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Offline Flyin6

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2002 Suburban 2500 build thread, Part 3
« 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
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #1 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
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #2 on: March 25, 2019, 10:59:54 PM »
Which allowed me to set the spring onto the ground
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Offline Flyin6

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

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #4 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
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #5 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
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #6 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
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #7 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.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #8 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
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #9 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
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #10 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.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #11 on: March 25, 2019, 11:18:31 PM »
I had a pile of hardware to start with.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #12 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
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #13 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
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #14 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
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #15 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
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Offline Bigdave_185

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #16 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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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #17 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.
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Offline Bigdave_185

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #18 on: March 26, 2019, 12:07:40 AM »
How do you determine where the new plate will go?


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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #19 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.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #20 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!!!!!!
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Offline stlaser

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #21 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:
« Last Edit: March 26, 2019, 05:58:38 PM by stlaser »
Living in the remote north hoping Ken doesn’t bring H up here any time soon…..

Offline wilsonphil

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #22 on: March 26, 2019, 06:49:35 PM »
I think he means 4 3/8 long

Offline Sammconn

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #23 on: March 26, 2019, 06:50:24 PM »
I’m thinking 4@ 3/8” , 1@ 1/4”, and 1@ 5/16”
« Last Edit: March 26, 2019, 06:52:50 PM by Sammconn »
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline TexasRedNeck

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #24 on: March 26, 2019, 07:08:50 PM »
Commas and decimal points are really important. Especially in finance


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Offline Sammconn

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #25 on: March 26, 2019, 08:16:23 PM »
Agreed.

And if it were the behemoth sizes listed I’d say 48 bucks is cheap...
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #26 on: March 26, 2019, 09:07:27 PM »
I’m thinking 4@ 3/8” , 1@ 1/4”, and 1@ 5/16”
Winna!
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #27 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
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #28 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.
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #29 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
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #30 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
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #31 on: March 26, 2019, 09:16:33 PM »
Alignment worked out very well.
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #32 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
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #33 on: March 26, 2019, 09:18:05 PM »
And secured them temporarily to the springs
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #34 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #35 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #36 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
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #37 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...
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #38 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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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #39 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...

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #40 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...???
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #41 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.
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Offline swbhobie16

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #42 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

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #43 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:
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Offline BobbyB

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #44 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.
So, Bobby...being the calculating trained warrior NCO that you are.  Take the appropriate action, Execute!
your standard grunt level CQB is just putting rounds and rounds on scary stuff till it stops scaring you!

Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #45 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
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #46 on: March 27, 2019, 08:26:38 PM »
So, I got those rear suspension compression bumpers cut off the frame
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Offline Flyin6

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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #47 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
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #48 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.
Site owner    Isaiah 6:8, Psalm 91 
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Re: 2002 Suburban 2500 build thread, Part 3
« Reply #49 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
Site owner    Isaiah 6:8, Psalm 91 
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