2002 Suburban 2500 build thread, Part 3

[Bigdave_185]

Are you going to put some other color on that white pipe?


Sent from my iPhone using Tapatalk

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


Sent from my iPhone using Tapatalk

[Flyin6]

Are you going to put some other color on that white pipe?


Sent from my iPhone using Tapatalk

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


Sent from my iPhone using Tapatalk

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???

[stlaser]

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...... 

[Flyin6]

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

[Flyin6]

Then I finished off the aux electrical accessories area under the hood.

[Flyin6]

Following that, I connected the rear battery to the system and slid the battery box up into the travel position.

[rpar86]

Did you figure out the parasitic draw issue (or did I miss that)?


Sent from my iPhone using Tapatalk

[Flyin6]

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.

[Flyin6]

Did you figure out the parasitic draw issue (or did I miss that)?


Sent from my iPhone using Tapatalk

Did you figure out the parasitic draw issue (or did I miss that)?


Sent from my iPhone using Tapatalk

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.

[rpar86]

Thought there was a battery not remaining charged?


Sent from my iPhone using Tapatalk

[Flyin6]

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.

[Flyin6]

Thought there was a battery not remaining charged?


Sent from my iPhone using Tapatalk

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.

[Flyin6]

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

[Flyin6]

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.

[Flyin6]

And this is the last time the way-too-long shocks are to be seen on the truck!

[Flyin6]

Because, now some correctly sized reservoir shocks have been installed

[Flyin6]

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.

[Flyin6]

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.

[Flyin6]

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.

[BobbyB]

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.

[Flyin6]

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.

[JR]

It's getting there, lots of good stuff.

That 80 will be sweet when done.

But afraid, Dana 80=tach topper.

[Bigdave_185]

Found your hood design Don




Sent from my iPhone using Tapatalk

[TexasRedNeck]

Good progress Don.  Getting closer.


Sent from my iPad using Tapatalk

[stlaser]

Found your hood design Don




Sent from my iPhone using Tapatalk

On an old guy Buick no less..... 

[Flyin6]

Found your hood design Don




Sent from my iPhone using Tapatalk

Looks like the arms of this Biker guy who I'm working with on the hubs.

[Flyin6]

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!

[dave945]

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. ;)


Sent from my iPhone using Tapatalk

[Flyin6]

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. ;)


Sent from my iPhone using Tapatalk

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' !!!

[Bigdave_185]

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


Sent from my iPhone using Tapatalk

[JR]

Flintstone foot brake?

[cudakidd53]

Emergency Brake = 2 4x4 timbers about 12" each and you're golden - bigger incline, double the timbers!

[Bigdave_185]

Could we maybe think of a anchor.  Toss it out the window and attach to a pillar


Sent from my iPhone using Tapatalk

[dave945]

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.


Sent from my iPhone using Tapatalk

[Flyin6]

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.


Sent from my iPhone using Tapatalk

Rotor brake...


HMMM


Hadn't considered that


What's the number over at Agusta-Westland Helicopters?

[TexasRedNeck]

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?


Sent from my iPhone using Tapatalk

[longball]

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?


Sent from my iPhone using Tapatalk

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.


Sent from my iPhone using Tapatalk

[stlaser]

Don, got another idea. What’s the hole spacing center to center on those fancy dual caliper mounts?

[Flyin6]

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?


Sent from my iPhone using Tapatalk

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??

[Flyin6]

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.

[Flyin6]

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

[Flyin6]

Rust removal removed the remaining bristles from my rotary wire cup grinder, but I got them pretty clean

[Flyin6]

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

[Flyin6]

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

[Flyin6]

I won't be reusing these pads, but I could. Still in nice shape:

[stlaser]

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.

[Nate]

Will Ford f450 brake hardware stuff work?

[stlaser]

Will Ford f450 brake hardware stuff work?

Metric

[TexasRedNeck]

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.


Sent from my iPhone using Tapatalk

[stlaser]

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.