolts (I think Shawn has me covered on that)
Wire up back up lights
Throw in the fog lights, although I could depart without them
Mount the roof top tent
Align the front end
Drive and record data
Send that off to Justin...reload his tune, then I'm ready to go

I have two of those things in progress at the moment...

Pics tomorrow

Those girdles showed delivered
Mail?

Have to check...Pre-Rangers...!!!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on May 31, 2019, 08:16:52 AM
All this good stuff as the farm gets forgotten.


More like abandoned! I hear the grass is ten feet tall and a pack of wolves has moved in and taken up residence!

I hope the outhouse makes it so I have a nice place to stay!

After the trip my friend...after the trip
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 11:00:25 AM
The girdles did show. Little box found on momma's desk

Shawn, you big ole wonderful guy! And THEY FIT
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 11:02:03 AM
And so did the floor matts!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 11:03:30 AM
Pretty thick rubber, aggressive pattern that should hold dirt, but they do not fully cover the floor like some others
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 11:05:20 AM
They sent me a single front matt, so I cut out the section where the console occupies floor space
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 11:06:53 AM
Made this matching console tray cover from the unused, cut away section to bruise my elbow on during long drives
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 11:08:35 AM
Got the Trans-Dapt wheel spacers in, removed a wheel and discovered they do not fit.

They had an advertised ID of 5" but they actually had a 4.8" ID

I threw them away
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 11:10:42 AM
After all the crawling around on the steps, the rubber anti-skid plates had all moved or fallen off. So I glued them back on with contact cement. They don't move now!   :smiley:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 11:12:14 AM
The stock underhood light with its out of level switch did not work. I couldn't get it to work. So I applied the "Don-Effect" to it
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 11:14:37 AM
And I believe we were talking about brake parts. Well here theys is:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 11:16:00 AM
The adapter fittings adapt the 37 degree "AN" fittings to the 1/2 X 20 stock brake sizing
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 11:18:48 AM
The lines are measured for length, cut and the ends screwed on.

This is PTFE type hose built to withstand, 3,000 psi I believe. The ends attach by way of a bronze collar which squeezes onto the plastic inner line, crushing that against a nipple that inserts inside the line. The screw on part secures it all for three days short of forever.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 11:19:55 AM
1/8th NPT sealed with teflon tape adapts the shut-off isolation valve to the AN -4 fittings
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 11:21:12 AM
I made a mount for the valve from some angle aluminum, taking great care to countersink the screw heads into the wrong side
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 11:22:06 AM
Screw it, the thing fits anyway!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 11:24:29 AM
I placed that in such a way that it would scrape my knee and serve as a constant reminder to buy a stock axle next time.

Under the hood everything is all buttoned back up.

But for some weird reason, although fluid pours from the MC port, nothing is getting to the caliper! WTH!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 11:25:35 AM
I use the synthetic DOT 3/4 fluid because it looks a little better in my hair and on my sleeves than the standard stuff.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 11:26:34 AM
Oh, and here is something else I stored somewhere on board that I will discover a couple weeks after we get back!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on June 01, 2019, 11:30:16 AM
Wow. Is that one of those Nick Bolton Tac Lanterns??


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on June 01, 2019, 11:49:34 AM
The girdles did show. Little box found on momma's desk

Shawn, you big ole wonderful guy! And THEY FIT

Sweet!  :likebutton:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on June 01, 2019, 11:51:33 AM
Got the Trans-Dapt wheel spacers in, removed a wheel and discovered they do not fit.

They had an advertised ID of 5" but they actually had a 4.8" ID

I threw them away

I have a company I use if you want the link. They make 90% of the spacers and adapters for resellers out there. You plug in your measurements.....
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wilsonphil on June 01, 2019, 11:58:35 AM
The girdles did show. Little box found on momma's desk

Shawn, you big ole wonderful guy! And THEY FIT

Shawn, are these as good or better that going to the Ubolt type setup?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on June 01, 2019, 04:18:04 PM
The girdles did show. Little box found on momma's desk

Shawn, you big ole wonderful guy! And THEY FIT

Shawn, are these as good or better that going to the Ubolt type setup?

Phil, you’re the engineer!  :tongue:

They’re pretty strong, I’ve been doing these over ten years and never heard of an issue. I used to have a company up North of the border that built nascar chassis who would buy these in bulk.

If you can get a larger diameter u-bolt and bore the yoke for that and still retain the strength of the yoke the u-bolt would be stronger I would think. These bolts are 5/16 fine thread gr 8
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wilsonphil on June 01, 2019, 05:32:35 PM
Paper and calculations are one thing real life usage is what you always go by!!!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on June 01, 2019, 08:16:53 PM
Paper and calculations are one thing real life usage is what you always go by!!!

Well, then they are invincible :likebutton:

Realize though if you have a u-bolt yoke these don’t line up with those holes typically. These were made as an upgrade from flimsy straps.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 01, 2019, 08:44:08 PM
Wow. Is that one of those Nick Bolton Tac Lanterns??


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Not that cool (Yikes!!!)

Naw, just some lantern I had laying around in the house. I put some batteries in it and just like that, it made light!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wilsonphil on June 01, 2019, 09:35:49 PM
Paper and calculations are one thing real life usage is what you always go by!!!

Well, then they are invincible :likebutton:

Realize though if you have a u-bolt yoke these don’t line up with those holes typically. These were made as an upgrade from flimsy straps.

I was just asking because I had never seen those before.  My RC has 1410 yoke with the straps and I bought a Ubolt strap style yoke that I was going to swap it out with.  these give me an option.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on June 01, 2019, 10:02:35 PM
Yeah, these are most likely just as strong and no need to swap yokes.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 04, 2019, 09:16:20 AM
Brake Bleeding on this generation Chevy truck

OK when bleeding the brakes with this GM Anti-Lock system, it seems you need to bleed the anti lock module along with all the calipers and corresponding lines.

Once I bled the anti-lock module I was able to get fluid, then pressurized fluid to all calipers and successfully remove most of the air from the system. I say "Most" because until I cycle the anti lock motor and clear the accumulators, the system will retain a bit of spongy stuff.

But as soon as I got brakes, for the first time since October, I drove it out of the garage under its own well mannered power.

It moves! It stops! It starts and shuts off!

I think I am getting it finished............FINALLY!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on June 04, 2019, 09:34:20 AM
Brake Bleeding on this generation Chevy truck

OK when bleeding the brakes with this GM Anti-Lock system, it seems you need to bleed the anti lock module along with all the calipers and corresponding lines.

Once I bled the anti-lock module I was able to get fluid, then pressurized fluid to all calipers and successfully remove most of the air from the system. I say "Most" because until I cycle the anti lock motor and clear the accumulators, the system will retain a bit of spongy stuff.

But as soon as I got brakes, for the first time since October, I drove it out of the garage under its own well mannered power.

It moves! It stops! It starts and shuts off!

I think I am getting it finished............FINALLY!

awesome!

is this before, during or after it leaked fluids all over your driveway?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 04, 2019, 09:38:43 AM
Brake Bleeding on this generation Chevy truck

OK when bleeding the brakes with this GM Anti-Lock system, it seems you need to bleed the anti lock module along with all the calipers and corresponding lines.

Once I bled the anti-lock module I was able to get fluid, then pressurized fluid to all calipers and successfully remove most of the air from the system. I say "Most" because until I cycle the anti lock motor and clear the accumulators, the system will retain a bit of spongy stuff.

But as soon as I got brakes, for the first time since October, I drove it out of the garage under its own well mannered power.

It moves! It stops! It starts and shuts off!

I think I am getting it finished............FINALLY!

awesome!

is this before, during or after it leaked fluids all over your driveway?
Water, That's water son!

From sprayin' the brake fluid off all that fresh paint underneath!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on June 04, 2019, 09:43:36 AM
Looks killer !   Time to wash that blue paint off the white walls


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Title: 2002 Suburban 2500 build thread, Part 3
Post by: longball on June 04, 2019, 09:47:27 AM
That’s what all suburbans should be. Well done Chief!


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 04, 2019, 09:49:10 AM
Looks killer !   Time to wash that blue paint off the white walls


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UK: Blue

Duh...

;-))
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: dave945 on June 04, 2019, 09:49:22 AM
That suburban looks good. I think you and the pre-rangers are going to have a fun trip.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 04, 2019, 09:50:08 AM
That suburban looks good. I think you and the pre-rangers are going to have a fun trip.


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Yup!

Off to the alignment rack...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on June 04, 2019, 09:52:48 AM
Booyah!! Looks awesome
Title: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on June 04, 2019, 10:30:30 AM
Yea this is awesome to see!! I too drove our truck out of the garage this weekend... but not to wash it, just clean some welds and keep the dust outside :)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on June 04, 2019, 10:44:18 AM
Sweet, rangers getting tall!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: dave945 on June 04, 2019, 11:01:32 AM
Hey Don, if you decide the 35” tires just don’t look right, I can probably find a spot under the blazer for them. They aren’t TOO used so I’m sure we could make a deal. ;)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on June 04, 2019, 11:27:34 AM
Yep, needs 37s.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on June 04, 2019, 02:01:43 PM
Be careful out there Don. That CG looks pretty high.

Congrats on finishing.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cruizng on June 04, 2019, 08:43:54 PM
Really sharp rig but I think it needs the step ladder and grannies rocking chair on top!  Bet the pre rangers are excited to hit the road also.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: oklawall on June 04, 2019, 09:15:48 PM
Don, That suburban looks outstanding! Well done. I hope you 3 enjoy your adventure. You could start a business of building these for forum members 
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 04, 2019, 10:38:23 PM
OK, alignment complete and I actually got to drive it a wee bit today.

So a couple of strange things happened. I expected some hiccups so i guess they have arrived

First of all, the truck did some idling on the alignment rack, then it had a test drive. A little while later I was backing it up back onto the trailer to take it hope and it starts just pouring antifreeze out. I think it was coming from the over flow and I'd say it puked between one to two quarts!

Why???

I have no explanation as to why that happened. I did have the reservoir topped up really well, so normal expansion may have accounted for the burping of fluid, but that much???

After getting home I topped it up more and it burped a little bit, so I'll call that one normal.

I drove it around the neighborhood then down the road and back and it seemed normal. In fact the temp gage showed nothing above approximately 180F.

Then I grab the pre-Ranger and go for a slightly longer drive and arriving at a country store to buy a peach tea, again, it seems normal, although the idle is way too low at around 500 RPM. On the drive home I romp on it at about 35 and it hit pretty well, then "Boom!" Followed by a strong vibration. I brought it to a stop and looked underneath, and discovered the driveshaft had shoved one of the U-joint caps out of its pocket and beat the other one half way out.

I pulled the driveshaft at home and found some damage to the end of the shaft. The U-joint cap bores were no longer round. So I tapped a bit with a ball peen, then forced an old cap into the pocket and straightened that business out. I put two new caps onto the U-joint Tater sold me and shoved all that back into place, installing new U-joint cap retaining clips to the outside seated into the grooves. So, call that repaired, and then the daylight ran out.

Through all of that I dropped my new camera and broke it. Yep it died, so instead of working into the night, I was off to best buy to get another new one. This one, you may recall was purchased in March (Short life span)

So, I guess I'm a bit rattled at the moment. I can't explain why the fluid is burping out, and the electric fan never came on, and now will this driveshaft hold up???
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 04, 2019, 10:40:21 PM
Be careful out there Don. That CG looks pretty high.

Congrats on finishing.


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Handles normally to better than stock is what I am seeing. rear bar now/stock: no rear bar. Front bar is upgraded and much larger. Air bags killin' some of the lean too. It actually drives well and has a very tight turning radius. About that, I am surprised.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 04, 2019, 10:43:11 PM
Hey Don, if you decide the 35” tires just don’t look right, I can probably find a spot under the blazer for them. They aren’t TOO used so I’m sure we could make a deal. ;)


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Yea, I think it could use 37's

So if I can keep the wear down, I could sell them to you highly discounted when I get back. I plan to rotate them once or twice during the trip. Once in Dave's lawn, and once in Shawn's ;-)))
Title: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on June 04, 2019, 10:57:37 PM
OK, alignment complete and I actually got to drive it a wee bit today.

So a couple of strange things happened. I expected some hiccups so i guess they have arrived

First of all, the truck did some idling on the alignment rack, then it had a test drive. A little while later I was backing it up back onto the trailer to take it hope and it starts just pouring antifreeze out. I think it was coming from the over flow and I'd say it puked between one to two quarts!

Why???

I have no explanation as to why that happened. I did have the reservoir topped up really well, so normal expansion may have accounted for the burping of fluid, but that much???

After getting home I topped it up more and it burped a little bit, so I'll call that one normal.

I drove it around the neighborhood then down the road and back and it seemed normal. In fact the temp gage showed nothing above approximately 180F.

Then I grab the pre-Ranger and go for a slightly longer drive and arriving at a country store to buy a peach tea, again, it seems normal, although the idle is way too low at around 500 RPM. On the drive home I romp on it at about 35 and it hit pretty well, then "Boom!" Followed by a strong vibration. I brought it to a stop and looked underneath, and discovered the driveshaft had shoved one of the U-joint caps out of its pocket and beat the other one half way out.

I pulled the driveshaft at home and found some damage to the end of the shaft. The U-joint cap bores were no longer round. So I tapped a bit with a ball peen, then forced an old cap into the pocket and straightened that business out. I put two new caps onto the U-joint Tater sold me and shoved all that back into place, installing new U-joint cap retaining clips to the outside seated into the grooves. So, call that repaired, and then the daylight ran out.

Through all of that I dropped my new camera and broke it. Yep it died, so instead of working into the night, I was off to best buy to get another new one. This one, you may recall was purchased in March (Short life span)

So, I guess I'm a bit rattled at the moment. I can't explain why the fluid is burping out, and the electric fan never came on, and now will this driveshaft hold up???

You broke one of Shawn’s u joint straps? Or was it a different end of drive shaft.

Also, if you have a valuable personal property insurance policy, you might be able to add your camera to it. We did that with ours because USAA will cover anything that happens to it, even stolen if I recall correctly.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on June 04, 2019, 11:08:25 PM
Turner, it sounds like the cap backed off the driveshaft side not the yoke side. I’ve never witnessed anyone breaking those girdles not that it couldn’t be accomplished by Don....

Rotation, we can handle that....
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on June 04, 2019, 11:18:49 PM
Burping because it's air locked.  It will eventually bleed itself out.  The temp sensor won't read properly,  and the fans won't come on,  if the sensor is not submerged in coolant.  They won't accurately measure air or steam temps...well they will,  but there's a huge delay,  usually after it's already overheated.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on June 04, 2019, 11:31:55 PM
I still have a dirt yard so..... donuts it is!!


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on June 04, 2019, 11:36:41 PM
Could be worse, easy fixes for sure.

You were sure the coolant crossover was open? Knew you had a time finding the O rings for it.

Just do the 37s now and what is it you have about cameras and chainsaws? I keep the lanyard around my wrist now!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on June 04, 2019, 11:46:22 PM
Turner, it sounds like the cap backed off the driveshaft side not the yoke side. I’ve never witnessed anyone breaking those girdles not that it couldn’t be accomplished by Don....

Rotation, we can handle that....

Ok that makes more sense.

My first thought was, only Don could break something that has yet to have a reported breakage!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cj7ox on June 05, 2019, 03:26:45 AM
Looking good, Big D! I think Pre-ranger 1 has grand designs of taking primary usage from you. Sleep with one eye open! LOL
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 05, 2019, 08:51:04 AM
Turner, it sounds like the cap backed off the driveshaft side not the yoke side. I’ve never witnessed anyone breaking those girdles not that it couldn’t be accomplished by Don....

Rotation, we can handle that....
^^^^ What he said

Strap girdle thing is G-T-G

Camera not so much...it died...right after I dropped it...I don't see the correlation...

Shawn is korrekt, looks like one of the caps backed out causing an elongation stress spreadin' too much force shovin in too little of a spot kinda failure.

What scares me is just how, exactly, did that happen??

Ya see, when the drive shaft was modified, they welded a non chevy saddle yoke thing onto the end. Makes me thing it may be one of uncle Ho's chinaman's specials made from scraps of old cartridge cases that we fired at them at some point...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 05, 2019, 08:52:59 AM
Looking good, Big D! I think Pre-ranger 1 has grand designs of taking primary usage from you. Sleep with one eye open! LOL

Never happen!

I may be slow but at least I do poor work! And since he has designs on becoming a lieutenant, I just can't let him get a leg up. You know the deal...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 05, 2019, 08:57:13 AM
Turner, it sounds like the cap backed off the driveshaft side not the yoke side. I’ve never witnessed anyone breaking those girdles not that it couldn’t be accomplished by Don....

Rotation, we can handle that....

Ok that makes more sense.

My first thought was, only Don could break something that has yet to have a reported breakage!
Two MARINE privates are locked in a room which has nothing, just four walls, a ceiling and a floor, along with two steel balls. A sergeant comes back in an hour to check on the condition of the Marines and the steel balls.

The privates report that that one of the steel balls is broken, and the other is missing, and no one knows what happened!

Please note that Marines are the central characters in this amusing story

Aren't you a Marine?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 05, 2019, 08:59:19 AM
Burping because it's air locked.  It will eventually bleed itself out.  The temp sensor won't read properly,  and the fans won't come on,  if the sensor is not submerged in coolant.  They won't accurately measure air or steam temps...well they will,  but there's a huge delay,  usually after it's already overheated.
I was thinking so. Start with the coolant crossover, or thermostat, or???
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 05, 2019, 10:46:52 PM
So today I warmed up the truck with the front and rear heater on low and ran it with the cap removed from the coolant resevoir. I observed a burping of air bubbles off and on for maybe five minutes.

Checking the temp gage showed no change at 170 ish.

It burped a bunch of fluid before things got crazy.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 05, 2019, 10:48:05 PM
Allowing it to run more the temp gage still stayed low but then this happened:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 05, 2019, 10:51:32 PM
After the volcano eruption subsided I added a gallon and a half more of fresh fluid to get it to nearly top off.

After that I started it and allowed it to run for some time. It did not behave badly, but the temp gage stayed around 170F and I did not remove the cap at all until it had cooled maybe 45 minutes later. It only released some pressure and no fluid at that time. I topped it off with another half quart and put the cap back on.

Honestly, I am concerned that something is amiss. I have never seen bad manners like this before...wondering...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 05, 2019, 10:53:42 PM
With no time to waste, I began with the installation of the tent.

I unboxed the thing and unfolded it. Doing so caused it be become "set up!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 05, 2019, 10:55:05 PM
The ladder, additional bow, parts and hardware were located inside.

So far, I have to say it looks to be fairly well constructed
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 05, 2019, 10:56:59 PM
I had the option to open it to the rear which was recommended for heavy trucks like mine, but I chose to open it to the side since I already have a rear hatch to provide some cover. The aluminum ribs are more of the extruded stuff and attach easily
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 05, 2019, 11:00:58 PM
The actual roof rack I have has enough space to mount the tent to, although, I needed to create a 2 3/8" thick spacer to get the base of the tent above the side mounted tube and some hardware on the other side.

I ripped some pine into the thickness I needed, then cut those pieces to the proper length.

The concept here is to lay this spacer grid on top of the existing metal structure where I can and to provide a total of seven ribs upon to rest the aluminum ribs on the base of the tent. I'd like to distribute the weight of my lardy buttok evenly across the span of the burbs roof.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 05, 2019, 11:02:17 PM
I cut the bottom side for bolt head relief so that the wood surface would rest on the aluminum 80/20 structure.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on June 06, 2019, 12:19:02 AM
Next up(https://uploads.tapatalk-cdn.com/20190606/6dfa593290cb1632d9a9c7466aa61ed7.jpg)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on June 06, 2019, 12:56:07 AM
Instead of all that weight and building, why not just foam sheets?

I would get the cooling system pressure tested.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on June 06, 2019, 12:59:37 AM
Oh no, this tent is starting to take on a familiar look.  Trying to remember what it was called... Tic Tac..no..let me think..Tic Tock?...maybe it was Tack Driver. Yeah that was it.

:evil

..cooling system is fine now.  The only way to do it different is to drill a small bleed hole in the thermostat,  or to use what a lot of us shops use, a vacuum filler,   similar to what the factory uses.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on June 06, 2019, 01:08:28 AM
Rangers ready, batteries charging.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cj7ox on June 06, 2019, 01:50:32 AM
THIS JUST IN...IN AN EFFORT TO SAVE WEIGHT AND KEEP A LOW CENTER OF GRAVITY ON HIS LATEST EXPEDITIONARY VEHICLE PROJECT, BIG D USES COPIOUS AMOUNTS OF HEAVY WOOD FRAMING TO INSTALL A ROOF TOP TENT TO HIS VEHICLE. THIS PART OF THE PROJECT, KNOWN AS THE TAC-TOP-TENT, IS REPORTED TO DECREASE THE WEIGHT ON THE ROOF BY ADDING 432LBS. AT THIS TIME, IT IS UNCLEAR AS TO WHETHER THIS WILL HAVE A POSITIVE IMPACT ON THE PROJECT. WE WILL CONTINUE TO LOOK FOR REPORTS OF THIS VEHICLE'S PERFORMANCE OFF-ROAD, AND WHETHER THE TAC-TOP-TENT CONTRIBUTES TO EVENTUAL ROLL-OVERS, AS BIG D NEGOTIATES VARIOUS NEFARIOUS MULCH PITS AT MALLS ACROSS THE UNITED STATES. STAY TUNED!

 :evil:

 :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on June 06, 2019, 02:01:16 AM
 :likebutton:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on June 06, 2019, 02:01:46 AM
THIS JUST IN...IN AN EFFORT TO SAVE WEIGHT AND KEEP A LOW CENTER OF GRAVITY ON HIS LATEST EXPEDITIONARY VEHICLE PROJECT, BIG D USES COPIOUS AMOUNTS OF HEAVY WOOD FRAMING TO INSTALL A ROOF TOP TENT TO HIS VEHICLE. THIS PART OF THE PROJECT, KNOWN AS THE TAC-TOP-TENT, IS REPORTED TO DECREASE THE WEIGHT ON THE ROOF BY ADDING 432LBS. AT THIS TIME, IT IS UNCLEAR AS TO WHETHER THIS WILL HAVE A POSITIVE IMPACT ON THE PROJECT. WE WILL CONTINUE TO LOOK FOR REPORTS OF THIS VEHICLE'S PERFORMANCE OFF-ROAD, AND WHETHER THE TAC-TOP-TENT CONTRIBUTES TO EVENTUAL ROLL-OVERS, AS BIG D NEGOTIATES VARIOUS NEFARIOUS MULCH PITS AT MALLS ACROSS THE UNITED STATES. STAY TUNED!

 :evil:

 :popcorn:

Well, at least it’s pine and not red oak or mahogany.

But I got a real good chuckle out of that!


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cj7ox on June 06, 2019, 02:06:37 AM
But I got a real good chuckle out of that!


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I figured it'd been awhile since I'd been fired, and I was due. LOL  :wink:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on June 06, 2019, 03:54:30 AM
Fired, that was a full broadside!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cj7ox on June 06, 2019, 03:57:15 AM
LOL! I had a Division run at oh dark thirty this morning, and the quoffee afterwards is necessarily strong.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on June 06, 2019, 08:25:50 AM
Better spray this thing so the termites don’t get at it. 


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 06, 2019, 08:55:21 AM
But I got a real good chuckle out of that!


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I figured it'd been awhile since I'd been fired, and I was due. LOL  :wink:
Yea, come to think of it, I shouldn't fire you because of you serving our nation, and being deployed, in harms way, and all that. But I think I'll make an exception.
Yup, fired ya are
Not sure for how long...Maybe just until I forget I did it...
Anyone disagree?
If so, then Sean will get some company ;-))
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 06, 2019, 08:56:38 AM
Frikkin people! :facepalm: :knucklehead: :sad: :sad:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cj7ox on June 06, 2019, 08:58:11 AM

Yea, come to think of it, I shouldn't fire you because of you serving our nation, and being deployed, in harms way, and all that. But I think I'll make an exception.
Yup, fired ya are
Not sure for how long...Maybe just until I forget I did it...
Anyone disagree?
If so, then Sean will get some company ;-))

LOL! ;-)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on June 06, 2019, 09:41:06 AM
LOL! I had a Division run at oh dark thirty this morning, and the quoffee afterwards is necessarily strong.

I am so glad that I never had to spend any amount of time in Kuwait  :facepalm:  just the few days it took to get in and out of theater were bad enough. 
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on June 06, 2019, 10:46:08 AM
Keep Don on his toes guys.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on June 06, 2019, 05:26:54 PM
LOL! I had a Division run at oh dark thirty this morning, and the quoffee afterwards is necessarily strong.

I am so glad that I never had to spend any amount of time in Kuwait  :facepalm:  just the few days it took to get in and out of theater were bad enough.

Did you fly through Qatar? I personally would take Kuwait over Qatar, but I was also stuck in Qatar because of plane breakage issues.... for ten days. And then in Germany on the flight for about 7 hours. What a return trip that was! Thankfully I was traveling solo so I was able to be an anonymous blender inner!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on June 06, 2019, 05:40:52 PM
LOL! I had a Division run at oh dark thirty this morning, and the quoffee afterwards is necessarily strong.

I am so glad that I never had to spend any amount of time in Kuwait  :facepalm:  just the few days it took to get in and out of theater were bad enough.

Did you fly through Qatar? I personally would take Kuwait over Qatar, but I was also stuck in Qatar because of plane breakage issues.... for ten days. And then in Germany on the flight for about 7 hours. What a return trip that was! Thankfully I was traveling solo so I was able to be an anonymous blender inner!

I took a C-130 flight from salerno to Kuwait and we stopped in Qatar just long enough to off load some cargo and to refuel.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on June 06, 2019, 06:13:06 PM
LOL! I had a Division run at oh dark thirty this morning, and the quoffee afterwards is necessarily strong.

I am so glad that I never had to spend any amount of time in Kuwait  :facepalm:  just the few days it took to get in and out of theater were bad enough.

Did you fly through Qatar? I personally would take Kuwait over Qatar, but I was also stuck in Qatar because of plane breakage issues.... for ten days. And then in Germany on the flight for about 7 hours. What a return trip that was! Thankfully I was traveling solo so I was able to be an anonymous blender inner!

I took a C-130 flight from salerno to Kuwait and we stopped in Qatar just long enough to off load some cargo and to refuel.

Ahh, ok that makes sense. Which is probably one of the better ways to go.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 06, 2019, 11:05:02 PM
I got the spacer assembly which isn't very heavy at all, (I'd make it 30-35 pounds) undercoated, painted and bolted up
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 06, 2019, 11:06:20 PM
I used 1/4" X 4" long bolts, countersunk into the material to fasten the spacer to the roof rack
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 06, 2019, 11:07:16 PM
It was a balancing act, but one of the pre-Rangers and I wrestled the tent onto its new perch
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 06, 2019, 11:08:35 PM
The supplied ladder was too short and required a short extension to reach the ground to provide both access and proper support
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 06, 2019, 11:10:00 PM
The ladder bolts onto the tent frame through some predrilled holes
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 06, 2019, 11:10:35 PM
And it is pretty spacious inside
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 06, 2019, 11:12:56 PM
I put up a strip of LED  lights and ran a supply wire from a rear power port in the Burb
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 06, 2019, 11:13:48 PM
Back into the garage for some more fitting
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 06, 2019, 11:15:28 PM
And after moving it I noticed this!!!!!!!!!!

Honestly, am I ever going to get actually finished??? :shocked:

Oh and did I mention there is no cold air coming out of the AC???!!! :facepalm:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on June 06, 2019, 11:16:34 PM
Time to part into it and start on the next one isn’t it?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cj7ox on June 07, 2019, 07:47:30 AM
LOL! I had a Division run at oh dark thirty this morning, and the quoffee afterwards is necessarily strong.

I am so glad that I never had to spend any amount of time in Kuwait  :facepalm:  just the few days it took to get in and out of theater were bad enough.

Did you fly through Qatar? I personally would take Kuwait over Qatar, but I was also stuck in Qatar because of plane breakage issues.... for ten days. And then in Germany on the flight for about 7 hours. What a return trip that was! Thankfully I was traveling solo so I was able to be an anonymous blender inner!

I took a C-130 flight from salerno to Kuwait and we stopped in Qatar just long enough to off load some cargo and to refuel.

Ahh, ok that makes sense. Which is probably one of the better ways to go.

At least in Qatar you can drink beer. ;-)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on June 07, 2019, 09:15:13 AM
And after moving it I noticed this!!!!!!!!!!

Honestly, am I ever going to get actually finished??? :shocked:

Oh and did I mention there is no cold air coming out of the AC???!!! :facepalm:

Looks reddish, trans?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 07, 2019, 10:31:37 AM
Time to part into it and start on the next one isn’t it?


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Aren't you supposed to be banned or something? :-?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 07, 2019, 10:33:00 AM
And after moving it I noticed this!!!!!!!!!!

Honestly, am I ever going to get actually finished??? :shocked:

Oh and did I mention there is no cold air coming out of the AC???!!! :facepalm:

Looks reddish, trans?
Yea, that's my guess and initial investigation isn't good. Not conclusive, but looks to be coming from parting line between trans output and front of transfer.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on June 07, 2019, 10:50:14 AM
And after moving it I noticed this!!!!!!!!!!

Honestly, am I ever going to get actually finished??? :shocked:

Oh and did I mention there is no cold air coming out of the AC???!!! :facepalm:

Looks reddish, trans?
Yea, that's my guess and initial investigation isn't good. Not conclusive, but looks to be coming from parting line between trans output and front of transfer.

Well if it is that location I’m going to be hopeful that it just needs a new gasket. Other than the heft of the transfer it is an easy job as you know.

Ours was leaking from the same spot, but I knew it was because there was no gasket between the two.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 07, 2019, 11:00:45 AM
And after moving it I noticed this!!!!!!!!!!

Honestly, am I ever going to get actually finished??? :shocked:

Oh and did I mention there is no cold air coming out of the AC???!!! :facepalm:

Looks reddish, trans?
Yea, that's my guess and initial investigation isn't good. Not conclusive, but looks to be coming from parting line between trans output and front of transfer.

Well if it is that location I’m going to be hopeful that it just needs a new gasket. Other than the heft of the transfer it is an easy job as you know.

Ours was leaking from the same spot, but I knew it was because there was no gasket between the two.
More serious than that I think.
I believe the transfer has a seal on the input and the trans, one on the output.

Not sure, anyone know for sure?

I did put a new seal onto the transfer input, but I don't recall doing anything to the trans output. I installed a new gasket between the two
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on June 07, 2019, 11:02:36 AM
Time to part into it and start on the next one isn’t it?


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Aren't you supposed to be banned or something? :-?



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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on June 07, 2019, 12:10:02 PM
The trans doesn't have an output seal. The input on the TC is the only seal. That whole cavity between the 2 is full of tranny fluid making the gasket mucho importante .
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on June 07, 2019, 12:20:18 PM
I wonder if those bolts worked themselves loose during test drive and drive shaft issue?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: EL TATE on June 07, 2019, 12:30:25 PM
I wonder if those bolts worked themselves loose during test drive and drive shaft issue?

I was just thinking of this
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on June 07, 2019, 12:50:42 PM
I wonder if those bolts worked themselves loose during test drive and drive shaft issue?
Or he used silicone on the gasket and the gasket squished out. may or may not be speaking from experience.  :embarrassed:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 07, 2019, 09:40:57 PM
I wonder if those bolts worked themselves loose during test drive and drive shaft issue?
Or he used silicone on the gasket and the gasket squished out. may or may not be speaking from experience.  :embarrassed:
I was waiting for the response to figure out what next.
So, I did install a new gasket that came with the transfer case pump fix kit. I don't recall putting any silicone on it. I'll look more closely at it.
So here is what the leak/seep/drip/whatever looks like:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 07, 2019, 09:42:59 PM
I can find nothing showing any evidence of fluid anywhere above the low point of the mating surface between the two components.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 07, 2019, 09:46:18 PM
And after examining the photos, I don't see any silicone, so I think I'm correct in saying I just placed the gasket onto two clean surfaces.

So I didn't get any further into it for the moment as I was waiting for the brain trust to kick in with their advice.

And as per SOP, when one thing grinds to a halt, I start something else.

On the punchout list was, securing the line on the brake isolation valve. One clamp and that was done
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 07, 2019, 09:48:21 PM
Then it was time to complete the wiring for the top mount back up light. I grounded it on the stoplight screw, then used adhesive blocks to route the wire from the tail light housing up to the light
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 07, 2019, 09:49:18 PM
And now that is working and completed
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 07, 2019, 09:52:09 PM
Next up, I installed the 800 watt inverter. This is needed to power my computer, and perhaps some low amp draw something, maybe a fan...
It is wired to the aft battery only.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 07, 2019, 09:54:35 PM
So, the way I did it was to run another hot battery cable into the passenger compartment to a homemade fuse block. I like the combustible stuff (Carryover from my welding days). I placed two 40 amp mega fuses onto the block to power the inverter and some unforeseen future something or another.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 07, 2019, 09:57:19 PM
I mounted it on the forward bulkhead of the drawer cabinet and just behind the passenger seat. The inverter is positioned a bit more toward the center and below the door to the storage drawers.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 07, 2019, 10:00:03 PM
The rear hatch opens just a bit too far to deploy the awning without interference. To remedy that, I fashioned up a simple strap to hold the hatch in a 80% open position.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 07, 2019, 10:01:26 PM
A small section of pile allows for the strap to be stowed out of the way where it will not protrude when not in use
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 07, 2019, 10:02:44 PM
You may not notice as some changes are subtle, but I am slowly adding provisions and stowing them here and there. The back end is filling up
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 07, 2019, 10:04:49 PM
No, the weapon will not be going with us

I upgraded the toolbox with more stuff. I went from the 3"ish deep box to a 4.something inch deep box and added more spare hardware and some more tools.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on June 07, 2019, 10:29:33 PM
Can't remember on the 4l80s, but on the Allys,  when they blow fluid out of the transmission vent tube,  it will run down the left side and end up right where yours is wet. Something to look for.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 08, 2019, 08:46:54 PM
Can't remember on the 4l80s, but on the Allys,  when they blow fluid out of the transmission vent tube,  it will run down the left side and end up right where yours is wet. Something to look for.
I'll look again ken, but after studying and examining it for some time, I did not see any evidience of any wetness anywhere above the low point I pointed out.

So on another point, I think I may have nicked or drilled into an AC line. I am getting no cool air at all, and I remember when drilling for the electric step bracket, the drill punching through and digging into that group of heater and AC lines which run along the inner rocker on the right side.

I will have to dig into that and see what is going on, and if that is why I do not have cooling. The compressor is cycling like it should...

The larger problem is that I have missed my launch date now by two weeks...with a rapidly closing window before pre-ranger number small has to start football practice...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on June 09, 2019, 12:10:06 AM
If the compressor is running,  it has freon. Is the drier getting cold?
Going out on a limb, but sounds like the temp door motor acting up. If so, it  probably had something to do with your dead battery issues.
..drier cold (40* ish) means problem is in the dash.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on June 09, 2019, 12:13:42 AM
Just remembered it had rear a/c. The back would still be cold even if the front temp door was acting up.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 09, 2019, 08:09:16 AM
If the compressor is running,  it has freon. Is the drier getting cold?
Going out on a limb, but sounds like the temp door motor acting up. If so, it  probably had something to do with your dead battery issues.
..drier cold (40* ish) means problem is in the dash.
I'll check the drier out when I get back from church.
But no cold air at all coming out of dash vent
Rear discharge was not checked

So plan of attack today is to check that out, and look for that vent tube connection. I did find a rubber hose which was not connected to anything on the top of the transmission...

If the compressor is running and nothing else is amiss, then perhaps just needs a recharge. I never checked that out when the thing arrived here last fall.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: swbhobie16 on June 09, 2019, 10:06:10 AM

.. I did find a rubber hose which was not connected to anything on the top of the transmission.

  :facepalm: hah

in all honesty.. i hope that’s it. would be a quick and easy solution to a leaky trans. especially with no other real suspects..
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 09, 2019, 04:42:13 PM

.. I did find a rubber hose which was not connected to anything on the top of the transmission.

  :facepalm: hah

in all honesty.. i hope that’s it. would be a quick and easy solution to a leaky trans. especially with no other real suspects..
OK, back from an awesome church service. Eyelid check complete...no holes!

Jockin' up with ma work clothes. gunna find out pdq...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on June 10, 2019, 05:54:27 PM
What in the tarnation is going on here? You get stuck in a KY mulch bed at the local piggly wiggly again?

Perhaps you were transporting Kens gf (hopefully to a big hole on the back 40) and blew out all four tires simultaneously?

Or you dropped it off at Dave’s cabinet shop for a hippy color makeover?

Yeah I know probably not but all of those above sounded better than going the way of SQ D.......  :facepalm:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on June 10, 2019, 07:34:00 PM
Harsh words my friend,  harsh words.
..especially the part about Dave.  Rofl
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 10, 2019, 07:49:04 PM
I think I'm just going to take it to a transmission shop of to the local Ken's Auto place.

I wiped the trans area down really well, then only started it up for like 30 seconds on Sunday. Today, I see wet spots and a bunch of drips hanging on the crossmember. And I can't find the first leak from anywhere north of the bottom of the trans output flange.

So it doesn't look like I am going to get any sort of a break, and although I have been trying to save myself some money, Its time to just get it done so i can pull off some kind of trip. Honestly it is now doubtful that I have enough time to do the big trip I wanted to go on so much. Pre-Ranger little starts his varsity football team training in earnest 10 July. He has actually been in training all summer but that is the first day that is no longer optional. So do I take away his year of playing football? His first year in Highschool?

Back to the truck, I am trying to get it into the shop tomorrow morning.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 11, 2019, 11:53:26 PM
Update: I am scheduled for 0830 on Monday to drop it off. I'm having the AC serviced/fixed and that trans oil leak attended to. After that I'll start to drive to record data.

This all means several things

First, It will be getting done and will be useable
Second, There is no longer enough time to do the big trip I planned. If we get it fixed by say, COB Tuesday, and record data the following two days, then sending it off to Justin, I'm betting it will still be a few days to a week before I get anything back.
The situation has forced me to alter the travel plans to something closer in even hub and spoke. Not sure how that will work out, but we will hopefully be getting something done on the camping front.

I'm a bit disappointed but after the past, month or so, almost somewhat relieved. I worked my butt off on that thing. It was just too much work for one guy and there were several things that had issues that backed me up by a couple weeks. That, some nasty weather, having to still work on the house, be a father, serve at church, and 44 other commitments made this what it is. Additionally we completely dismantled the SquareD project and sorted and sold all those parts to perhaps 20 different folks.

No real lesson learned here, it was a major undertaking and in short order I will start to drive one magnificent truck, but just not to Washington. I apologize to those who were planning to meet and greet this year. Hopefully I can be in a good position to leave on time next year.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on June 12, 2019, 01:12:33 AM
I feel like Ken told you to not monkey with the rear axle!   Just sayin


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: longball on June 12, 2019, 01:48:48 AM
You’ve built one heck of a vehicle Chief. Thankfully there’s still an opportunity to spend quality time with you two young men this year and y’all will have plenty of time to plan for a big adventure next year.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: EL TATE on June 12, 2019, 11:39:41 AM
I'm sure little Don and I will survive, not sure about Bob or Ryan :evil: we'll get lunch next summer, have fun with your boys where and while you can. they will be grown and gone soon.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 12, 2019, 08:10:37 PM
I feel like Ken told you to not monkey with the rear axle!   Just sayin


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Well that's just it. We can always point to someone who told you so and so forth. At the end of the day we all make our own decisions because it is not for others to live our lives, we must.
I did what I wanted to do here and that's really all that matters. None of this is about making anyone else happy, satisfied or anything else. It is simply a progress report on the building of this Suburban. To that end, it is built.

As for me and the guys, something interesting has been happening. We all decided that we have neglected the house, and we should work on it. So every day we have been pouring over it, fixing everything in sight. In doing so we have been spending a lot of time together, talking, kidding around, eating, getting dirty and tired together. It seems trip or no, we are bonding pretty well.

And, whenever we do something, no one can really predict just how things are going to turn out. But it is important to note that this burb did turn out so to speak. I'm fairly certain that after this visit to Troy, my mechanic friend, the thing will get repaired correctly and I can do the data recording and the follow in tune. It is very close to being finished.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on June 12, 2019, 09:39:41 PM
For what it’s worth and regardless of what he might have said either way I will just blame Ken.

Why Ken you ask? Well, for starters that whole love affair with H.

Second the 1911 thing, I mean who still uses one of those?  :rolleyes: I mean why not blame him? I can’t come up with a single reason not to.

Then the fact we believe his middle name is Dave, yeah who knew right?!?

Oh, and he’s a fallen DOT member. I think Don even promoted him to just below a paid salary position. What the heck is with all that butt kissing anyhow?

So regardless of what all you other weak knee knuckleheads think I’m gunna just blame him for this debacle......
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on June 12, 2019, 10:40:52 PM
I had awhole excuse of a second trip to Moab when Don came here to Moab!   I am just mad I can’t use that excuse to make a second trip. 


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on June 13, 2019, 04:37:13 AM
I understand Don, I have been doing the same.

When/if next year maybe I can tag along to moab. Never been, told the boys and need to be led around the first tine.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on June 13, 2019, 09:08:57 AM
He there is really quite a great trail system here,  there are very few trail obstacles that don’t have a bypass trail, a obstacle warning.    I was shocked at what a little common sense did with the two other drivers that hadn’t been here before chose to drive.   

I’d tour guide anyone if it worked with my schedule. 


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cudakidd53 on June 13, 2019, 11:43:39 AM
Incredible amount of work done and improvements accomplished!  Your trip will be everything that it's supposed to be Don - God is in control!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 14, 2019, 09:34:58 AM
Yea, well, I feel like crap that I couldn't pull this off in time to make it happen. Maybe if the football thing didn't crop up, essentially killing off almost half of the summer I could still do it. But I can't take that boy's football aspirations away from him. He is successful out there. He is getting exposure to many strong men, and learning about payoffs from hard work, how to shake it off, and teamwork. That's a bunch of stuff and in my view it trumps what I wanted to do.
But I'm not throwing in the towel, I just have to repackage it and get the dad/son thing done within the fabric of the situation I have in front of me.

Shawn, you started something, and you're gonna be on your own with it. You criticized Ken's love for the venerable 1911 calling it out, well questioning it. My pre-ranger, small edition) owns one of those. His first pistol. He points out that when the glock served the US Army for many decades and won a world war, he will consider it a great weapon, but not until then. Now this young man is not going to stay a young man. He is getting bigger and stronger by the week. He will someday wear the rank of a US Army Officer (I think) with a gold tab on his shoulder that simply says, "Ranger." Now, I'd think twice about crossin' up one like that. And what if he ends up as your son in law? What then? Careful my friend where you tread or what you say. Words have a way of walking right up into your business if you know what I'm sayin' ;-)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on June 14, 2019, 11:16:48 AM
Still Kens fault somehow.....  :tongue:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on June 14, 2019, 10:57:11 PM
I’ll throw this out there. And I may live to regret it.  Anyone want to shoot a combat pistol course with a 1911 against me an a glock I have prizes for the winner. And it has to be muddy. . Jus saying. I ain’t afraid to pay up.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on June 14, 2019, 11:13:26 PM
Never-mind. That was an arrogant insensitive post.   I’m sure there are many who can outshoot me with a 1911. Or a glock or M&P or whatever.

My apologies.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on June 15, 2019, 12:40:54 AM
Naw, not arrogant.  Just misguided.  No mud in Az. ;)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 15, 2019, 11:31:50 AM
Naw, not arrogant.  Just misguided.  No mud in Az. ;)
Well, I was going to say, if we ever get to my farm, it can be muddy, and we could set up a shooting course, and Ken and Tex could square off...
So on the Burb, Monday morning remains the time when this thing gets thrown into the chock blocks. The chock blocks that this runner uses to take off on the rece. I am hopeful that everything can be wrapped up in a quick bit of time and possibly get it out on the road for some son/dad time.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on June 15, 2019, 01:02:20 PM
What did the trans shop find about your leak ?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 15, 2019, 04:25:41 PM
What did the trans shop find about your leak ?


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My appointment is for 0830, Monday, in two days...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on June 15, 2019, 06:29:23 PM
Copy


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on June 17, 2019, 02:06:01 PM
I just wanna know when Don is bringing me some mantel wood that’s signed by everyone!


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on June 17, 2019, 04:30:05 PM
Burn out video? 


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 17, 2019, 08:52:21 PM
I just wanna know when Don is bringing me some mantel wood that’s signed by everyone!


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That wood be cool! (Get it, "wood")
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on June 17, 2019, 09:01:19 PM
I just wanna know when Don is bringing me some mantel wood that’s signed by everyone!


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That wood be cool! (Get it, "wood")

Not you too.....smh
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on June 17, 2019, 10:02:59 PM
I just wanna know when Don is bringing me some mantel wood that’s signed by everyone!


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That wood be cool! (Get it, "wood")

Not you too.....smh
Dad jokes. Gotta love ‘em.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 17, 2019, 10:03:14 PM
Sorry, I have limited material to work with :-(
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on June 17, 2019, 10:58:19 PM
What’s the results of the trans shop


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: EL TATE on June 18, 2019, 09:57:16 AM
I just wanna know when Don is bringing me some mantel wood that’s signed by everyone!


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That wood be cool! (Get it, "wood")

Not you too.....smh

It's a disease Nate, lol
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 18, 2019, 12:40:09 PM
What’s the results of the trans shop


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Haven't checked. Not a transmission shop. Gen mechanic like Ken
Doing Trans leak and AC problem.
Had to work all day yesterday moving a friend out of his old home into another one. 9 hours of, well, you know how that goes.

My pre-Rangers were magnificent. They worked all day long, and hard and never said a single word to complain and easily outworked every man there.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on June 19, 2019, 07:08:33 PM
Still have to nudge mine to keep working. Way easily distracted.

Don, as I said in the other thread after your comment on the 6ltr power. Just find a LBZ and do it. Power, mileage and well, its cool!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on June 19, 2019, 08:18:01 PM
So is your vacation completely cancelled now?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on June 19, 2019, 10:16:18 PM
Sell it


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 20, 2019, 07:52:34 AM
Still have to nudge mine to keep working. Way easily distracted.

Don, as I said in the other thread after your comment on the 6ltr power. Just find a LBZ and do it. Power, mileage and well, its cool!
Am strongly considering it JR. But first let me put some miles on it. I'm thinking I could get a good price on my super clean and lower mileage 6.0 and 4L80E... And I stumbled across a rebuildable LB7 for $700 not too far away.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 20, 2019, 07:53:33 AM
So is your vacation completely cancelled now?
The full west jaunt is. But I'll get them out for a shorter run shortly after getting the tune finished in the truck.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 20, 2019, 07:57:33 AM
So update is: Parts on order.

Troy is replacing the front double seal on the transfer case. I guess I must have buggered it up or something. And I never looked at the transfer case autotrac fluid to see if it was the same color as the trans fluid is. But he concurs, the only leak he can find is at the mating of the cases.
As for the AC, he didn't get far enough into it to give me any answer, but thinks it is the climate control motor like Ken suggested. He actually has another 6.0 truck in the shop with the identical problem.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on June 20, 2019, 08:35:46 AM
Skip the LB7 and get an LLY

You want the injectors out from under the valve covers.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 20, 2019, 09:04:22 AM
Skip the LB7 and get an LLY

You want the injectors out from under the valve covers.


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Not saying I'm doing it, but I'd want a LML mostly because of the much better transmission, if that is possible

But having just looked at the prices, my immediate inclination is No Freakin' way!

So to convert a harness is like $600

I'm guessing a Duramax engine and Ally is not free. So a good running set with low mileage, what $7K-$10K???

And if it's one of these engines loaded up on miles, then I'd go through it and that, also is not free. Guessing $3K on top of the acquisition price of the engine, and we all know the trans is $5K.

I saw a push button transfer case harness at $980!!!!!!!!!!!!!!
the transfer case $1750
another EFI Live tune and switch $700
Then there's the Intercooler, radiator, trans lines, driveshaft mod, all also free.

So unless I miss the mark on this wouldn't I be adding another $20K to the investment?

I am a bit disgusted by the price that things have gotten themselves to these days, just outrageous!

I am actually happy from this morning's little exercise. It helped clear my mind of any such foolishness of installing one of these oil burners into the Burb. So, it will be slow, but then again, it does not to be quick, just has to get to point B from "A."

For a bit more than one tenth the cost of a D-Max conversion I should be able to add a turbo onto the end of some exhaust piping and double the output, and learn to be satisified with that.

After the very short drive yesterday, I was most dissatisfied with the gearing of the 4L80E. seems like you stay in first and second for an eternity, waiting for the engine to climb into a useable power band that I was not able to locate.

All this said knowing the tune I have is ONLY the starter tune designed just to get it running enough to be able to record data which leads to a useable tune. But, there is simply not very much power in there to work with, so whatever I end up with will just be an adjustment from my well tuned D-Max powerhouse.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: EL TATE on June 20, 2019, 10:34:29 AM
what's the stall limit on the converter you got again? with the cam you threw in there and the better breathing heads I'm sorry to say I'm not really surprised, as these motors don't really even start to make decent power until around 4500rpm. you opened up the exhale portion of the motor a ton and a turbo makes sense as you now need to get more air in there, but off-throttle response would be better with a supercharger and the gearing you have in it. my 4l80/6.0 in the Yukon are the same symptoms as you. We rebuilt the trans with a 2500 shift kit for towing the trailer when we still had it, and it would stay in 1st and 2nd longer to keep the RPMs up, shifts hard too. now with the new motor there's more power since the old one had a failing cam, but still doesn't really start pulling till around 4500. turbo lag in the 6.0L might still feel like you don't really have much out of the gate, but a supercharger would be on-demand power, bolt on to the manifold without as much modification as plumbing a turbo in. just my $.02 sir. Maybe Ken or Shawn can chime in here.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wilsonphil on June 20, 2019, 11:56:01 AM
becuase I think Don need more things to work on.

https://gsaauctions.gov/gsaauctions/aucindx/?sl=91QSCI19170301

It sad to see them come to this state.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on June 20, 2019, 12:54:34 PM
Don, you seem to be judging aweful prematurely. Nothings broken in, not to mention the tuning. You could possibly be 20-80 horses short of the final product, not to mention that something could actually be wrong, which the tuner will probably catch. Be patient my friend.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on June 20, 2019, 02:25:47 PM
I agree with Ken, darn it that is hard to say! Kind of a mix between Canadian mist straight and vomit!   :tongue:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on June 20, 2019, 07:36:52 PM
Don. A cc/lb duramax is 75k. CustomiZed the way you have the burb is what 85/90?

You have what in the burb? 25/30?

So with a DMax conversion. You’re at 45?  Perspective my friend.

Not a bad deal if you plan to keep it and you have a rock solid base to start with.

I say forget doing anything other than the updated tunes and then wait a year and convert it.

You’ll be happy and you’ll never want to get rid of it.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on June 20, 2019, 07:39:40 PM
Don. A cc/lb duramax is 75k. CustomiZed the way you have the burb is what 85/90?

You have what in the burb? 25/30?

So with a DMax conversion. You’re at 45?  Perspective my friend.

Not a bad deal if you plan to keep it and you have a rock solid base to start with.

I say forget doing anything other than the updated tunes and then wait a year and convert it.

You’ll be happy and you’ll never want to get rid of it.


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Nice LLY will set you back 4k with refresh probably 6 (rings gaskets etc)

Built trans 4k if you r&r yourself.

Bits and pieces and harnesses 2-3k

Your labor and $15k



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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 20, 2019, 08:21:48 PM
Don, you seem to be judging aweful prematurely. Nothings broken in, not to mention the tuning. You could possibly be 20-80 horses short of the final product, not to mention that something could actually be wrong, which the tuner will probably catch. Be patient my friend.
Rog, Ken
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 20, 2019, 08:25:09 PM
Don. A cc/lb duramax is 75k. CustomiZed the way you have the burb is what 85/90?

You have what in the burb? 25/30?

So with a DMax conversion. You’re at 45?  Perspective my friend.

Not a bad deal if you plan to keep it and you have a rock solid base to start with.

I say forget doing anything other than the updated tunes and then wait a year and convert it.

You’ll be happy and you’ll never want to get rid of it.


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Well, I am not going to do anything in the short term, to be sure.

As for keeping it, After looking at newer Burbs, I did the math and you are very close on the numbers. I think it would be much "Cooler" to keep the classic and update over time. I don't think I will sell it ever. I may own a newer one some day, but this one will maintain a spot in the upcoming barn.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 20, 2019, 08:39:43 PM
And for the real progress report. The leak is gone. It was the seal in the input of the transfer. Call it me somehow, but I really don't know how I buggered it up, but I did replace it, and it was leaking like a sieve...

On to the AC. Now this one turned out to be very interesting. They found several things. First the electric fans were not coming on at all. They went as far as to check the wiring in the two plugs going into the computer. And guess what?? I placed the new wires in the correct position, in the wrong plug!!!

So those got sorted and we immediately got a engine fan number one.

Note: I was not there and am trying to tell this as best I can from memory after having talked to Andy, the freakin genius who found this. I think he said he had some sort of electrical engineering degree and dows automotive wiring professionally.

And the AC compressor is putting out ice cold air so that's all good, but there is some wiring mixup that they can't seem to solve. He mentioned that this setup would work great if I didn't have automatic climate control. But because I do, the fans will not turn off when the motor is off and the compressor clutch will not disengage.

So I need to contact the folks who sold this fan to me and see what they recommend. There is a hillbilly way to get it operational, to simply place a switch in the dash to turn off the fans, but I think that would be retarded. I or she would forget it and come out later to a dead battery.

One way to fix for sure would be to install the factory clutch fan setup again, but I already trashed that, but I could source a used one. I would like to try and figure out the electric fans before going back to the 20th century.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 20, 2019, 09:07:49 PM
Message he just sent me:

"May have backwards, but green wire ground controls relays to run both fans, blue wire runs just one. Want to hook blue wire up to a coolant temp switch in drivers cyl head to keep it from overheating. Tried hooking up green wire to pin 43 on connector 2 to pcm. It ground controls the relay for the compressor clutch. Worked to kick fans on with air conditioning, but when truck turned off, system grounds through compressor clutch and keeps fans on and clutch engaged. HVAC is automatic controls w/o sunroof, 2002 Suburban."


Make any sense to anyone???
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on June 20, 2019, 09:13:46 PM
A diode would probably keep it from feeding back.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: swbhobie16 on June 20, 2019, 09:30:58 PM
circling back to your 6.6 dilemma.. i may have a building LBZ for you. minus injectors  :laugh:

Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on June 20, 2019, 11:07:18 PM
As it’s been said before, you’ll want to stick to an engine from the same platform/year (or very close) because of all the electrical tie in. Going from an lb7 to an lly or even lbz isn’t too hard, but they did change all the electrical in ‘03. An LBZ is like the holy grail - most issues sorted out and pre-emission. Get into an LMM or LML and now you’re dealing with emissions (which can, and would likely be deleted immediately), plus a myriad of electrical issues to sort out.

Unless you go all mechanical Cummins...


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: kampfitt on June 21, 2019, 09:38:41 AM
I like that one!!{Unless you go all mechanical Cummins...}
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 21, 2019, 10:20:42 AM
A diode would probably keep it from feeding back.
BINGO!!!!!!!!!!!

Love ya man!

(In a manly, non LBGT, girly way, of course!)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: longball on June 21, 2019, 05:30:18 PM
Still have to nudge mine to keep working. Way easily distracted.

Don, as I said in the other thread after your comment on the 6ltr power. Just find a LBZ and do it. Power, mileage and well, its cool!
Am strongly considering it JR. But first let me put some miles on it. I'm thinking I could get a good price on my super clean and lower mileage 6.0 and 4L80E... And I stumbled across a rebuildable LB7 for $700 not too far away.
Skip the LB7 and get an LLY

You want the injectors out from under the valve covers.


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I thought I read somewhere that the SACS style injectors was the fix for the older trucks. If so, the $700 LB7 starts to look like a pretty good place to start if a guy wants a diesel powered 2002 burb. If you’re not happy with the 4 speed and staying with gasoline power, what about a swap to 6 speed? Cheaper than building a Duramax even if you did start with a $700 block.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 21, 2019, 11:48:12 PM
Well, I hear that the six speed swap is either near impossible or very difficult to sort. Besides, a turboed up 6.0 would work better with long gears.

Bottom line is that this discussion is academic only for the time being. I only want to get the engine in it sorted and providing power to get this Burb moving.

It was at the shop all day today, and may well be fixed, don't know. I worked on the Silverado and cut grass until nearly 2000. I'll know more tomorrow about where this all sits
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 25, 2019, 09:50:47 PM
Update: The thing is still in the shop. Like I said earlier, trans/transfer case all fixed, but the electrical engineer person working on it is not in until tomorrow. Sure would like to drive it some...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on June 29, 2019, 09:31:14 PM
And another update: The thing is still in the shop. The seal that was replaced in the transfer case is now dry rotting due to excessive age!!!!!!!!!

Or maybe not

So, I guess it is just my luck, but again we seem to have developed a bit of a story. The climate control/HVAC problem turned into some electrical engineering thing without my knowing it as we all know. The job of figuring it out was given to a local college teacher/instructor who teaches automotive electrical systems at GateWay college. He dove right in quickly dissembling my wiring harness (Read: I'm committed now!) but he only works at Troy's shop like two days a week. Well this week, a water line decided to burst in his home causing a bunch of damage. He had to skip working for troy to try to save his household goods. I understand, but that cost me a whole week.

So I don't think it was touched at all this week so at this point I think I may be losing the window for any kind of trip to anywhere save the grocery store. I suppose I am a bit discouraged at this point, but on the positive side, I am getting a ton of time with the boys, just not somewhere in Americaville.

Monday coming right up, we'll see if I get it fixed anytime soon...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on June 29, 2019, 10:02:29 PM
I’ll give ya $3500 for it as is


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on June 29, 2019, 11:14:02 PM
Wow Don.,  What a bummer.  Chin up and carry on


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cj7ox on July 02, 2019, 03:57:56 AM
That sucks, Don! At least its not preventing you from spending quality time with the future junior snake eaters.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on July 02, 2019, 10:51:42 PM
$3501  :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: swbhobie16 on July 03, 2019, 07:04:04 AM
$3501  :popcorn:

beat me to it
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 03, 2019, 11:04:55 AM
$3501  :popcorn:
^^^^

Whatcha think Tex, hold out for $3505?

I'm glad i started off in another direction. I didn't know that Troy shut down operations for a week starting this past monday. Went by there and it was all locked up...errr

I called him to find out it is vacation time.

Ya know, its all good. I am getting a lot of time with my pre-rangers.

Good news is the electrical engineer/college automotive systems instructor guy, Andy, has been talking with Justin at Black Bear. So after all this has run its course, I should be better off than I had expected
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on July 03, 2019, 11:20:40 AM
Continue the mission Chief.  People busting your chops.  You built the right vehicle.  Soon you’ll see that it’s worthy of a DMax swap


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on July 03, 2019, 12:18:50 PM
Continue the mission Chief.  People busting your chops.  You built the right vehicle.  Soon you’ll see that it’s worthy of a DMax swap


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I have a feeling he has already begun the mental preparation for a Dmax swap. You know the whole what all parts is needed for this type research, creating a list type thing.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 03, 2019, 03:47:12 PM
Continue the mission Chief.  People busting your chops.  You built the right vehicle.  Soon you’ll see that it’s worthy of a DMax swap


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I have a feeling he has already begun the mental preparation for a Dmax swap. You know the whole what all parts is needed for this type research, creating a list type thing.
Actually further along than that. Member here has a core...I am checking out parts here and there

Won't be cheap, but would put a period on ever needing to upgrade for power. It would have it
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on July 03, 2019, 05:10:48 PM
Continue the mission Chief.  People busting your chops.  You built the right vehicle.  Soon you’ll see that it’s worthy of a DMax swap


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I have a feeling he has already begun the mental preparation for a Dmax swap. You know the whole what all parts is needed for this type research, creating a list type thing.
Actually further along than that. Member here has a core...I am checking out parts here and there

Won't be cheap, but would put a period on ever needing to upgrade for power. It would have it

Oh sweet BURBIMAX!  HH6 here wants one too.... but she wants something like the late 80s model.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on July 04, 2019, 02:02:37 AM
Continue the mission Chief.  People busting your chops.  You built the right vehicle.  Soon you’ll see that it’s worthy of a DMax swap


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I have a feeling he has already begun the mental preparation for a Dmax swap. You know the whole what all parts is needed for this type research, creating a list type thing.
Actually further along than that. Member here has a core...I am checking out parts here and there

Won't be cheap, but would put a period on ever needing to upgrade for power. It would have it

Oh sweet BURBIMAX!  HH6 here wants one too.... but she wants something like the late 80s model.

Burbamax - thats a new one. I’ve always referred to them as Duraburbs, but maybe that’s because that’s the company’s name the does the conversions.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on July 04, 2019, 02:41:06 AM
Continue the mission Chief.  People busting your chops.  You built the right vehicle.  Soon you’ll see that it’s worthy of a DMax swap


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I have a feeling he has already begun the mental preparation for a Dmax swap. You know the whole what all parts is needed for this type research, creating a list type thing.
Actually further along than that. Member here has a core...I am checking out parts here and there

Won't be cheap, but would put a period on ever needing to upgrade for power. It would have it

Oh sweet BURBIMAX!  HH6 here wants one too.... but she wants something like the late 80s model.

Burbamax - thats a new one. I’ve always referred to them as Duraburbs, but maybe that’s because that’s the company’s name the does the conversions.


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Ya, It seems everyone calls them duraburbs, so I’m trying to find a different name. Maxiburb is another one.... I don’t know just don’t want to call the one we build a duraburb.  Don May though.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 04, 2019, 01:23:21 PM
Ya know, you peeps name it, that's fine with me.

And the jury is still out, but the think Tex started is still a glowing ember that just may ignite into a flame...a flame which burns down my property!

But what the heck, Who Dares, Wins!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: BobbyB on July 04, 2019, 01:50:50 PM
Ya know, you peeps name it, that's fine with me.

And the jury is still out, but the think Tex started is still a glowing ember that just may ignite into a flame...a flame which burns down my property!

But what the heck, Who Dares, Wins!

Too bad I couldn't get the fixed up motor into the Jeep Grand Cherokee, just don't like V6 lately.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on July 04, 2019, 10:12:47 PM
Here we go again.  Suppose we'll start seeing 'burb pieces on CL in about 2 years. 

Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 05, 2019, 08:39:01 AM
Here we go again.  Suppose we'll start seeing 'burb pieces on CL in about 2 years. 


No, not like that

and

time for a little story

Some of you know this, most do not.

I purchased Square D from its owner all fairly and properly (or so I thought). We met, I paid the money, we wrote up and signed a bill of sale and he signed the vehicles title. I loaded up Square D and hauled it home. I was in no hurry to get the thing registered, it just wasn't on my mind. Maybe a year into the project I decided one day to get the paperwork transferred at the county clerk's office.

Well, the clerk there noted that I hadn't gotten the signature of the seller notarized and he had signed in the wrong place. So to get this all fixed, I'd simply have to find him and have him make the corrections and then proceed.

I noted that this guy was covered in tattoos, a lot of them espousing the Harley-Davidson namesake. It turns out that:
1. Yes he was a biker
and
2. He was gone for parts unknown
So I went back to my courthouse and in typical government style, they simply fold their arms until lunch time. You either die of hunger waiting them out, or you realize you are NEVER going to get any help from them
Well I searched high and low for the owner, but he was gone and that was that.

I tried to get a salvage title for it, but in the mean time, he, who was still responsible for paying the annual taxes on the thing did something with the title status that sort of froze it. My Recourse was to ask for his address. See the earlier statement about government clerks. I even thought about reporting it stolen and give them that to sort through, but the government, although unwilling to help you will  suddenly wake up and bite you if it senses you broke one of its rules.

It was about then that a guy I know offered to send me a title and a vin number, so I continued working on it. It took forever and in the end he was just hot air and never did. But by then I was way over the hump with a now painted body and engine nearing completion.

I'll make a note here. Do not say things like you are going to help and not follow through. Had it not been for that ray of hope, I would have shut it down years ago, before paint and been 2-3 years ahead on a Suburban project. I find myself guilty of this myself sometimes, but my advise is to just do what you say you are going to do...nuff said.

It was then that I met a lady in my church who worked there. The conversation got around to the title and she told me to give it to her. I asked what it was she was contemplating. Well, she didn't exactly say, but it sounded like she would have to forge a signature and falsify a document. (Read: I would be the agent causing her to sin)

Well I was torn by that one, but I decided not to ask and that was that. Another person who knew of the matter told me to meet this person who would mysteriously notarize the title with a signature for $100 and he had a proven track record. Well, again I thought, can you mess around "a little" with the neighbor's wife and it somehow be OK? Can you just catch a cat nap with the devil and not be soiled?

So I didn't do that either. But I did go on to finishing SquareD, almost that is trying to find this guy, but that never happened. I was then left with the fact that I could only ever operate the thing on my farm or tow it to shows, and not having the luxury of carrying a fleet of trucks and still maintaining a really pretty wife under the same roof, I made the call and chunked it up.

So what came of all that? Did I get my arse handed to me? Was I a fool?

In self analysis, I can say, I should have registered it the next day, so that's on me. But what of the building experience...Did I have a rockin' good time? Well, yes. Did I teach probably, hundreds of you how to do things? I think so. Did I meet some amazing people (most of you) who have enriched my life significantly? Well, ya... Did we as a group, centered on the building of one old Dodge start to look like a healthy God loving group of men that I'd wager, thousands of others got to see? Yes I believe we did. And did that living group dynamic possibly lead some others to a relationship with Jesus? I'd say there is a pretty good chance of that having happened. So that means God used me, and you...Think that was a net positive?...? And in the end, did I learn a lesson and didn't I recover $30K from all of that...Why yes I did!

Oh and BTW, I registered the Suburban the next day after buying it!!!!!!!!!!!!!!!!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 05, 2019, 08:49:31 AM
And on the diesel conversion thing.

I think that our brother in the Republic of Texas has it the mostest, rightest! (Yes I know those aren't real words, I wrote a book after all, I know hows 2 rite!)

This burb is a very long term ownership thing (Read: for the rest of ma daze...which may not be all that many, or may surprise all of us) Therefore I see it as the best I can make it, above reproach and FOC (Free of compromise) So a diesel it should be

with caveat

The diesel should be done extra-right. no leaky arse LB7 mess. Let's look at the state of the art and see what kind of cool transplant we can come up with...full tilt LML?? 6-speed 8-speed?? 10 speed??

Just looking at the price of the new offerings, heck for a fraction I already own a classic that is in most ways way coolerer than someone who smacked down double the cost of my first house + 7 acres on a depreciating TWOM (Total waste of monee). And for a bit more can own something that is a true hybrid that in our minds, Chevy should have built.

Mo caveat:

I need to haul the pre-rangers off on that epic trip before they are actually, real Rangers. So I'd say I keep it a gasser until after said gas guzzlin trip, then konvert it komrade to the "people's burb!"
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on July 05, 2019, 11:53:53 AM
Just find a wrecked truck..By the time you get all the parts, you will be ahead, maybe even has a nice rear too for that 80 thingy.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on July 05, 2019, 01:07:20 PM
Charles,  I hope you're proud of yourself.  Lol
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 05, 2019, 03:15:41 PM
Just find a wrecked truck..By the time you get all the parts, you will be ahead, maybe even has a nice rear too for that 80 thingy.
I'll start looking/sourcing parts later on in the fall. Too much going on right now. I'll just tear down and rebuild everything to new+ spec, then drop in as an assembly.
My plan would be to drop in a 2011+ LML if that is possible with computer and wiring and all that. I think earlier like the 02 has a 32 bit processor, and later has a 64 bit. That may be the bridge too far and point me to a LBZ. So if an LBZ, then a 500-6--hp build with new injectors, bigger turbo, pipes, big IC and some money poured into the Allison and I'd be satisfied. My 620HP Silvy is so powerful as to be somewhat unusable. I only use the #3 light tow tune setting. Anything more and its spinning, and pulling really hard. So some steps back from the rim is what i'd want in a vehicle 3/4 ton less than my truck and with more gear.
Title: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on July 05, 2019, 03:35:49 PM
LVTD
Living vicariously through Don

I’ll reiterate here again Don. It will be easier to swap an LB7 with LLY heads  the LB7 ficm will run the LLY injectors. 

It’s a tried true and proven concept with no learning curve for you.

Wagler rods and arp studs top and bottom and you can make 900 hp with no worries

JR is right. Get you a donor truck like a rollover or rear end accident


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: swbhobie16 on July 05, 2019, 03:37:58 PM
Just find a wrecked truck..By the time you get all the parts, you will be ahead, maybe even has a nice rear too for that 80 thingy.
I'll start looking/sourcing parts later on in the fall. Too much going on right now. I'll just tear down and rebuild everything to new+ spec, then drop in as an assembly.
My plan would be to drop in a 2011+ LML if that is possible with computer and wiring and all that. I think earlier like the 02 has a 32 bit processor, and later has a 64 bit. That may be the bridge too far and point me to a LBZ. So if an LBZ, then a 500-6--hp build with new injectors, bigger turbo, pipes, big IC and some money poured into the Allison and I'd be satisfied. My 620HP Silvy is so powerful as to be somewhat unusable. I only use the #3 light tow tune setting. Anything more and its spinning, and pulling really hard. So some steps back from the rim is what i'd want in a vehicle 3/4 ton less than my truck and with more gear.

just keep me posted. can do whatever you decide. the guy in FL can do any model engine.. price just changes for more emissions deletion. (which.. let’s  be honest.. is a must). and you know you have the CP4 to contend with. and initial purchase of said donor power plant.

probably be tit for tat on newer less miles donor than a built older motor with more power and easier electronics.

hard to say without actually have hard and fast numbers to go off of. either way, it’s going to be awesome.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: oklawall on July 05, 2019, 09:07:28 PM
Don, I make a yearly trip to Indian so if you find something around Oklahoma I could drag it your way
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 05, 2019, 09:53:39 PM
Wow, thanks for all the tips and offers men.

We are getting a bit ahead of the program here...I am just now really warming up to the swap (Deciding to do it)

I guess I messed where Tex mentioned it before, but that combo makes sense too. There is an LB7 motor around the block for $700, so that would be easy. Donor truck, thinking in the 3K ballpark possibly a bit more. There is a wrecked 01 or 02 around for under 4K.

But I'll have to research and I am not impressed with the early transmissions, 5-speed Ally's I think?

Anyway, that is late summer to fall stuff. Have to win the lottery first, but I think something is about to pop that will pay for all of this. Has to be fully outside of the normal income as my super-cop wife will detect an anomaly of say plus or minus a quarter and cause me to live on the roof for a month or two. Then I'll have to buy her a diamond and I'll be OK until the next anomaly!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on July 06, 2019, 03:17:17 AM
Just go 06 and up. I would say stay with the LBZ years. More stock power, emissions easy to delete and 6 speed tranny.

Use the tranny as a core for a built unit. The 6.0 will fetch a good price too.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on July 06, 2019, 07:06:43 AM
I believe the issue Don is going to confront is the communication protocol of the early DMax. If it were 04+ (iirc) he could swap pretty much anything into it.

He can build whatever block he likes but he will need to use the LB7 ecm/tcm/ficm to drive it and that’s why the LLY headed motor is the best compromise since the LB7 ficm is known to be able to reliably drive the LLY injectors and conversion harnesses are available.

There is nothing wrong with the LB7 blocks. The weak link is the con rods.  ARP studs and  wagler street rods will hold whatever he’d want the power level to be in the burb.

And Don, you can put a six speed behind an LB7. And for what you’ll be running it would need to be built anyway.


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Title: 2002 Suburban 2500 build thread, Part 3
Post by: longball on July 06, 2019, 09:07:38 AM
Can you run the 06+ six speed or are you talking about a 6 speed conversion? A buddy of mine has been exchanging emails with duramaxtuner.com about their 6 speed conversion. If I remember correctly he said the cost after returning his core will be right around $1,300. Considerably cheaper than the suncoast kit.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on July 06, 2019, 09:12:59 AM
I’m not sure if you can run a native 6 speed trans off the 5 speed tcm. Bet Mike L would know. For sure when Don has his built they can convert it. That’s the one thing I wish I had done when I got mine built


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on July 06, 2019, 09:53:45 AM
Maybe I’m the naysayer but why not just drop a Cummins in it? Say an 2003-7.5?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on July 06, 2019, 11:34:43 AM
I'm thinking something like a 2000 Cummins 24v would be perfect,  with a power glide,  converted to 2wd and propane with skinnies on the front and Mickey slicks out back.

Or, better yet if you wanna go with a gm platform....17 up LP5 Dmax with 910 ft lbs stock. Might even come with a warranty!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on July 06, 2019, 11:44:57 AM
Maybe I’m the naysayer but why not just drop a Cummins in it? Say an 2003-7.5?

Too bad theres not one just laying around anymore....

I'm thinking something like a 2000 Cummins 24v would be perfect,  with a power glide,  converted to 2wd and propane with skinnies on the front and Mickey slicks out back.

Or, better yet if you wanna go with a gm platform....17 up LP5 Dmax with 910 ft lbs stock. Might even come with a warranty!

The ecms are encrypted, and after the obummer administration cracked down on the tuners, the only ones you can get to do anything come from canada?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: swbhobie16 on July 06, 2019, 12:18:11 PM
i actually know where one of each of those motors are!

(LBZ [core], 06 common rail 5.9 and an 01 24 valve 5.9)

hahah
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on July 06, 2019, 01:46:31 PM
Pretty sure the codes have all been broken. get updates from EFI all the time.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on July 06, 2019, 01:55:09 PM
Nate, I was just dotting like everybody else,  but Kory still tunes.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on July 06, 2019, 02:01:50 PM
Pretty sure the codes have all been broken. get updates from EFI all the time.

Nate, I was just dotting like everybody else,  but Kory still tunes.

For older ones i am sure, last i knew  one has been able to crack the new one yet.....have they?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on July 06, 2019, 08:56:16 PM
Nate, I was just dotting like everybody else,  but Kory still tunes.

Yeah but Kory doesn’t actually do the tunes anymore. Quality of his offering has really gone downhill from what I’ve heard. I wouldn’t give him my business.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: swbhobie16 on July 07, 2019, 09:41:09 AM
i know the guy in CA that did mine (LBZ) does it all the way through LML. (not sure about L5P) and it fired right up in 2 seconds after being flashed.

hopefully we will have to collectively figure this out  :grin:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 07, 2019, 10:33:06 AM
Hi there! Thought I'd check in on the DGT (Don's Garbage Thread, short for Someone turned my 2002 Suburban build thread into some useless discussion thread again...but that's too long, so just DGT) to see what the weather is in shanghai and the latest recipe tweaks for atlantic lobster plug soup!

Emoji: Don's not happee... :blank:(Needs filled in right there) :angry:
and
He thinks he is working with a bunch of, one-delta-india-zero-tangos   :blank:
and he has accrued enough quality information
to write, An expert's guide to herding kats!" :police:
Errrrr.....  :facepalm:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 07, 2019, 10:42:55 AM
i know the guy in CA that did mine (LBZ) does it all the way through LML. (not sure about L5P) and it fired right up in 2 seconds after being flashed.

hopefully we will have to collectively figure this out  :grin:
OK, so this is how it works
To the man who steps forward and volunteers
You get to own it
You are now married to the Texan RedNeck
You can be the head, but he is the longhorn neck.
Track down the road Tex set in motion. LB-7 with rods, good pistons, studs, and LLY or later heads.
Figure out if I can bolt a 2011 and later Ally 1000 to that mess and figure out what is required, who makes harnesses, what I need from a doner/junkyard and come up with a plan.
I'll set you up on the payroll, same as the rest of us
Work hard, take few breaks, and get A FREAKIN REAL plan together that does not involve some detroit diesel or cat engine coupled to a submarine transmission.
Present such plan here after you have created it. Start a new thread and call it something like, "Bonehead and knucklehead design's Big-D's next monee pit. Do not, say again, do not clutter my personal and wonderful Burb thread with the nonsense that is sure to be generated by the DOTs
Copy?
Move out-
Report on assigned frequency when REAL progress is made
Take no advice from anyone else here or anyone who knows anyone here ;-)
Out
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 07, 2019, 10:48:06 AM
That's that Armee in me comin' out right there ^^^^^
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on July 07, 2019, 10:55:08 AM
HAHAHA
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on July 07, 2019, 11:20:35 AM
Is thing even back in your driveway yet?  Everyone still out for a week vacation?  Who takes a week off for the 4th?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on July 07, 2019, 01:50:15 PM
Who's this Flyin6 guy? Acts like this is his thread or something.
Anywho,  now that he's gone,  yes Nate he started LP5s last year.

Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: dave945 on July 07, 2019, 02:41:23 PM
Is thing even back in your driveway yet?  Everyone still out for a week vacation?  Who takes a week off for the 4th?


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I took the whole week off for the 4th, Dave. Had family come in and we went to the Ark. is this the right thread to give my travelogue about that?  ;)


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on July 07, 2019, 03:09:00 PM
Works for me,,,,,,,,,,,,,
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on July 07, 2019, 06:12:28 PM
Anyone see H’s buddy Epstein got arrested for sex trafficking?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on July 07, 2019, 06:44:02 PM
Any one have a fighting argument for one brand of another of air intake systems for these duramax?


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Sammconn on July 07, 2019, 07:20:43 PM
From a few different timers: LBZ and later stock good till 650.

Not sure where you’re at, but that’s from a few of them years ago.
Simple. No oiling. No cleaning. Etc.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on July 07, 2019, 07:34:04 PM
I have stock box now and it’s warped just enough to not hold the stock filter in place .   Either need a new factory replacement box or aftermarket

No particular reason for one or the other.  I am maybe 500hp.  Pushing the big tune



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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on July 07, 2019, 07:41:02 PM
Try 500hp with lower gears, wow!

I have the SB. Got tired of the high priced filter and pain in the arse changing. Sure not all the time, but a pain.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on July 07, 2019, 07:45:34 PM
What filter did you have that was high priced? He


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on July 07, 2019, 07:57:14 PM
Stock. I thought it was pricey and a pain to put in.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on July 07, 2019, 08:16:28 PM
I currently have a afe stock replacement.   The rubber is deteriorating from being cleaned.   It’s kind of gummy now.  So I need a new filter 1 way or another,  $68 for a new one, the no I have is twisted up and not holding the filter correctly.  So.... looks like buy a stock box and filter or buy a aftermarket kit


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 07, 2019, 09:06:15 PM
Is thing even back in your driveway yet?  Everyone still out for a week vacation?  Who takes a week off for the 4th?


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Well, the guys at the corner garage do (Take a week off)
Yea, took me by surprise
But this is Kentucky. Not all that unusual for folks to close up shop. I wish I would have known, cause I would have liked to have had the week to take a stab at it myself.
But, no, its still boxed up over there!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 07, 2019, 09:07:25 PM
Is thing even back in your driveway yet?  Everyone still out for a week vacation?  Who takes a week off for the 4th?


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I took the whole week off for the 4th, Dave. Had family come in and we went to the Ark. is this the right thread to give my travelogue about that?  ;)


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No...No it's not!
Title: 2002 Suburban 2500 build thread, Part 3
Post by: longball on July 07, 2019, 10:38:03 PM
Serious question Chief. If you’re gonna have a built transmission (which we all assume will happen) wouldn’t it just make the most sense to build one suited to the year model of the engine and the rest of the vehicle? The newer ones are stronger in stock form but this one won’t be factory. There are thousands of built 5 speeds holding way more power than your stated desires, all with none of the fuss and headache of “making it work”. If the 6th gear is a deal breaker, there’s an option for that also. I’d be willing to bet that the additional purchase cost, wiring, tuning, and figuring out of the 11+ model would pay for the 6 speed conversion. That being said, if the process of mating the old and the new is a challenge you’d enjoy, then by all means, throw this comment right out the window. It’s your money and your vehicle. This is just $.02 from a guy enjoying this awesomeness unfold from the cheap seats.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: oklawall on July 07, 2019, 10:41:15 PM
Don,

I'll email my son (the one in UAE) he was a Allison tech before he joined the Air Force so he may know what is needed for a early block to a 6 speed swap
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 07, 2019, 11:03:20 PM
OK
Title: 2002 Suburban 2500 build thread, Part 3
Post by: rpar86 on July 07, 2019, 11:51:03 PM
Who's this Flyin6 guy? Acts like this is his thread or something.
Anywho,  now that he's gone,  yes Nate he started LP5s last year.


L5P*

;)



Serious question Chief. If you’re gonna have a built transmission (which we all assume will happen) wouldn’t it just make the most sense to build one suited to the year model of the engine and the rest of the vehicle? The newer ones are stronger in stock form but this one won’t be factory. There are thousands of built 5 speeds holding way more power than your stated desires, all with none of the fuss and headache of “making it work”. If the 6th gear is a deal breaker, there’s an option for that also. I’d be willing to bet that the additional purchase cost, wiring, tuning, and figuring out of the 11+ model would pay for the 6 speed conversion. That being said, if the process of mating the old and the new is a challenge you’d enjoy, then by all means, throw this comment right out the window. It’s your money and your vehicle. This is just $.02 from a guy enjoying this awesomeness unfold from the cheap seats.


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Some good thinking here.

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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on July 08, 2019, 09:58:10 AM
Why you wait so long to correct me knucklehead!!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on July 08, 2019, 10:41:25 AM
Why you wait so long to correct me knucklehead!!

HAHAHAHAHAHA...………...ryan just re-iterated what I said a few post earlier
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on July 08, 2019, 06:03:58 PM
But I listen to that knucklehead, not you ! :)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Nate on July 08, 2019, 07:00:19 PM
But I listen to that knucklehead, not you ! :)

 :kiss:  :kiss: :kiss: :beercheers:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: oklawall on July 08, 2019, 07:56:24 PM
Don,

Couldn't get a email to the boy today he was working on airplanes. I did talk to one of his friends who still works as a field service guy for Allison. For the 5 to 6 speed he suggested getting a donor truck and use its TCM (TCM should be a Gen 4 he said you could use some Gen 3 but it depends on the program in it) and transmission. He also thought that all the Allison have the same bolt pattern for the Duramax, they have a pentagon shaped front section / bell housing and all the others are round. He also said that the wiring is the same between gen 3 and 4 . I hope that helps let me know if I can try and track anything else down for you.

Steve 
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on July 08, 2019, 09:19:05 PM
Ive seen kits to convert the 5s to a 6s, but is pricy! Valve body and TCM.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on July 15, 2019, 01:17:48 PM
This thing still broke? Think it needs a caddy 500 conversion.....
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on July 15, 2019, 01:21:56 PM
Why don't you go back to sleep and leave the boss alone,  or else I'll ask Big Nate to fire you..

...or at least a demotion with cut in salary.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: EL TATE on July 15, 2019, 02:33:49 PM
This thing still broke? Think it needs a caddy 500 conversion.....
That quote looks a little salty Shawn... dog problems?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on July 15, 2019, 02:55:03 PM
I really think $3505 is a fair price


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on July 15, 2019, 04:24:19 PM
$3535
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on July 15, 2019, 06:32:38 PM
Come on now,  I thought we were friends.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on July 15, 2019, 06:41:50 PM
This thing still broke? Think it needs a caddy 500 conversion.....
That quote looks a little salty Shawn... dog problems?

Kid problems, if I didn’t have kids a single 3.5 cent 22 LR would fix the dog issue......  :rolleyes:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 15, 2019, 08:25:33 PM
This thing still broke? Think it needs a caddy 500 conversion.....
...As far as I know...it is
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on July 15, 2019, 09:41:07 PM
You are all fired...

(so really Don, whats the skinny?)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 16, 2019, 08:02:01 AM
You are all fired...

(so really Don, whats the skinny?)
As far as I know, this part time automotive electrical engineer/professor guy had gotten into things far and above the capabilities of my friend who owns the garage. He brought in the man with the best of intentions, however, this professor guy is only a part timer and is exceedingly meticulous. That took time along with the fact that one week the engineer had a home emergency and was not here. That and the week Troy closed for vacation has taken its toll. I will find out shortly, but I think we are about done. At least I hope so!
And I think the decision to put a Duramax in it, having done it myself is solid. I'll have the motor/trans zero-timed with fresh rebuild and I will do the install, so I'll know where every single wire goes to. Once done I'll have a lifetime vehicle.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on July 16, 2019, 10:54:07 AM
Anxiously awaiting the results.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: wyorunner on July 16, 2019, 11:21:01 AM
What he said ^^^^


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on July 16, 2019, 12:22:32 PM
 :popcorn:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on July 16, 2019, 02:04:49 PM
$3550


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on July 16, 2019, 05:05:05 PM
$3550


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I thought this was Dons thread? You know we only low ball Ken on stuff......
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on July 16, 2019, 08:47:33 PM
I'd go 5,000 before Don molested that clean ride


Just kidding boss, please don't fire me again..Shawn made me say it.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 16, 2019, 09:04:47 PM
I was hoping today would be the day

But you can't make this stuff up

My friend is in the hospital! Has been there for 2 days...

Suffice it to say, if I could have read the future, I would have just muscled through and fixed it myself...Darn!

But the man's health is far more important...I can wait.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cj7ox on July 17, 2019, 03:54:53 AM
Sorry to hear about your friend being hospitalized! Could your modifications have been the cause for his ails? J/K! I hope he gets better soon! Hospitals and illness suck!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 17, 2019, 11:09:38 AM
Sorry to hear about your friend being hospitalized! Could your modifications have been the cause for his ails? J/K! I hope he gets better soon! Hospitals and illness suck!
Troy is solid old school Kentucky, God fearing good family man. He works hard and although he may not have much he has earned it all honest! I respect that, and can easily understand and wait out something like not having my car. In the end I will get a well sorted and mission ready burb, as the bible states it, "In the fullness of time"
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: cj7ox on July 18, 2019, 03:17:29 AM
 :likebutton:
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 20, 2019, 10:05:33 AM
Update:

The truck is still over at Troy's. That is both good and bad. Good because some really bright people are taking a hard look at how that thing is all wired up, and bad because a good percentage of the useable summer is now gone. Ma boyz head back to school on 8 August and football practice has already begun, 5 days a week. Our district consistiently ranks in the very top of Kentucky academics and sports, so it is taken seriously. Therefore the window for me to take the Pre-Rangers anywhere significant has passed, however a couple of weekenders is still a possibility if the Burb gets finished.

So on the good side. The electric fan system operates exactly as it should if it were stock. It keeps the engine cooled and fan number two switches on with the AC. The leak around the trans/transfer is repaired.

The bad is that because of how a luxury equipped Suburban in 2002 is wired, we do not have control of the climate control motor. That means I am getting a cold source in the HVAC plenum, but I cannot get any of the pumped air to flow across the heat exchanger and enter the distribution system. We are essentially having to invent a system to make that happen. The electrical guy was working with some other experts to include blackbear tuning to come up with a strategy.

I could easily just install a switch to force the motor one way or another, but I want the system to operate like it was factory, so more research is required. At this point we know and have examined the various wires going into the PCM, know their purpose/voltage/switching logic and so forth.

But we are not done...yet

So close...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on July 20, 2019, 11:29:03 AM
You say experts working on ...... how much a hour are they gonna hit the pocketbook with this?  Weeks of expert time sounds like $150 a hour?   




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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 20, 2019, 01:34:07 PM
You say experts working on ...... how much a hour are they gonna hit the pocketbook with this?  Weeks of expert time sounds like $150 a hour?
   

Dave, this is Kentucky...

You sort of have to forget what you understand about how things work in the highly regulated/high cost world to understand that even though experts are working on this the charge may be small. Some folks work on stuff just because it is interesting or are dual tasking. That is the case here...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: stlaser on July 20, 2019, 01:55:29 PM
Dave, it’s the tuck they don’t even require running or brake lights on trailers..... 
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on July 20, 2019, 02:51:32 PM
Trying to understand why you lost ventilation.  It doesn't run through the pcm, just the compressor does.  Ventilation runs through the Bcm, which should be immune to the programming performed on the pcm.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on July 20, 2019, 08:33:44 PM
Yeah. Ken is on to something.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: oklawall on July 21, 2019, 09:32:06 AM
Ken makes a good point. But Don keep plugging along this is a great adventure and even for a short weekend the time you get to spend with the Pre rangers is priceless

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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 21, 2019, 10:58:29 AM
Trying to understand why you lost ventilation.  It doesn't run through the pcm, just the compressor does.  Ventilation runs through the Bcm, which should be immune to the programming performed on the pcm.

K-I don't know!

Interesting question for the professor tomorrow or whenever he shows

BTW, the truck is looking great. I was almost surprised to see it the other day!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 22, 2019, 10:47:01 AM
More information.
The BCM does control the climate control motor (The thing that swings the door from cold to hot)

But the BCM gets the OAT, engine temp, and cooling fan info from the PCM.

Apparently this information is not being seen by the BCM. The BCM tested fine, one of the early on checks, apparently. And this issue is acknowledged by some tuners in the industry...the early GMT800 suburban wiring with the auto temp feature (In the Suburban)

So it is going to need some engineering to get everything to work, and that is where we still are

Meanwhile, I am working on a multi-function display screen to be used for various things...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: EL TATE on July 22, 2019, 05:18:20 PM
Help me out here Ken, and I may be off base but don't they have the little control module with the alum heat sink behind the glove box on these that like to melt down?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Sammconn on July 22, 2019, 05:29:12 PM
They do. But I think that is only the fan control not the air mix.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 22, 2019, 06:34:37 PM
Well, its still not done, but Troy took over the job from the professor. He needs the bay for a waiting motor replacement job and wants this thing done. I suspect he will have it done pdq, but with all this time and no motor tune, the summer travel plans are a bust.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on July 23, 2019, 12:21:08 AM
And to think I almost had my yard finished before you got here.  I guess I’ll never know if the mulch beds are deep enough. 


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on July 23, 2019, 03:24:20 PM
Bet it would just sink.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on July 24, 2019, 10:28:28 PM
...Still not done...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Dfarm01 on July 31, 2019, 09:21:54 PM
Looks like I missed a bunch of progress. Lol

I'm actually getting ready to dig into my burb a bit. After shopping for newer rigs, I've decided that my money will go farther fixing mine up. My next big project is going to be a rebuilt transmission and transfer case. I'm leaning towards a "heavy duty" 4l80E from monster transmission. And I'll take care of the rebuild on the t case. I actually found a company that makes a slip yoke eliminator for the front output on the 246.  I'm hoping that getting rid of the sloppy slip yoke that's on there will get rid of the vibration that is coming from the front shaft.

Speaking of the front shaft, I noticed that yours doesn't have a cv joint at the top.  Do you have any vibration from it?  Mine has a dual cardan joint at the top.  I figured that was pretty standard for lifting these things.

How much lift do you think you got from the shackle flip ?  I have blocks on the back of mine, which are ok, but a shackle flip might be better?

Sorry to hear that you aren't going on the long trip that you were hoping for.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on August 01, 2019, 08:16:07 AM
Looks like I missed a bunch of progress. Lol

I'm actually getting ready to dig into my burb a bit. After shopping for newer rigs, I've decided that my money will go farther fixing mine up. My next big project is going to be a rebuilt transmission and transfer case. I'm leaning towards a "heavy duty" 4l80E from monster transmission. And I'll take care of the rebuild on the t case. I actually found a company that makes a slip yoke eliminator for the front output on the 246.  I'm hoping that getting rid of the sloppy slip yoke that's on there will get rid of the vibration that is coming from the front shaft.

Speaking of the front shaft, I noticed that yours doesn't have a cv joint at the top.  Do you have any vibration from it?  Mine has a dual cardan joint at the top.  I figured that was pretty standard for lifting these things.

How much lift do you think you got from the shackle flip ?  I have blocks on the back of mine, which are ok, but a shackle flip might be better?

Sorry to hear that you aren't going on the long trip that you were hoping for.
I only drove it a couple times before I realized I had fan problems so really can't say about any added vibration. But since I do not recall anything along those lines, it was probably fine. BDS suspensions do not call for the need of any change to the front driveshaft and the angular change is miminal anyway, so given the choice, I would not have elected to change the driveshaft.

As for the lift from flipping the shackle, I'd say 5"-6".

It seems that you get the length of the shackle in added lift. If you had a 4.5" shackle in the factory configuration and simply flipped it then expect a 4.5" lift over what it was stock. That may not be a hard and fast rule, but it is what I experienced.

Flipping the shackle is much better than lift blocks. For safety reasons and for added flex in the suspension it is a great modification.

And ya, I really want that truck back!

So, Troy tells me he has the issue solved and the AC will flat freeze you out of the thing. He is now tracing all the wiring on the PCM bundles to make sure they are all in the correct orientation. I sure hope this doesn't go on much longer...
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bigdave_185 on August 01, 2019, 08:33:07 AM
They have had the burb for two months now !


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on August 01, 2019, 08:49:40 AM
They have had the burb for two months now !


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Close to it...

And that took out my summer plans!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on August 01, 2019, 09:19:21 AM
Good to hear progress is being made. Even if it’s slow. One of the things I noticed on my trip to Teton and Yellowstone is that adventure vans are all the craze. Benz, Ram being the most popular. Some nice kits people had together.


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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on August 01, 2019, 01:10:38 PM
Good to hear its almost done, like some road reports!

Then you can plan the Dmax swap once you are not happy with the power. (funny how we get older and need more power)
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Dfarm01 on August 01, 2019, 07:13:40 PM
Looks like I missed a bunch of progress. Lol

I'm actually getting ready to dig into my burb a bit. After shopping for newer rigs, I've decided that my money will go farther fixing mine up. My next big project is going to be a rebuilt transmission and transfer case. I'm leaning towards a "heavy duty" 4l80E from monster transmission. And I'll take care of the rebuild on the t case. I actually found a company that makes a slip yoke eliminator for the front output on the 246.  I'm hoping that getting rid of the sloppy slip yoke that's on there will get rid of the vibration that is coming from the front shaft.

Speaking of the front shaft, I noticed that yours doesn't have a cv joint at the top.  Do you have any vibration from it?  Mine has a dual cardan joint at the top.  I figured that was pretty standard for lifting these things.

How much lift do you think you got from the shackle flip ?  I have blocks on the back of mine, which are ok, but a shackle flip might be better?

Sorry to hear that you aren't going on the long trip that you were hoping for.
I only drove it a couple times before I realized I had fan problems so really can't say about any added vibration. But since I do not recall anything along those lines, it was probably fine. BDS suspensions do not call for the need of any change to the front driveshaft and the angular change is miminal anyway, so given the choice, I would not have elected to change the driveshaft.

As for the lift from flipping the shackle, I'd say 5"-6".

It seems that you get the length of the shackle in added lift. If you had a 4.5" shackle in the factory configuration and simply flipped it then expect a 4.5" lift over what it was stock. That may not be a hard and fast rule, but it is what I experienced.

Flipping the shackle is much better than lift blocks. For safety reasons and for added flex in the suspension it is a great modification.

And ya, I really want that truck back!

So, Troy tells me he has the issue solved and the AC will flat freeze you out of the thing. He is now tracing all the wiring on the PCM bundles to make sure they are all in the correct orientation. I sure hope this doesn't go on much longer...

That's interesting about the front shaft.

Thanks for the info on the shackle flip. I'll definitely look I to that some more.

Glad to hear that it's getting sorted out!
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on August 01, 2019, 08:44:19 PM
I'd go back and look at the photos of the BDS kit going in.

Even though they drop the front diff enough to keep the axles at stock geometry, the driveshaft is long enough due to the length of the vehicle to minimize the angular change.

Troy is hoping to have the Burb tidied up by the weekend. It will be so good to finally start to drive the thing and collect some engine maps to get the final programming in there.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on August 02, 2019, 04:38:45 PM
I know cognito recommended a CV driveline on the 4-6" lift I got for my '12 truck, and I found out that if I do a hard 4wd launch, it feels like the transfer case is going to explode. That's with it set at about 3-1/2" of lift... but..the 12s are a different platform.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on August 03, 2019, 03:51:50 PM
Think I may add a CV when I do mine, don't want issues and that is cheaper than buying a new shaft.

Unless you have some deals Ken?
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on August 03, 2019, 08:50:14 PM
Think I may add a CV when I do mine, don't want issues and that is cheaper than buying a new shaft.

Unless you have some deals Ken?
JR, FYI, I don't have a CV shaft on the front or the rear of my D-Max which is lifted 6"-7". My front diff is dropped btw. Have driven over 85,000 miles that way in all sorts of terrain with no vibration or problems to speak of.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on August 03, 2019, 09:51:12 PM
Understand, but the cognito lift call for a new shaft. No spacer option like yours. As mild as the angle will change, wonder if there would be an issue at all. I need 4x4 at freeway speeds.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Bob Smith on August 03, 2019, 10:05:10 PM
JR, why would you need 4x4 at freeway speeds? Slippery area at 75+ puts you in the pucker brush even with 4x4. And if need be, doesn't help stopping any better either. We could always tell when the storms were all but over, the out of control traffic ended up further off the roads.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: TexasRedNeck on August 03, 2019, 10:47:34 PM
Yeah any 6 inch lift has only needed a cv shaft at 55+




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Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: KensAuto on August 03, 2019, 11:44:06 PM
Should have been more specific JR. I've had my truck at 80 in 4wd with no vibration... yes by accident. It's when I raced my neighbor on the 200 hp tune, with 4wd launch. It was scary.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: JR on August 04, 2019, 12:30:43 AM
Not 80mph, but don't want any issues. I have the Cog 4-5, wil prob settle around 5 for the 37s.
Title: Re: 2002 Suburban 2500 build thread, Part 3
Post by: Flyin6 on August 09, 2019, 04:35:32 PM
Closing out this thread and starting part 4...
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