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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #650 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.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #651 on: May 05, 2019, 08:07:47 PM »
Then I finalized the air bag air line, "T"ing the two sides together for now.
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #652 on: May 05, 2019, 08:09:01 PM »
Just waiting for a tent...It's sitting in the next garage.
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #653 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #654 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
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #655 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #656 on: May 05, 2019, 08:20:26 PM »
Removal or adjustment of the things previously shown in red got me this far:
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #657 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #658 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #659 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.
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #660 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.
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #661 on: May 05, 2019, 08:30:04 PM »
Here it is hanging from the bolts and tacked together
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #662 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #663 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.
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #664 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.
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #665 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:
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #666 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...
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #667 on: May 07, 2019, 08:22:06 AM »
A couple of straps supports the theng, now hanging while I work on the underside
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #668 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #669 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #670 on: May 07, 2019, 08:26:17 AM »
Then I tied in the old bash plate crossmember to the new mount
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #671 on: May 07, 2019, 08:28:44 AM »
Next I stiffened up the winch plate and added forward bumper mount supports
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #672 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.
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #673 on: May 07, 2019, 08:33:54 AM »
Then it was removed, disassembled and welded up
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #674 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #675 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... ;-)
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Offline Bigdave_185

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #676 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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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #677 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #678 on: May 07, 2019, 10:23:51 AM »
Looks like a solid winch plate! Should do the job well.

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #679 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.
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #680 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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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #681 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #682 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??
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Offline stlaser

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #683 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:
Living in the remote north hoping Ken doesn’t bring H up here any time soon…..

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #684 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #685 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.
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #686 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #687 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #688 on: May 07, 2019, 08:37:53 PM »
Have to get that radio mounted!
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #689 on: May 07, 2019, 08:39:21 PM »
The bobbin goes on super easy and makes for a pretty clean front end
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #690 on: May 07, 2019, 08:40:53 PM »
The cable access is perfect, somewhat shielded, but easy to get to quickly
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #691 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...
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #692 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #693 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #694 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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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #695 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.
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #696 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.
Living in the remote north hoping Ken doesn’t bring H up here any time soon…..

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #697 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:
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #698 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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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #699 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:
Living in the remote north hoping Ken doesn’t bring H up here any time soon…..

 

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