REAL MAN TRUCKWORKS & SURVIVAL

VEHICLES, CAMPERS, BOATS, and COMMUNICATIONS => Build Threads => Topic started by: OVERWATCH_09 on September 25, 2014, 02:22:09 PM

Title: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:22:09 PM
Note to viewers: The following posts from Overwatch and KensAuto are actually Flyin6's, unless noted and highlighted. They were copied from the DF forum, where this project started. The page numbers are not accurate at this time. They will change as this build thread is transferred from it's original setting.

My Build Thread
"CMAX"

--------------------------------------------------------------------------------

This will be the start of my build thread. My newly purchased 2011 2500HD LTZ will be undergoing a plethorea of modifications to make it more "capable" as it were. I already own a super capable off road sort of semi militarized truck so this one will not focus on the off road thing as the primary design factor.
I think the truck should retain all it's off road prowess and perhaps even be enhanced in some areas such ar undercarriage armor and suspension travel, but I am not going to SAS this truck like I did with my other truck.

Edit: When I wrote this I thought Obama was finished in 1 term...He got re-elected...I have hence forth lost my mind and after some 7oo odd pages from here, you will see I was not telling the truth about the SAS thing, nor have I kept this project as sane as I envisioned when I thought our nation was soon to be saved...

I want it to have good bumpers just in case I need to push stuff out of the way, a self recovery capability if I need that, more engine power but only if it does not adversly affect mileage, much longer range while enhancing the multi fuel capabilities. It would be able to safely carry my family over great distances while negotiating anything from a tractor trail around a field to a debris strewn roadway. Well, more on my thinking and the vehicle mission statement later on as this thread developes. I think some of you will understand where I am going with this especially in view of the particuliar design charactersitics of my Tundra.
So here it is on zero day when I purchased it this past fall

So far the modifications include: (I update this list every time I make a change)
1. Glock pistol holster mod Pg. 1
2. MBRP 4" exhaust w/muffler Pg. 2,3
3. H&S XT Pro Pg. 3
4. S&B air filter/intake system Pg. 1,2
5. Stainless exhaust clamps Pg. 2,3
6. 6" Fabtech lift Pg. 7-17
7. Dirt Logic 2.25" shocks Pg. 7-17
8. Pro Comp 18 X 9 wheels Pg. 18
9. Toyo 12.50 X 35" MT's Pg. 18
10. Road Armor front bumper Pg. 22-25
11. T-Max 9K winch Pg. 21,22
12. Synthetic winch line Pg. 21-22
13. Poly fairhead rollers and poly bobbin Pg. 20
14. 4 ea. Warn 350F fog lights Pg. 22
15. Hella Optilux HID driving lights Pg. 22,24,28
16. Air Dog 165 fuel pump Pg. 32-36
17. Alligator Performance fuel tank sump Pg. 32-34
18. Merchant Automotive tie rod sleeves Pg. 39
19. S&B paper filter and filter wrap Pg. 55
20. Yukon 4.56 gears Pg. 60-64,81-84
21. Yukon Grizzly locker in rear axle Pg. 52
22. Amsoil dual bypass filter system Pg. 86
23 Fumoto engine oil drain valve Pg. 87
24. Extra exhaust hangar pg. 66
25. Opti Lube Pg. 43-50
26. Fuel tank skid plate mod Pg. 67
27. Great Lakes Off Road rear cover Pg. 71
28. Overhead switch mod Pg. 69
29. Great Lakes Off Road (GLO) rear Axle cover pg. 97,98,103,104
30. Bug out bag/medical bag pg. 101-102
31. Steering stablizer, Fabtech pg. 108-109
32. U-Pol Raptor bed liner pg. 117
33. GLO U-Bolt flip kit Pg. 130
34. Relocated lower shock mounts (rear axle) pg. 140
35. Cognito steering truss kit pg. 144-145
36. Swiss topper mod pg. 157-182
37. Sulastic Shackles pg. 183-184
38. 12 gage shotgun mount install 188-189
39. Fuel and oil filter rock shields 194-195
40. Edge CTS pg. 208-209
41. Turbo resonator block off pg 214-215
42. HID headlights pg 216
43. LED back up and map reading lights pg. 217
44. EGR Delete/downpipe install pg 238-244
45 Hypertech speedometer in line calibration unit pg 249-250
46 Cognito UCA pg 256-257
47 Kenwood GPS/tuner pg 262-263
48 Pro Flow manifolds and up pipes pg 303-312
49 3" Alligator intercooler pipe pg. 312
50 PPE Deep trans pan pg. 315
51 Rare Parts tie rods pg. 333-334
52 AMP Research steps pg 337-339
53 Road Armor rear bumper pg 377-430
54 Rear tire and fuel can carrier 377-430
55 PCV Delete 456-458
56 Tire Pressure Sensor removal 461
57 Solar panel 481-482, 487
58 Mossberg 930 Modification 486
59 Spare tire mod and latch painting 487
60 Mag Light mount 490
61 Pac-Air Air Bags installation and modification 492-496
62 10K Trailer 502, 510, 523
63 Articulating trailer coupling 518-519, 524, 528-529
64 Side exit exhaust 554-556
65 Titan fuel tank 564
66 Back up camera 583
67 Back Up LED lights 583
68 Tac-Topper restart 591-690ish (Project incomplete, discontinued)
69 T-Rex Y-bridge test fit #1 609
70 T-Rex Y-bridge test fit #2 653
71 SAS project starts (parts acquisition) 703
72 HPD60 axle purchased 724
73 ARE Aluminum commercial topper 757

(http://i.imgur.com/vJCMs9o.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:22:33 PM
Here's the first modification that any country gentleman will well understand.
The position of the Glock is only inches from my hand while holding the steering wheel. I need to practice at a range (farm) drawing and engaging so I don't ventilate my passenger door frame!
      
(http://i.imgur.com/IODpm7s.jpg)
(http://i.imgur.com/hohSiEj.jpg)
(http://i.imgur.com/Ribj48g.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:22:45 PM
Next I decided to do something to improve the mileage which was historically running in at 16.4 overall.
I started with adding an air intake system. After talking to Holton over at Alligator performance, he recommended an S&B intake for my application
Here is the factory intake system after removal .

(http://i.imgur.com/HUBnv2g.jpg)
Here is the vacant spot sans factory air box
(http://i.imgur.com/Ra54u53.jpg)
Next the factory steel air box mount is removed
(http://i.imgur.com/jlnwNLX.jpg)
(http://i.imgur.com/rt80tDB.jpg)
The factory MAF and filter life units are removed and installed on the new air box
(http://i.imgur.com/vUGiYT2.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:22:58 PM
Here is the intake tube end showing the air bellows which is a smooth venturi molded into the tube itself       
(http://i.imgur.com/mBe2WxU.jpg)
The build up of the S&B continues. The filter element is much like the K&N which I have used on everything from past trucks to even Huey and Chinook helicopters


(http://i.imgur.com/q8FXUIt.jpg)
(http://i.imgur.com/ToHzNu2.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:23:05 PM
The air box has an option to either leave the bottom of the box open for additional air flow or to colse it off. Since the orientation of the opening is straight down, and considering the possibility for emergency deep water fording, I elected to close it off
      
(http://i.imgur.com/PbZDOej.jpg)
(http://i.imgur.com/o1EKElA.jpg)

side by side of factory and S&B air tube
(http://i.imgur.com/jzxMTZu.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:23:15 PM
New air box and filter installed       

(http://i.imgur.com/fjU6gPp.jpg)
(http://i.imgur.com/nnAgbOG.jpg)
(http://i.imgur.com/9fWHgLf.jpg)
(http://i.imgur.com/mI3l6OH.jpg)

Air intake box install complete!
This was an easy mod that I casually took about 2 hours to complete.
(http://i.imgur.com/nFtM09x.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:23:26 PM
For the next project I had to temporarily remove some things to gain room to install the new parts. The garage floor became quite cluttered as the disassembly continued.      
(http://i.imgur.com/qF3mZsP.jpg)
The MBRP 4" exhaust went on quite easily, although some minor trimming was required. I did not, however, use the supplied muffler clamps which came directly from the old testament!
I purchased stainless steel band clamps and secured the system with those. Also I would critique the MBRP system for not using all the factory hangars. They elect to skip one which in my opinion is not a good idea. I will rectify that by securing some steel rod and fashioning my own hangar and welding that to the supplied pipe.

I suffered a temporary brain malfunction and forgot to take pics of this particuliar install, so I took these (poor) shots later after, of course, the exhaust system was plastered with dirt and mud
I painted the tailpipe section semi gloss black to get a stealth look out of it. (http://i.imgur.com/PtY4Myf.jpg)
(http://i.imgur.com/pEHHOhT.jpg)
(http://i.imgur.com/K35j5q2.jpg)
(http://i.imgur.com/35B9mcF.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:34:31 PM
Next the new engine programming is installed
I chose this H&S unit because I didn't want to squint at the credit card display in the mini unit. This unit cost significantly less and I wanted to upgrade to real gages. The pilot in me likes to look at stuff and know what's going on with the mechanical stuff I'm strapped to, just a habit I guess...       

(http://i.imgur.com/qoIoBsq.jpg)

Upcoming projects (which are in progress) include:
(http://i.imgur.com/1qtUFwj.jpg)
(http://i.imgur.com/x08zhan.jpg)

Lift and suspension
(http://i.imgur.com/lzbEPAS.jpg)
(http://i.imgur.com/hgfi8bw.jpg)
(http://i.imgur.com/sarcnYk.jpg)
(http://i.imgur.com/kCLVt3u.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:34:45 PM
Wheels (Pro Comp 18 X 9's) and tires

(http://i.imgur.com/QuUTaW3.jpg)
(http://i.imgur.com/Y2f6C5L.jpg)
(http://i.imgur.com/TRYgsAd.jpg)
   
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:34:55 PM
OK, more pics of stuff which is piling up around here awaiting install time on Mr. HD

I went with the standard Road Armor bumper. I actually had one of the trucks issued to my unit in Kandahar get VBIED'd. The blast tore the holy heck out of the Ford F250 but that RA bumper remained more or less intact. Obviously it was not in the main part of the blast, but when the truck was recovered by dragging the suspensionless ford off the X with a recovery strap, the bumper carried all the tugging force and remained mostly intact.

(http://i.imgur.com/eM2bvDA.jpg)
(http://i.imgur.com/qFlry4A.jpg)

Here's the lights
Warn 350F, 4 ea to be used as fog lights. My thought is to just create enough heat out in front of the truck to ignite the fog and burn it out of the way. Sorry if any TH (tree huggers) are offended by my burning away virgin acreage, but you know what they say, "Safety first!"
(http://i.imgur.com/BPmoayL.jpg)
(http://i.imgur.com/oAxmXPw.jpg)

I am also adding either two or three of these 4" HID driving lights on top of the bumper. They will be wired in to the high beam circut to boost vis out in front when I need it. So what do we think, 2 or 3 lights???
I think the Optilux are Hellas.
(http://i.imgur.com/2mGyi9u.jpg)
(http://i.imgur.com/zwzc5QJ.jpg)
(http://i.imgur.com/TvOHO2q.jpg)
      
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:35:06 PM
Finally, to finish off the bumper installation, I'm adding my trusty T-Max winch. It's a perky little reel rated at 9K line pull. I always use a pulley to double so I'm looking at 18,000 lbs worth of pull out of around 60 lbs. The line is aramid, with the inner 30 feet spliced into the heat resistient "red" plastic line stuff. Yes, it is all dusty and has seen some miles, but is still plenty servicable, so why not go for it and get another service life out of it. This will be vehicle number 3 for this winch!

 (http://i.imgur.com/QsANgsK.jpg)
(http://i.imgur.com/zDAsQJt.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:35:16 PM
OK, here we go again.
This series will show the installation of the Fabtech 6" lift kit
Here is the truck on jack stands wearing the stock stuff for the last couple minutes.
      
(http://i.imgur.com/tfCI8wc.jpg)

First you remove the tires and wheels, no big deal there
Next you have to tackle the torsion bars.
I just picked up a new Ready-Lift torsion bar tool, here it is in action
(http://i.imgur.com/D55p9JD.jpg)
(http://i.imgur.com/Qy2fV0A.jpg)

Here is the factory torsion bar key
It is different than the earlier keys. I snapped a shot of the part number in case anyone needs that info
(http://i.imgur.com/AYxplYV.jpg)
(http://i.imgur.com/8tyXHW8.jpg)

I measured the torsion bars which can be removed when and if you drop the torsion bar crossmember. I had two different part numbers
Left: AAF
Right: AAG
Left: 1.54"
Right: 1.552"
(http://i.imgur.com/nnmH86f.jpg)
(http://i.imgur.com/eL0hpd1.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:35:32 PM
Next the stock shocks come out
I'm a little concerned at this point because the stockers top mount consists of a two bolt T-Shaped arrangement. THe replacement Fabtech units feature a top stud which is all together different, time will tell I suppose

(http://i.imgur.com/XIVdM6Z.jpg)

Where it all is at this point
(http://i.imgur.com/1PE7mME.jpg)

Parts on the floor are increasing, but I haven't tripped over anything yet!
I'd note that this kit or rather working on this HD truck is truely akin to heavy lifting. I mean nothing is easy. THe bolts are torqued to 76,000 ft lbs. the nuts weigh 45 pounds each! Well maybe not that much, but I'm telling you, if you were planning on a morning workout, skip it, a day on this will more than suffice.
Fabtech says to discard the factory skid pans
(http://i.imgur.com/lPcQoUW.jpg)
View of things at this point
(http://i.imgur.com/w5qKmr5.jpg)
Don't discard used up rotors. Weld a bar inbetween two of them and you have a pretty decent curling bar. Girly men better stick to the Mustang 2 rotors!

These rotors are serious equipment. Mine measure 14" in diameter!!!!!!
(http://i.imgur.com/HVvelao.jpg)
(http://i.imgur.com/CatfH3e.jpg)
(http://i.imgur.com/otUKNTk.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:35:45 PM
With the rotor removed       
      
(http://i.imgur.com/mKPuivd.jpg)
4 large bolts and the wheel bearing assembly is out
(http://i.imgur.com/fJbEzRO.jpg)
Wheel bearing and rotors
(http://i.imgur.com/E05WULf.jpg)
The spindle comes out relatively easily. This part will not be reused
(http://i.imgur.com/UOOZQEK.jpg)
(http://i.imgur.com/3QeLuAI.jpg)
Next the axle shafts are remove, then the lower control arm.
(http://i.imgur.com/e7DN5uL.jpg)
(http://i.imgur.com/3aODOGb.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:36:00 PM
Next I removed the front drive shaft from the front diff and let it hang. That was as far as I got today working from 10AM until 1700. I lost about an hour having to go to the parts store to purchase a 35mm socket for the axle shafts. Somehow, I lost my old one!!!!! That was $20 I didn't want to spend. But having just shelled out 10,000 for parts so far, I guess it's a small thing.
Tomorrow morning I'll get back into it and see if I can get the front lift installed by sundown tomorrow!

...........OK, here we go, day 2 of the Fabtech lift install
Next the aft front diff crossmember is removed and discarded       
(http://i.imgur.com/kmwv7fq.jpg)
(http://i.imgur.com/FmcSSnS.jpg)
Next the differential assembly is removed. That is no easy task BTW, I had to use a jack and carefully lower it clear of the wreckage of what's left of the front end.
(http://i.imgur.com/X6Su7iP.jpg)
(http://i.imgur.com/pNNUlcd.jpg)
Here's a view of the bottom side of the oil pan, something most folks will never see I guess. So for reference and education purposes, here it is:
(http://i.imgur.com/6mgBCAU.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:36:11 PM
Next the sawzall comes out to remove some of the rear cross member mounting tabs. This is necessary to make way for the repositioned front diff.

This is a particuliarly nerve racking step. Ever here the guy say, "I cut it twice and it's still too short!" Yea, don't be that guy! I measured, and measured, and measured again. In the final analysis, it really doesn't have to be all that precise.      
(http://i.imgur.com/IFyJuEl.jpg)
(http://i.imgur.com/U9KgbKd.jpg)
(http://i.imgur.com/wI71Htf.jpg)
A view of the cut on the passenger side
(http://i.imgur.com/kRHjyYm.jpg)
Finally an easy step. A hole in the front diff had to be drilled out to 1/2"
(http://i.imgur.com/3bOxvGu.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:36:32 PM
Finally the reassembly is started. Both new front differential drop brackets which are thick, reinforced, and cadium or zinc plated, are bolted to the factory mounts and the diff is reinstalled.
Reinstalling that axle is quite a chore. I did it by myself, but I'd say it would be much better to do it with two capable men. That thing is very heavy and difficult to balance. All the while it is dangling up there just inches away from crushing one of your body parts, you have to thread it onto four bolts and somehow with your third and forth hand get a washer and nut on something. Gravity was in full effect in my garage today, so I got to do the balancing act several times!
      
(http://i.imgur.com/R5vYDST.jpg)
(http://i.imgur.com/5rpwdqA.jpg)
(http://i.imgur.com/FWgl7QV.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:36:46 PM
Now the drive shaft is reconnected and the new aft crossmenber is installed using the factory bolts.      
(http://i.imgur.com/QDEjb2i.jpg)
(http://i.imgur.com/Dx2DgOb.jpg)
And the new front crossmember
(http://i.imgur.com/wDJqsfm.jpg)
The lower control arms need to have the stock shock bushings removed. That is done with a ball joint press. Here is mine set up ready to push out the stock bushing
(http://i.imgur.com/2SIXrI0.jpg)
(http://i.imgur.com/CRHb5PS.jpg)
(http://i.imgur.com/d4WoI6T.jpg)
The bushing presses right out. The job would probably stop you right here if you don't have this tool
(http://i.imgur.com/vvcVaQf.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:37:22 PM
Fabtech supplies some large aluminum bushings which get inserted into the factory torsion bar socket

(http://i.imgur.com/avZwZXh.jpg)
(http://i.imgur.com/AECWHMw.jpg)

The other half of the bushing occupying the old torsion bar hole
(http://i.imgur.com/jOcajtV.jpg)
(http://i.imgur.com/EN0FzJW.jpg)

The last of the aluminum bushings, a smaller set is inserted into the hole where the factory shock bushing used to reside.
(http://i.imgur.com/AFlJTkM.jpg)
(http://i.imgur.com/SqhArD7.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:37:37 PM
The cold temperature abated somewhat in the late afternoon so I took advantage of it and coated my new wheels with a product called "SharkHide" made by the Eastwood company. It was originally formulated for aluminum pontoon boats. One wipe on application protects the metal against the corrosive effects of water for a couple to several years. THe wheels will basically stay just like this for a long time.
THe stuff is expensive, over $60 for that little can, but it's worth it. I also coated the plated parts I already installed and am yet to install.
      
(http://i.imgur.com/hiF1IE6.jpg)
(http://i.imgur.com/3mBAaTs.jpg)

OK, just finished Day 3 and this thing is like wrestling alligators, not that I've done that, but it just doesn't let up. This is just plain hard work. If you are going to do it on the floor using jacks and jack stands, well, good luck. I had hoped to finish with the front today, but it just didn't happen. I am close though, but I don't like to rush anything. When I get tired, there is a probability for sloppiness, and I'll have none of that, thank you very much.
Here is the torsion bar relocation bracket. It is very substantial and well engineered. It requires you to temporarily bolt it into place to mark the spot to drill a 1/2" hole for an additional mount.
(http://i.imgur.com/kZkGlV9.jpg)
(http://i.imgur.com/z2bRrxe.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:38:07 PM
With the drilling complete and the hole checked (It turned out perfect both times) the lower control arm gets remounted. The bolts stay loose for now
      
(http://i.imgur.com/8KUSnPH.jpg)
(http://i.imgur.com/fmVXAoR.jpg)

The torsion bar relocation brackets can now be permanently mounted and torqued in place.
(http://i.imgur.com/srCbTH0.jpg)
Next, the tie rod ends are removed and 1/2" is cut off the threaded rod
(http://i.imgur.com/muAcPGL.jpg)
(http://i.imgur.com/wjdCKb3.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:38:43 PM
Fabtech supplies a upper shock mount plate which bolts in place using the factory boltholes.      
(http://i.imgur.com/RMyVPUU.jpg)
(http://i.imgur.com/Xy8V18a.jpg)
(http://i.imgur.com/at4uoXk.jpg)

Here's a comparo of the factory shocks with the dirt logics
(http://i.imgur.com/qHXEeSL.jpg)
(http://i.imgur.com/XNrOmHa.jpg)

Here a better shot of that new upper shock mount
(http://i.imgur.com/SVRdCu1.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:39:00 PM
Now the front shocks can get mounted. There is a lower mount already provided for dual shocks if I want to do that in the future.
      
(http://i.imgur.com/gqIUG5O.jpg)
(http://i.imgur.com/Kymk2eh.jpg)

Tool time...
TO slightly enlarge a 2" area on a crossmember where the torsion bar needs some clearance, out came the handy carbide cutter
(http://i.imgur.com/kxWJXCg.jpg)

Next, the factory torsion bars get loaded from the front. I needed to be about two feet taller and have dextrous feet to have done it the first time without trouble. Like I said it is just a wrestling match. THe torsion bars are heavy and the going is just plain slow. But everything is fitting just fine as I go
(http://i.imgur.com/yTEKXLi.jpg)
(http://i.imgur.com/Kxupo5a.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:39:25 PM
Here are the factory and Fabtech spindles. Lots of mother earth in the Fabtech piece!

(http://i.imgur.com/q2X7TaS.jpg)

I installed the heavy spindles with the help of a jact. THen installed the "O" rings into the new spindle.
I coated everything with a small amount of high temp disc brake grease to aid in removal at some future point in time
(http://i.imgur.com/eN9X7FI.jpg)
(http://i.imgur.com/5ooql0C.jpg)

Then the backing plates and wheel bearing assemblies can be reinstalled. They take something like 175 ft lbs torque times 8 bolts which was another workout.
At this point it was past 1700 and time to call it quits after another long day. Tomorrow I should finish the front and maybe the entire install, we'll see how it goes!
(http://i.imgur.com/FnOQUe9.jpg)
(http://i.imgur.com/NIu3AxX.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:39:43 PM
OK, here we go, off and running, well barely crawling, onto day 4
Here's a shot of something, heck, I can't remember of what, but there is some progress in there somewhere!
      
(http://i.imgur.com/rA9VZhc.jpg)
(http://i.imgur.com/ICchuns.jpg)

The factory sway bar gets two horizontal extensions that will then mount to the factory link onto the new torsion bar mount
(http://i.imgur.com/7uUz2mO.jpg)

I painted the factory links with John Deere flat black. THis is a very high quality paint that is reasonably priced
(http://i.imgur.com/8VswTEQ.jpg)
(http://i.imgur.com/h5Z2rjE.jpg)
(http://i.imgur.com/hywDWZW.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:39:55 PM
Here is the sway bar extension and the factory link all installed as looking pretty

(http://i.imgur.com/7Qevdo1.jpg)
(http://i.imgur.com/bLbDo0X.jpg)
(http://i.imgur.com/zV4D6lB.jpg)

The brake lines which are hard mounted to the chassis forward of the suspension needs to be relocated. These plated brackets do that. I checked the line to be sure there was no contact anywhere to later chaff through and cause a loss of braking.
(http://i.imgur.com/vwVxFRj.jpg)
(http://i.imgur.com/Ze5wBk7.jpg)
(http://i.imgur.com/3xOLTsi.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:40:10 PM
Next the shorter tie rod ends get installed. THis was probably the easiest task I had encountered to this point. It was like a mini vacation!
      
(http://i.imgur.com/5723sdm.jpg)

At this point I mounted the new Fabtech front differential skid plate. It looks pretty beefy and like everything else was heavy.
(http://i.imgur.com/VBSrl3B.jpg)
(http://i.imgur.com/Nf4vlbe.jpg)
(http://i.imgur.com/lzQnoLE.jpg)

Next came the scary part, reinstalling those torsion bar keys. You just can't imagine just how much pressure that torsion bar exerts. It is nothing to mess with. My special tool slipped just a tad while loaded and this is what happened!
(http://i.imgur.com/Zn0iCsT.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:40:22 PM
After some praying I got back under there and got it done. I think I was more worried about cranking those bars without the keeper in place than I have been landing in a hot LZ. Heck over there I could only have been killed. This torsion bar stuff will flat mess you up!

Finally, I got to see what it is all for. I mounted the 35" Toyos and let the thing off the jack stands. At this point the rear is still stock everything

(http://i.imgur.com/Y6GY7Q3.jpg)
(http://i.imgur.com/v5e8alB.jpg)
(http://i.imgur.com/LsISSSl.jpg)
No, I didn't install no stinkin caps! And, yes, I chose black lug nuts for a reason

By comparision the rear was a piece of cake. I literally did the whole thing in about an hour and a half!
Here the rear blocks are going in. This was uber simple. I simply removed the U-bolts from one side and let the weight of the housing warp the opposing spring. I then positioned the vlock and lightly tightened the new U-bolts, then repeated the opposite side.

(http://i.imgur.com/RPG31TB.jpg)
(http://i.imgur.com/0IzdtwJ.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:40:32 PM
There are a myriad of extension brackets that attach to the rear axle repositioning things north a couple inches. Another bracket drops the emergency brake cable on the left side.

(http://i.imgur.com/4qXXFHA.jpg)
(http://i.imgur.com/nPf4ucn.jpg)

The shocks were installed and just like that I was done, well sort of
(http://i.imgur.com/Drvf0hk.jpg)
(http://i.imgur.com/A52QtiR.jpg)
(http://i.imgur.com/mdCvZcc.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:40:43 PM
Front shot done in the garage at night

(http://i.imgur.com/F3mJp8c.jpg)

Undercarriage shot resting on the ground
(http://i.imgur.com/m0C02iR.jpg)
(http://i.imgur.com/ZYwsrSj.jpg)

I drove it over to the alignment shop after fussing with leveling it using the key adjustment bolts. Final lift came in a tad over 7" in the front. THe darn thing is so tall now, I will need to do the step/rock rail thing PDQ

Surprisingly, the ride was good over to the shop and the alignment I had set by eyeball was remarkably close.

After the alignment the I drove home at normal speeds. The ride is, well. remarkable! It rides very well indeed and so far hasn't shown any quirky habits. It is definately smoother than it was, however has lost some power. I have so much of the latter that it really is no issue what so ever, but since I like power, I'll probably opt for a regear. Braking is normal and cornering is near stock and we have our share of corners here in the "Tucky.

All in all, I am pleased with this install, and the kit as a whole. It is not a novice project and will definately be a long and ardrous task for anyone undertaking it. But the end result is a good looking well engineered setup that you can be proud of!(http://i.imgur.com/23PNjcY.jpg)
(http://i.imgur.com/Dygi3sS.jpg)
(http://i.imgur.com/0OkldXA.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:40:57 PM
Quote:
Originally Posted by *****
"Looks great. What are you going to do for center caps. I know you said you are not going to put the stock ones on but I hope you are going to do something".
 

Sorry bro, no center caps. I think it looks fine the way it is. Center caps are just fake plastic junk anyway and I don't like stuff like that. Not going for any particuliar look, but I choose function over appearance every day of the week.
That's why the bumpers are going away. The factory ones are little more than air dams, totally inadequate when pushing small foreign cars out of the way!

...........OK, the next project is going to be the Road Armor bumper install. This will be a slow start out of the gate. Being a Saturday, my list of family activities and honey do's (starting with fixing a toilet!) out weighs my desire to bolt that cool bumper on.
So I just fussed around a little rounding up parts and hardware and fooled a little with the winch.
I have chosen to reuse a T-Max 9000 winch I once had used on other vehicles. It is an excellent winch featuring a 6.6HP motor. THe warn, notably only has 4.6HP! When I was buying this winch I scrutinized the winch components of the various winches and actually found this T-Max to be more robust in construction than the venerable Warn. The planetary gear set was slightly thicker in the T-Max and of course the motor was much more powerful. Retrival line speed of the T-Max also eclipised the Warn, and finally at 2/3rds the price of a Warn, I purchased this winch.
I carry a recovery bag which contains a tree sling, a tow strap, several clevis, some chain and hooks, and a pulley.
Ah yes, the pulley??? You actually have an option, that is to either mount a 150 lb 16,000 winch or simply double the line with the use of a pulley to get a pull of 18,000 lbs out of the 75lb 9K winch. Since every time you step on the loud pedal you are applying a force to acclerate a mas, well, the less mass you have to push, the less force (fuel) needed. So the math was pretty easy even for a thick headed guy like me. Forgo the 16.5 K bragging rights and get more done for less and save $$$ for as long as I own the truck.
OK the winch has synthetic line for safety reasons. Steel wire will stretch then when it snaps it recoils with sufficient force to kill. Synthetic line will just tear and fall to the ground. Then it is also much lighter. You can use either a hause fairhead which is just smoothed out aluminum or opt for a set of rollers. Here is a standard set of rollers used with a standard winch with steel cable.
(http://i.imgur.com/YmqzeCz.jpg)
To make it compatible with the Aramid fiber rope I am using, the rollers need to be made of poly or DelRin. Here is a replacement set of rollers
(http://i.imgur.com/cGW6ZwY.jpg)
Not a great pic, my humble apologies, and here is yet another poor pic showing the roller itself
(http://i.imgur.com/nfWaQxi.jpg)
4 quick snap rings later and the steel rollers were, well, rolling away!
The new poly rollers were actually too long to fit, so I carefully cut them down to size with a miter saw.
(http://i.imgur.com/422XhHx.jpg)
(http://i.imgur.com/U3UuV6G.jpg)
The new rollers slid right into place in a jiffy completing this simple but necessary modification.
(http://i.imgur.com/QbmoHVV.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:41:07 PM
I also picked up a poly bobbin to save the winch line while in it's travel position. THis cool little chunk of synthetic something or another slides over the line and provides for a more gentle transition through the rollers while you have it presumably secured to an anchor point on the bumper. Looks cool too!

(http://i.imgur.com/xDCdGy2.jpg)
Here's Mr T-Max that will shortly once again call a GM truck it's home. (I once had it installed on my Hummer).
And this will conclude the rather short entry today while I resume toilet repair duties! The plan is to fit everything onto the Road Armor on Montag, then actually mount it on the truck on Dienstag. Should be ready to start running over things in just a couple days!

(http://i.imgur.com/1rJhdWf.jpg)
(http://i.imgur.com/l54JTDd.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:41:16 PM
Quote:
Originally Posted by ********
"Everything looking good, tell us how she runs, any problems with the mini maxx, exhaust, etc? I have a hypertech and S&B, doing a lot of adjusting and testing to see what works best with my truck, when I'm done will post a report on the forum".
 

I have driven the truck a couple hundred miles so far. The ride is both softer and different. I do get a little roll in the corners, but well within the green. The ride is cushy whereas the stocker was more percise although harsher. I have noticed a slight loss of power that is becoming more noticeable. Instead of cruising at 1700-1800RPM, I am now 1500-1650RPM. That has resulted in a loss of fuel economy. When I started the lift the truck was making 18.9MPG. At the moment that figure has dipped to 18.2 MPG.
The speedo is actually very close. It is now indicating 2-3 MPH slower than actual speed as measured by those handy roadside radar units.
I can now see the definite need to regear. I would think a 4.56 ratio would be ideal and should get me back to the 18.9MPG or maybe even a tad better. In any event, it will return the "snappy" throttle response I was used to before the 35" tires. It will also open the door to future 37" tires. My other truck, the Tundra was running 37" tires with a 4.88 gear and that was fine for the highway as well as crawling around in the rocks.
Finally my two young boys have both wiped out badly! They step out of the truck expecting to find terra-firma and instead discover they just jumped of the ramp of a C130 on a HALO jump! Yup!!! But, judging from the bruises and scrapes they should be pretty fast learners!

Stickers removed!!!!!
Easiest project day so far!
(http://i.imgur.com/2PAHj4N.jpg)
(http://i.imgur.com/Qhpe16W.jpg)
(http://i.imgur.com/EkDXQpM.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:41:27 PM
OK, here we go with the Road armor and lights install. THis would be the first serious half day work fitting stuff together
Here I'm getting the bumper off the skid and onto the work bench. If I had two people working, the tractor would not be necessary at least at this point

(http://i.imgur.com/tJSnXTT.jpg)
(http://i.imgur.com/q1hVR17.jpg)
I planned to install the winch first but before starting I wanted to replace the rusty old snap rings with new ones. That took 5 minutes
(http://i.imgur.com/MsyE1Dc.jpg)
(http://i.imgur.com/81OTz9W.jpg)
The winch goes in with 4 easily installed 3/8" bolts
(http://i.imgur.com/m9fBwaL.jpg)
(http://i.imgur.com/qvZSrJg.jpg)

Next the roller fairhead is installed. Access to the back side of the two bolts that secure it is iffy at best. I installed the bolts from the inside protruding outward and then worked the bolts slowly until they too were tight
(http://i.imgur.com/JHNH1C1.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:41:38 PM
The winch has a remotely mounted control box. I decided to mount it on to the top of the bumper for easy access. I fabbed up a mount made of 1/8" steel and used angles to completely encase the delicate box, thus affording it some protection.
      
(http://i.imgur.com/saqirYT.jpg)
(http://i.imgur.com/0Gp92AD.jpg)
Using cleco's I temporarily secured the bracket while drilling 1/8" pilot holes. Afterward, I drilled the holes to 1/4" their final size.
(http://i.imgur.com/Icyiy3x.jpg)
(http://i.imgur.com/MVOwhsw.jpg)
I ground the welds mostly flush and treated the steel before spraying with two coats of the John Deere black paint
(http://i.imgur.com/800tT9S.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:41:47 PM
I welded bolts to several places on the bumper to act as ground points for the winch and the lights. I plan to run a ground strap from the battery, to the frame, from the frame to the bumper and then to each component. I have successfully used this technique many times in the past eliminating long runs of wire and keeping things neat and tucked away.
You can see a 1/4" bolt under each side of the light ports, and another on the right side for the winch ground cable.

(http://i.imgur.com/GCu8TcD.jpg)
(http://i.imgur.com/v6vPXwR.jpg)

In go the Warn 350F fog lights, 4 of them total to replace the two factory fog lights.
(http://i.imgur.com/rwPMBcd.jpg)
(http://i.imgur.com/MiaHLGw.jpg)
This is as far as I got tonight as far as installing things
(http://i.imgur.com/6ltvsYG.jpg)
(http://i.imgur.com/uDiKwYw.jpg)
I played with the position of the HID driving lights some. Dunno exactly where they will end up just yet, but not far from here me thinks...
(http://i.imgur.com/HPT5NUO.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:42:03 PM
Quote:
Originally Posted by *****
"Is that winch 9000 lbs or is that just the model number?
Just asking because if its 9000lbs you may want to upgrade. As a general rule, you want 1.5 times vehicle weight, so id say a 14-15k winch would be a good match. Depends on if youre planning on using it to pull the truck out of thick mud or up some rocks or if youre just using it to pull the little jeeps and such out. But then again, you probably already know all of this, im just throwing my 2 cents in".
 
You don't need a large winch.
Everytime you double the line with a pulley, you mechanically multiply the line pull. straight line = 9000 lbs. double the line with a pulley and you get 18,000 lbs pull, although at half the line retrival speed. Triple it and get 27,000 lbs pull.
A long time ago in a galaxy far, far away, I attended the US Army's recovery school in Aberdeen Maryland. Back then I was a tanker and had a secondary as a recovery specialist. THis was obviously long before my pilot days. I learned a vehicle mired to it's undercarriage in average mud required a force equal to it's weight plus 60%. So my fully loaded truck at 8,000 lbs would need 12,800 of pull to free it, well under the 18,000 lbs I normally use.

........OK, here we go with Day 2 of the bumper install.
It was easy going right up to the point where I had to bolt it to the truck. THen everything went into slow motion mode. It was so slow getting to all those difficult to access bolts that I didn't get the lights hooked up.
Anyway, here's the fabbed up winch control box sitting securely in it's new home.
(http://i.imgur.com/7hHznvh.jpg)
(http://i.imgur.com/dTWFsyq.jpg)
Here's how I did the winch ground cable. Simple and out of the way. THe winch gets grounded to the bumper, and the bumper in turn gets grounded to the frame and the battery
(http://i.imgur.com/fXZAAM3.jpg)
I wraped the positive cables in plastic wire loom then paid attention to securing everything so that no wire can chaff, or get in the way of anything. Murphy's law is in full force when playing with electrical fire starting stuff. Take a little time now and forget about it for years
(http://i.imgur.com/fvVJyQe.jpg)
(http://i.imgur.com/wWRZkIo.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:42:13 PM
Next I drilled two 3/8" holes and temporarily mounted the HID lights. The position seemed OK and looked like they would clear the grill while not inhibiting air flow to the hot stuff up front.
      
(http://i.imgur.com/FgPBtbh.jpg)
(http://i.imgur.com/UkRvekh.jpg)
(http://i.imgur.com/piuwrdW.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:42:22 PM
Finally it was time to remove the stock bumper.
There is absolutely nothing behind it to protect the front end of our trucks!

(http://i.imgur.com/ELKxiyv.jpg)
(http://i.imgur.com/AbRjOiq.jpg)

The rather beefy Road Armor bumper brackets get installed next. I left all the bolts pretty loose at this point
(http://i.imgur.com/luw8U8j.jpg)
(http://i.imgur.com/aTJuCW5.jpg)
Time for the heavy lifting. I decided to give that chore to by best friend, Mr. Hydraulics. By rigging the bumper with 4 opposing slings, I was able to jockey the angle. THe front loader and the tractor did the rest getting it into position.
(http://i.imgur.com/CSDdGUx.jpg)
(http://i.imgur.com/4UgMhML.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:42:36 PM
Hours later, here's what it ended up looking like!
I connected the winch cable and got that working. I then off loaded the cable and installed the poly bobbin.

(http://i.imgur.com/IZ7mfAK.jpg)
(http://i.imgur.com/PyjlEAX.jpg)
(http://i.imgur.com/CMT44UX.jpg)
(http://i.imgur.com/V802QxT.jpg)
(http://i.imgur.com/LKndgpu.jpg)
(http://i.imgur.com/2R3VX4g.jpg)
(http://i.imgur.com/oygmnLx.jpg)
Close up of the winch/bobbin/clevis thing
(http://i.imgur.com/uasyJCR.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:42:44 PM
I carry a winch accessoriy kit.
It has:
Several Clevis
Tow strap
Tree saver
some tools
Shovel
Some gloves
Pulley
Extra nylon strap
And what ever else I might think I need on any given day
(http://i.imgur.com/Yi0275Z.jpg)
(http://i.imgur.com/lQ8k4DS.jpg)
(http://i.imgur.com/d1MudzJ.jpg)
....I got the lights installed this morning, well into the afternoon if I'm being completely truthful.
First off, I mounted the HID's back into the previously drilled holes, leveled them and snugged up the stud bolts.
(this is where ken accidently deleted the wiring pics....oops)
....I plugged it all together and tested the operation, one fog at a time, then eventually all four. THe wire did not even get warm and all the lights worked seamlessly.
The HID's were similiarly plugged in to the blue power leads from the fuse box and tested. They, too worked without problem.
So, no new switches, no holes in the firewall.
The HID driving lights come on when the high beam is activated. The 4 ea warn fog lights come on when you push the factory fog light switch
(http://i.imgur.com/ba494CX.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:43:15 PM
I spent some time zip tieing everything up and out of harms way starting at both ends and finishing in the middle just below the bumper
The grill and the plastic cover went on in a snap (literally!). Prior to pulling it out in the rain, I wiped everything down well with armor all and silicone to shine it up and give it some more H2O protection.      
(http://i.imgur.com/HnDyzDK.jpg)
(http://i.imgur.com/IT8Wsbm.jpg)
(http://i.imgur.com/UbP9Rnx.jpg)
Here's the low beams illuminated with all four fog lights on as well.
Sorry for the daytime pic, but I'm not in control of all of that!
(http://i.imgur.com/RAoUuFR.jpg)
(http://i.imgur.com/pZtkl2B.jpg)
Here's the high beams on with the HID on as well...still daylight...
(http://i.imgur.com/UloDMsn.jpg)
(http://i.imgur.com/HZkV4UI.jpg)
(http://i.imgur.com/fPcnlLJ.jpg)
Here's a couple prfile shots to show how far out things are positioned and the protection that bumper provides.
(http://i.imgur.com/5Ucwsvt.jpg)
(http://i.imgur.com/f4tEI0v.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:43:24 PM
Time for some more mods!
This time I am going to install an Air Dog 165
Earlier I did some piliminary work when I cut up an unused mount on the frame and constructed a sturdy mount using it and some square tubing.
      
(http://i.imgur.com/Nl12hmM.jpg)
(http://i.imgur.com/08hJPyw.jpg)
What was left of the mount when I finished cutting
(http://i.imgur.com/465l2ZQ.jpg)
This is the Air Dog 165 backing plate that was welded to the truck and reinforced
(http://i.imgur.com/WRo0NXq.jpg)
Here is the Air Dog pump being test fitted.
I mounted it at a 20 degree angle relative to the vehilde CL to give the fuel pickup line as much room as I could
(http://i.imgur.com/hXNumXg.jpg)
(http://i.imgur.com/x9PsxHQ.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:43:32 PM
Next I removed the fuel tank skid plate
      
(http://i.imgur.com/0XcCPGM.jpg)
Next I marked and drilled a 1/4" hole in the center of the sump area underneath the in tank sending unit.
I did not want to fool around with a draw straw and quarter tank fueling issues, so I'm going straight to a sump. THanks again to Holton over at Alligator who both advised me to do so and sold me the part.
(http://i.imgur.com/2SrxEdY.jpg)
(http://i.imgur.com/LtQk5TZ.jpg)
(http://i.imgur.com/gtBqyVq.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:43:44 PM
I installed all the fittings onto the pump/filter unit
      
(http://i.imgur.com/ZsksR4s.jpg)
(http://i.imgur.com/GotkrOm.jpg)
(http://i.imgur.com/iYkM1u1.jpg)
This piece is supposed to fit inline in the factory fuel filler line...more on that later
(http://i.imgur.com/6PVQzDZ.jpg)
I cut about 3/4" out of the filler line then came the big surprise!
(http://i.imgur.com/guJYZwW.jpg)
...The supplied piece was too big. The diameter was too large and it actually fit over the hose!
This is a nice time to find out I have the wrong part. Not like I can call and get another. So, what, my truck sits idle for a week while I wait for the correct part that should have been there all along, finally shows up? What if I actually needed the truck...Man there's a concept!
I had no choice but to fab up something myself or I'd be dead in the water!

Luckily I found a piece of steel the correct diameter and started cutting things apart
(http://i.imgur.com/pemxnIc.jpg)
Once I finished cutting this is all that was left of the Air Dog piece
(http://i.imgur.com/9ln3yS6.jpg)
(http://i.imgur.com/HRlA5nU.jpg)
After the sparks stopped flying, here is what I had. Not as pretty as the ill fitting piece, but it's in there and it works!
(http://i.imgur.com/jX8rvTF.jpg)
(http://i.imgur.com/vclV655.jpg)
(http://i.imgur.com/7rYtLn3.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:44:05 PM
Now the messy work started. I thought all the fuel was drained from the tank, well I was wrong...
I started drilling a 2.75" hole to fit the Alligator sump then quickly discovered I had a couple quarts of fuel still in there. No2 diesel does not taste all that bad I guess, especially when mixed with greasy gloves!
(http://i.imgur.com/WuEVl21.jpg)
(http://i.imgur.com/QunSarU.jpg)
The sump is an aluminum billet piece which is very well made. It has inside and exterior parts and studs to help one align the parts
(http://i.imgur.com/8oOsYhe.jpg)
(http://i.imgur.com/PxZ8hVN.jpg)
Here's the inside of the tank parts and how they all fit together
(http://i.imgur.com/TRq21hi.jpg)
(http://i.imgur.com/DDJvEMV.jpg)
(http://i.imgur.com/br9CHLt.jpg)
I used a piece of scrap to push the sending unit up out of the way while I fitted the ring halves to the inside of the tank
(http://i.imgur.com/oX6VXFY.jpg)
Next the sump gets carefully and slowly bolted in place after first installing the two "O" rings.
(http://i.imgur.com/x4Y83Rb.jpg)
(http://i.imgur.com/7cVRzit.jpg)
(http://i.imgur.com/FKVZ89X.jpg)
(http://i.imgur.com/mG5f9rw.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 25, 2014, 02:44:23 PM
I then finally mounted the Air Dog pump unit
      
(http://i.imgur.com/pjdb0Wm.jpg)
(http://i.imgur.com/bN7QNgR.jpg)
The sump line is now connected to the pump.
(http://i.imgur.com/6ba6AhD.jpg)
(http://i.imgur.com/Hzmmd20.jpg)
(http://i.imgur.com/Duf7RMg.jpg)
Here is the line going into the pump. Note the minimum of space for that big line to get around in
(http://i.imgur.com/wUaDhfr.jpg)
The rest of the lines are now able to be hooked up
(http://i.imgur.com/OvESxha.jpg)
(http://i.imgur.com/8eZ8eIG.jpg)
The air bleed return line was plumbed to the earlier fabbed return unit and plugged in
(http://i.imgur.com/67BseZy.jpg)

Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:13:17 AM
Todays installment will completely finish the air dog installation except for replacing my fabbed up part with the new AD part and the reinstallation of the fuel tank skid plate.
I wanted to hold off reinstalling the skid plate until I can verify the sump is not leaking. I think a full tank of fuel and a week of driving should be a fitting test.
Today I installed the wiring harness, which was a simple matter. I mounted the relay to an engine to firewall ground cable on the drivers side of the firewall.

(http://i.imgur.com/Er793vB.jpg)
Next came sorting through which fuse to tap into for the pump power supply. I tried several different fuses, finally settling on #47 which is the Misc switched ignition, a 10 amp circut. THe original 10 amp fuse plugged into the tap and a 2 amp fuse routed to the relay which switches voltage directly from the battery.
Some of these photos do not show the wire properly installed as I had the pump wired to many different circuts while I ferreted out which one I was going to use.
(http://i.imgur.com/dvAuM0i.jpg)
(http://i.imgur.com/5J4dc9C.jpg)
(http://i.imgur.com/aWhyQwI.jpg)
I decided to replace the fuel filter with a new one to be sure I'd get the max fuel the hungry 6.6 required.
If you haven't done a filter change, here's how:

First get the correct new filter. I stuck with an AC Delco
(http://i.imgur.com/T2YD5uI.jpg)
(http://i.imgur.com/pHL9FKy.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:13:32 AM
You have to drop the right inner fender splash liner which is an easy 5 minute job. Here's where you start

(http://i.imgur.com/OftIMci.jpg)
Remove all the aft and most of the middle fastners then pull the inner wheel well down to expose the filter.
(http://i.imgur.com/btIe67s.jpg)
The filter can be seen and accessed through the opening.
Disconnect the water level sensor wire and unscrew the filter. Sway the H20 detector onto the new filter with the new O ring, then install a new O ring into the filter top. I used heavy grease to hold the O ring in place while replacing the filter.
(http://i.imgur.com/1XWx1vw.jpg)
(http://i.imgur.com/lBbiYOu.jpg)
(http://i.imgur.com/n6eDK3p.jpg)
I then had to bleed the fuel system to remove all the trapped air from the empty filter and new lines. To do that I simply cracked the bleed screw and turned on the Air Dog for a few seconds, that was it!
I buttoned everything up and started the engine. It started immediately and never stumbled at all!
WHile inspecting the job as a QC check afterward, I noticed fuell dripping from a corner of the Air Dog pump unit itself. After some investigation, it turned out to be coming from a factory (AD) installed allen head plug in the supply side of things.
Yup, none of my installed fittings were leaking but the AD factory plug was!!!
I loosened it several turns then tightened it back up. I noted it was in there monster tight. I just snugged it up and perhaps another 1/4 turn. THat fixed the leak!
I have to say that I did not expect all these pesky problems out of a well engineered $700+ unit. THe issue with the filler adapter was in someone not packing the unit of checking. THe leak problem was an assembly issue. THe lack of a way of mounting the unit and the instructions showing the wrong year frame is a mangement, production control, and quality issue.
I'd say Air Dog has a little homework to do unless they risk this becoming a larger issue.
(http://i.imgur.com/P34h5fD.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:13:43 AM
OK, time to get this thread rolling again.
This time I am installing Merchant Automotive tie rod sleeves.
In the past on my H2, I installed some high quality and thourghly expensive Fabtech tie rod assemblies. I off roaded that Hummer and even on days when I would break something in half such as a sway bar link, I never experienced a tie rod failure.
Knowing the tie rods are a weak point in our trucks, I wanted to get some insurance in there early on so I wasn't left stranded on a hill side in plain view of a bunch of Ford owners. Yes some fates are worse than death!
The tie rod can flex which leads to failure about where it and the tie rod end on the steering knuckle are causing a complete loss of steering.
The Merchant Automotive sleeves solve this problem by simply sliding over the existing tie rod. The factory shaft might flex a few thousands, however would immediately bind against the interior of the sleeve, effectively strengthening the whole assembly.
I like two things about parts. 1. Simplicity and 2. Low cost. and 3. Low cost, well I said only 2 things, sorry...
Here is the Merchant Automotive sleeves:

(http://i.imgur.com/x30U4Wx.jpg)
(http://i.imgur.com/JW5yijK.jpg)
(http://i.imgur.com/5IIumcG.jpg)
(http://i.imgur.com/kQukK6X.jpg)
The last photo is a tad bit fuzzy, but if your vision is like mine. it won't matter.
The stock tie rod shaft is .590" at the thread and .700" thick further down it's length.
The MA shaft is 1.125" in diameter made from stainless steel and has a wall thickness of .210"
It is 6.15" long
It threads directly onto the tie rod shaft with no fuss what so ever!
Here's the stocker
(http://i.imgur.com/FropB09.jpg)
Next you remove the tie rod from the knuckle, then unscrew the tie rod end. I then measured the exposed thread, then took the lock nut off
(http://i.imgur.com/Bn3wSWy.jpg)
(http://i.imgur.com/odh0who.jpg)
Here the MA sleeve is screwed loosely onto the tie rod shaft
(http://i.imgur.com/YYQWGUZ.jpg)
I then threaded the lock nut, and tie rod end, seating it to the previous depth and reinstalled onto the spindle. Then I snugged the lock nut and then the MA sleeve...simple enough for a helo pilot, so it's pretty much idiot proof!
(http://i.imgur.com/U3La7Lx.jpg)
Here's a couple of installed part shots
(http://i.imgur.com/kRP4l97.jpg)
(http://i.imgur.com/tnTTSUf.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:13:52 AM
Today I had the pressure sensors moved from the factory wheels into my new Pro Comp wheels
I also had the front end aligned after the tie rod sleeve installation last night
Here's a couple shots of the tire pressure sensors which the technician is mounting.
Sorry, these are lower quality I-Phone pics

(http://i.imgur.com/3eb6HZQ.jpg)
(http://i.imgur.com/OSH5EVx.jpg)
Here's a shot of the actual sensor
(http://i.imgur.com/veb9pVZ.jpg)
Then when he tried to balance the tire once again, this is what we saw!!!!!!!!!!
(http://i.imgur.com/5pBQqka.jpg)
OK, that's WAAAAYYY too much weight and the runout was getting to be excessive. That little clue led to a discovery.
Pay close attention to how well the wheel is actually centered on the mandrel of the balancer. The tech played with it and found a tighter fitting centering collar and spun it all up again.
This was the result of the second attempt:
(http://i.imgur.com/2lAfKme.jpg)
With that issue solved, the rest of the balancing went just fine
(http://i.imgur.com/YwWiJDR.jpg)
Next, on to alignment
I was surprised to find I had set everything pretty close, only the right wheel was out slightly
(http://i.imgur.com/gdAo8BH.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:14:05 AM
Here's another not quite mod, but good idea (I think) that I have incorporated into the trucks DNA

(http://i.imgur.com/L72342A.jpg)
Quote:
Originally Posted by ***********
"What type of interior shotgun mount are you looking at? Not sure if you want one that is easily accessible or one that is just a good mount. I bought an under seat box by DU-HA. Best interior box I have found. Has a shotgun rack in it and compartments for other items. It is color matched to the interior and fits perfectly under the rear seat. I also add a high tension rubber bungee cord from the back and around the seat belt mounts and to the box again to ensure that it does not move a bit. Worked perfectly and nobody see's the box with the seat down".


I like a mount I had in the aircraft I was flying in Baghdad. It had a tube in which the muzzle rested then a spring loaded "clip" affair that securely grasped the culinder adjoining the butt stock on the M4 Carbine I carried.

You'll have to look really hard, but you can make it out in the lower corner of the front door opening. Sorry, but those are the best shots I have from back then. Anyway, you can see the weapon is held securely at the ready. I want to carry my shotgun the same way. The area under the seat is for the recovery kit, and things like that
(http://i.imgur.com/XsabGZ5.jpg)
(http://i.imgur.com/ydCopnz.jpg)
 Quote: "saw in your list you wanted a spray in liner. Check out raptor liner - I've got a feeling it's right down your alley"
That is one excellent suggestion! One cup of coffee for you, on me!
(http://i.imgur.com/7SyLlI8.jpg)
Back to the shotgun question, I want it to secure my modified Saiga 12. The poly choke would fit into a tube. say 2" deep. Then a rubber coated grip mechanism would hold the back of the weapon securely. Just in case those killer squirrels come around, I'd like to be ready!
(http://i.imgur.com/rvELOsS.jpg)
The Saiga is a great shotgun if you get it modified. Out of the box, they are tempramental. I had Cadiz Gun Works build mine, Tom Cole was an armorer for BlackWater and really hnows his Saigas. I had both a right and a left bolt lever installed, so my gun would work for you. It is not cheap, but mine will hit a 8" pie plate at 150 yards with a 1 oz. rifled slug. I built the gun as an evasion gun for my old work. If you get your helo shot out from underneath you, my thought was to get into a compound ricky-tick. A shotgun will get through most door hinges and make short work of any uninvited guests. Mine never jams and will run anything I can shove into the 10 round magazine or the 20 round drum.
I'd recommend the gun, but take a look at the Kel-Tec as well. For years I used a pump because it always works, the Kel Tec has an interesting design that is a full on combat gun. If it's bird hunting you're in to, bypass it...

This pic shows the charging handle on the other side of the Saiga. Compare it to the earlier shot.

OK, nuff on guns, dis be a truck thread!
I have a major order inbound at the moment, gonna be some big changes coming up on the horizon! I will post parts pics when the stuff actually gets here...

I wanted to show what you get when you order the one gallon kit from Opti-Lube. The Fedex guy just delivered this to my door.
It's enough of the stuff to treat 500 gallons of fuel and will get the scar rating under that all important 460 number Bosch recommends for our engines. Wanna own your motor a long time with tree hugger fuel??? Get this stuff or something like it!
(http://i.imgur.com/1ytBYCa.jpg)
(http://i.imgur.com/6LP0UXN.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:14:16 AM
The next batch of parts has begun to trickle in. Today Mr. UPS delivered a very heavy box from Randy's Ring and pinion. THose helpful folks were able to source everything I will need to upgrade both the performance and mileage through the 4.45 ratio change, and give me the ultimate in traction through front and rear lockers.
Here's the Grizzly rear locker:
(http://i.imgur.com/G8UbJG6.jpg)
(http://i.imgur.com/P1Lgq5M.jpg)
This thing is massive! It looks like it came out of the final drive of an Abrams tank! It is honestly scales over what I am used to dealing with. Take a look at the flange that the ring gear mounts to! Examining the exterior, I notice 4 shafts that would normally mount the spider gears, but I'm not sure what's inside this well packaged beast. I am sort of wanting to tear into this thing to see what's inside! But curosity did, in fact, kill the cat, so maybe I'll just leave well enough alone. Frankly the longer it sits here, the harder it will be for me to resist!
Here's some more close up shots showing the construction and the sheer size of this thing!
(http://i.imgur.com/dA8ahBz.jpg)
(http://i.imgur.com/eVUntAp.jpg)
Time to add another page or two.
Today, the UPS man has been very busy!
We'll call the next number of postings, "Parts is Parts!"
I just received the last of the parts necessary for the 4.56 gear install. I am however still waiting for 36mm thin wall 12 point deep well and a standard length 36mm socket to arrive. Also due in is a SWAG Off Road set of press Arbor plates I need to press the bearings onto the differentials.
I am going to replace everything in both differentials with aftermarket parts changing the gear ratio and adding locking differentials to both ends. I will also be using all new bearings and seals. The factory axles, however will remain as they are super strong and I've already paid for them.
Here's today's collection of boxes:
(http://i.imgur.com/OXkRHaL.jpg)
(http://i.imgur.com/xJG6cAo.jpg)
Talking with Tate out in Everett, Wa. at Randy's Ring and Pinion's main activity, he suggested I read this book they put out which has a wealth of information. I plan to do so, as I will install the rear diff and gears myself.
(http://i.imgur.com/w8GYhnu.jpg)
I have already shown pictures of that massive grizzly rear locker, well here are the massive gears which will soon turn it all. I don't think you can get a true appreciation for how large this stuff really is until you see it first hand. Holding it in my hand you might better understand that if you knew how big I AM! THat's the hand of a guy who is 6'3" and goes 245 on a good day. The size of these gears telegraph just how much over built our trucks really are!
(http://i.imgur.com/xhpAdo9.jpg)
(http://i.imgur.com/GZCH7rO.jpg)
(http://i.imgur.com/CRtwCMi.jpg)

(http://i.imgur.com/YNCrKyP.jpg)
(http://i.imgur.com/q6P1eu7.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:14:27 AM
The install kit is pretty complete. I see everything in there except for the ring gear bolts which I will reuse from the stocker diff and ring gear. Just look at the size (diameter) of those carrier bearings. THat's a lot of torque accomodation you're looking at!

(http://i.imgur.com/kc7jU4N.jpg)
(http://i.imgur.com/8NN4iGw.jpg)
Next is the front ring and pinion gear set. At 9.25" they are as strong as the gears found in the rear diff of a Dodge 1/2 ton truck!
(http://i.imgur.com/DiN53HI.jpg)
(http://i.imgur.com/vwXnD4S.jpg)
(http://i.imgur.com/ifXQCMU.jpg)
Here's a couple more views
(http://i.imgur.com/cXPjUro.jpg)
Here's the master install kit for the front. Very complete as well!
(http://i.imgur.com/glQAzpw.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:14:36 AM
Here's the Eaton front electric locker. Unlike a conventional locker, this device is either fully unlocked in the stock like off or open position, or fully locked like a spool in the magnetized locked position. There is no differentiation what so ever, so traction will be maximized and the ability to turn will be neutralized! But if you're stuck, a simple push of the magic button will get you right out, or else you're going to need one of my buddies who fly Chinooks!
(http://i.imgur.com/HJHKPBB.jpg)
(http://i.imgur.com/FPOIhzC.jpg)
(http://i.imgur.com/IWTOoyg.jpg)
(http://i.imgur.com/73DJebH.jpg)
(http://i.imgur.com/rbpmYZx.jpg)
Showing the all important electro-magnetic appratus that will make me berry, berry happy when crawling out of a mud hole (as if I am ever going to get this thing dirty!)
Actually being a guy from the country, regretfully, I am not very smart and subject to drive over trees, through fences, over small foreign cars and into water where I can't see the bottom, yea, ask me about that one!
(http://i.imgur.com/bLgh90g.jpg)
(http://i.imgur.com/q3ptLIf.jpg)
(http://i.imgur.com/Z2pWT4Y.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:14:48 AM
While I'm anxiously awaiting the rest of the tools to come in that I need for the gear change, I thought I'd switch out the S&B air filter. THey make a nifty paper long life unit and a filter wrap, sort of a prefilter screen thing.
Here's a view of the current oiled cloth filter which has worked quite qell up to this point.

(http://i.imgur.com/MLwWydb.jpg)
Here is the paper filter I will be installing next
(http://i.imgur.com/zQ1XfcM.jpg)
(http://i.imgur.com/iWDygz0.jpg)
Here's a good side by side comparo
(http://i.imgur.com/YQPQAjJ.jpg)
(http://i.imgur.com/4uh4P0q.jpg)
...and with the filter wrap fitted
(http://i.imgur.com/79fi78t.jpg)
(http://i.imgur.com/TuwFrzX.jpg)
Here's the new filter installed
(http://i.imgur.com/SfkuQrd.jpg)
(http://i.imgur.com/jES3jWe.jpg)
And the "new" spare.
I figure I'll swap out this unit in a year or so or if it gets damaged or really dirty.
This S&B product is some seriously good stuff!
(http://i.imgur.com/pKVr8O6.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:14:56 AM
Quote:
"Originally Posted by *******
Just curious, why did you decide to go with the paper filter for your s&b?"

...trying out different products.
This one increases air flow something like 46% over stock, is replaceable (ie throw away) and no oil. Not that the oiled cloth S&B gave me any trouble, but in an earlier life in a galaxy far, far away, I had a K&N oiled cloth filter mess up a MAF sensor. THis eliminates all possibility of that happening.

......I just made a huge mistake.
I just checked out ProFabPerformance...
those headers and pipes are killer
I can see a large capital expenditure now in the not-too-distant future.
I was going to wait on the turbo for some time. but after seeing those manifolds and EGR delete and 2 1/4" up pipes... I'm gonna need those. No, not want, I NEED them!
Suddenly I feel like something is wrong with my manifolds, and I need to get them off before they damage something... Yea, that's it, the stockers are doing physical harm to the motor and causing the turbo to fail early, like as in later this summer. Man, I better get on the ball and get that stuff coming this way before something serious happens...What, doesn't sound believable??? She's blonde!


......Getting ready to do the rear ring and pinion install.
I needed some tools to get the job done correctly. I ordered some Press Arbor plates from Swag Off Road up there in the upper left corner somewhere, and some special sockets from Grainger.
Here's the press plates, you have to see this:
Check out the size of these things! I think the battleship New Jersey had to sacrifice the bow section to get enough steel to make these!
(http://i.imgur.com/dTqYVxS.jpg)
(http://i.imgur.com/X8ZS84v.jpg)
No, I mean. like really look. Remember I have big hands
These plates are 1.5" thick!
I plan to use them on my 30 ton press in lieu of the cheapo junk I used to have. That cast junk will be sold to recast into cheap Korean cars!
(http://i.imgur.com/vCVc6rn.jpg)
(http://i.imgur.com/R1TC47K.jpg)
The side bearings of the AAM 11.5 are adjustable just like the old 14 bolt and the Ford 9", however, comma, I guess the spanner wrench adjustable collars of yesteryear was too simple, so the engineers changed it. Now you have to thread a 36mm thin wall socket into the side and crank away. Yup, you guessed it, 36mm thin wall sockets are neither abundant nor inexpensive! I bit the bullet and purchased a deep well and a regular 12 point just in case.
(http://i.imgur.com/N74ruZo.jpg)
(http://i.imgur.com/Uxu4Clf.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:15:09 AM
OK, here we go again
This time I will be installing 4.56 gears and a Grizzly locker into the rear AAM11.5 axle.
My Friend Duane helped me today get the teardown, source parts, eat sandwiches and do a lot of nugg work. Since he is a Black Hawk pilot he is uniquely suited to manual labor!
We started with draining the fluid, then pulling the axles.

(http://i.imgur.com/RT6jfTA.jpg)
(http://i.imgur.com/E2ypaE9.jpg)
Next I pulled the driveshaft
(http://i.imgur.com/NEUT3lu.jpg)
And then the rear cover
(http://i.imgur.com/p7fcwAs.jpg)
So far so good. I marked one of the caps, made notes of their orientation, then loosened the collars on either side with a 1/4" punch.
Then we unbolted the cap bolts and wrestled the carrier out of there
(http://i.imgur.com/b8ip6EW.jpg)
The next step is not for the faint of heart. I unbolted the Pinion yoke nut which is a 36mm 12 pt mugo nut held on with kryptonite, loosening it until it was even with the end of the pinion gear, and using a 32oz hammer literally beat the thing out of the case to the inside. You will not believe how tightly the yoke is held to the pinion splines with some special adhesive which comes from the earth's core. All I can say, is you will not like doing this part...
(http://i.imgur.com/OUfnDfm.jpg)
We cleande the case out which was pretty clean to begin with and moved on to reassembly.
I thought the shims for the pinion depth fitted behind the pinion bearing race. THerefore I pressed the new bearing onto the pinion gear on my press using the new Swag arbor plates, which also came from the earth's core.
I hadn't learned the bad news yet, so all this was just really a rehersal for later!!!!!!!!!
(http://i.imgur.com/Dp3rlaP.jpg)
(http://i.imgur.com/LAcrqDl.jpg)
Next I pressed the bearings onto the grizzly locker differential. first one side, then the other.
(http://i.imgur.com/ZRXKsiH.jpg)
(http://i.imgur.com/kNONCSX.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:15:19 AM
Next after removing the 12 9/16" bolts from the factory ring gear. I cleaned them and threaded them into the new ring gear. It literally just popped into place. The bolts were torqued to 175 ft/lbs
(http://i.imgur.com/EAUHDnX.jpg)
Here's a look at the assembled differential assembly ready for service in my truck or a D-9 catapillar! THis thing is huge, heavy, strong and uber kool!!!!!
(http://i.imgur.com/aHgNeA2.jpg)
(http://i.imgur.com/FwyTGP1.jpg)
Then we removed the rear larger pinion gear race expecting to find the shims.
Well using a brass drift, it came right out but had no shims behind it??? What, no shims???
Quick call to Tate over at Randy's Ring and Pinion. Ah, did I check behind the factory pinion and look for shims??? Well, not exactly, but, hey let me take a look. Yup, there's a shim in there. Oh, I have to pull the new freshly pressed on bearing back off, OK, no worries...
Hey, Duane, I don't own a bearing puller like that. Hmmm, Harbor freight have one? Yep, after a call we found out they had an assortment. So I bought all of them, discovering the mugo uber large one on steroids barely fit. Did I mention everything on this truck is really big??
So I get some more practice on the press taking it all apart again!
Note to self: Pay attention and check to see what size shims came with the kit!
(http://i.imgur.com/JZgcvQN.jpg)
(http://i.imgur.com/gCR2mLF.jpg)
(http://i.imgur.com/BhlYhVN.jpg)
So, another call to Tate, #4 for the day I believe, (Thanks Tate) and I came up with game plan #2.
Take the old bearing off the old pinion and hone out the inside enough so that it just slips on and off the pinion, then I can do the various changes mo-quicklier.

(http://i.imgur.com/Kb3FzSp.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:15:29 AM
If I'm reading the material correctly you set up a diff in steps. First you set the pinion depth looking for the correct gear pattern. Next you set pinion preload. Next you set carrier backlash, then check it all and torque it again and cover and fill. I hope I didn't miss anything, but that's basically it
To set up pinion depth, the book says to simply put the factory shim onto your new pinion and run a pattern. Tate suggested I start with a .035 shim since the smaller 4.56 gear needs to seat deeper into the gear than the old 3.73, larger gear.
I pulled out a .050 shim from the factory pinion. so I decided to add .015 to that and start with a total of .065 shim to run my first pattern.
(http://i.imgur.com/tXFVklA.jpg)
Here's one more look at the diff. Next time you see it it should be sitting neatly in the housing lookin spiffy
That's all for gear change day 1, time for some pizza ops...
(http://i.imgur.com/e8r29NI.jpg)
Today was a long one.
I wanted to get this thing done but I kept having problems with getting a good pattern on the gears. Here's what I started with this morning. You can see the drive part of the tooth is well to the inside which isn't bad, but there is only a line indicating only the edge of the gear is actually touching. Same thing on the coast side except it is at least centered. This, BTW is garbage for a pattern. I was using the factory .050 shim
(http://i.imgur.com/ZRlAWNi.jpg)
(http://i.imgur.com/ZGd8Tx7.jpg)
A quick call to Tate over at Randy's Ring and Pinion and after emailing him these pics, he noted the gear is too deep and I need to back off the shims some. So I pulled the pinion bearing and reduced the shim pack to .035"

Hmmm, same strange mark, and another bout of garbage!
(http://i.imgur.com/ZDFJCDt.jpg)
(http://i.imgur.com/g3FKvmO.jpg)
The diff was not spinning as freely as I wanted it to and the gears were making a clacking noise.
Also the bearing pressing got to be a real problem so I pulled the old bearings and relieved their inside diameter so they could be installed by hand instead of using my press
(http://i.imgur.com/TILxDmq.jpg)
Everything else was working fine. Back Lash was easy to set at the recommended .005-.007"
(http://i.imgur.com/pp8FNR5.jpg)
Another call to Tate, and this time he suggested I pull out all the shims and try it there. Here's what I got:

This still isn't good!
(http://i.imgur.com/GDcsGwq.jpg)
(http://i.imgur.com/6Eo13qS.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:15:38 AM
At this point I had repeated this assembly/dissembly exercise many times and it was getting late. That's when something cool happened.
Tate had gone home and I thought I was out of tech support. Out of the blue, Dale Coulson, a Randy's tech guy calls me. He says something is wrong and do not install the gears as is. He suggested I measure everything so I did. I pulled everything apart and miked everything. We compared my findings with the engineering spec, and sure enough everything was up to snuff, all the new parts checked out.
Dale then suggested the pinion bearing race might not be seated all the way.
Hmmm, I did punch that thing out, then decided to reuse the old bearing for setup and checking, so I hac reinstalled the race. THe thing is, I had just punched it back out in preparation to install the new race. So I installed the new race, and I noticed it sank much deeper into the housing!
Bingo!
THat was it all along! Good news was I knew what the problem was. THe bad news was that I was back to square 1!!!
Hey, I'm not going to let this thing beat me down, so I started all over again, this time with a .020 shim and pulled a pattern. Here's what I saw:
(http://i.imgur.com/cD12y90.jpg)
(http://i.imgur.com/YHE83gk.jpg)
OK, now I was getting somewhere. THat is a normal pattern for a gear too far away from the ring gear. Definate movement in the right direction, but requiring more adjustment.
I tore the thing down again and added shims uo to .030
Here's what that did:
(http://i.imgur.com/q8f4rbv.jpg)
(http://i.imgur.com/u9ZRSoT.jpg)
Definately moving in the right direction (finally)
THis pattern in my opinion is still not deep enough so since I had added .010" last time and got that much movement, I decided to all another .010, totalling .055" which is actually just .005" more than the factory had in there to begin with.
Here's the result which I think is OK. I am awaiting Dale and Tate's opinion which will have to be tomorrow morning since everyone is done working except for me!
If this is it, then in a couple hours tomorrow, I will finish this and claim victory over self installed gears and the locker!
(http://i.imgur.com/JoYCKb7.jpg)
(http://i.imgur.com/l6EfmLk.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:15:47 AM
Today, I finished the 4.56 gear install inthe rear axle!
After some emails to Tate and Dale, everyone was happy with the pattern so it was finally time to assemble it for the last time.
I started by removing the diff and the pinion gear for one final time. THen I cleaned the housing and painted the surfaces around the area I had been working in with John Deere black, a high quality enamel paint.
I paid particuliar attention to the parts shielded by the seal and diff cover in the back. I want to prevent rust from starting and causing a mess in the future

(http://i.imgur.com/wywB5d8.jpg)
I then installed a new front seal, scrapped the housing clean of the old paper gasket, and thourghly cleaned the inside one more time.
(http://i.imgur.com/BfYqz2o.jpg)
I checked the shim pack one more time, then pressed on the new bearing and slid the crush sleeve into place on the pinion all prior to installing it in the housing for the last time
(http://i.imgur.com/o5vLa9L.jpg)
(http://i.imgur.com/vEbia5X.jpg)
Take a look at the swipe pattern on the pinion gear teeth. That looks really pretty. A good long contact over much of the tooth...strong!
(http://i.imgur.com/1fVzv5c.jpg)
With the pinion in, I installed the yoke and tightened forever until I achieved the proper preload. I must self confess here that the first time I did it, I forgot the washer beneath that huge 36mm nut and the darned thing wouldn't tighten properly and still yield the proper preload. But, I discovered my error, removed the nut, added the washer then tightened the thing up to a near perfect preload
I also painted that rusty harmonic balancer/yoke thing while it was off.
(http://i.imgur.com/R1pX1qw.jpg)
Then the driveshaft
(http://i.imgur.com/Btx3Nzr.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:15:53 AM
I actually got things out of order here, before the driveshaft, I installed and set back lash on the carrier, the grizzly locker at .006"
(http://i.imgur.com/msKyuqh.jpg)
Next, I slid the axles home and bolted them back on. Finally, there was only the rear cover which I set in place over a bead of RTV Black and tightened the bolts. I filled it with 4 qts. of Valvoline 75W-90 synthetic
(http://i.imgur.com/UhEXeUX.jpg)
Both Dale and Tate were adamant about going through a proper break-in procedure, so my initial test drive was over to a nearby grocery store for some shopping.
The abundance of torque was immediately obvious. I was just babying it as per the instructions, but the power is definately there. The gears aren't making any noise and the locker is really smooth. I have driven a detroit locker, a lock rite and that other mini locker before. With those you had to be on your toes. If you mashed the throttle in a turn, Mr. Locker siad, "screw it, we're going straight!" Not this Grizzly. I couldn't even tell when it was locking or releasing except for the slightest of a "tug" when I'd let off it or step back on the acclerator. Could that be gear back lash instead??
If it remains this smooth, coupled with it's gorillia strength and no compromise traction, this diff will prove to be the go to traction device. It must be as close to indestructable as a differential can be! So far, 2 whole drives, 15 miles total, I LOVE it!

......Good news and bad news, although not that bad
First, I have been doing short trips to warm up the diff, then allowing the truck to cool off completely as a part of the break in process. I just started driving it again on the highway for any distance at all. I was curious about the combined mileage for the little bit of town and country combined with the highway mileage, so I zeroed out the mileage setting and started anew. Right before I did the gear change, the larger tires had pulled the 18.9, stock tire mileage down to the low 16's.
Driving this morning all over heck's half acre, arriving in the driveway afterward, the mileage computer showed just under 21 MPG!!!!!!
Now remember actual mileage with the stock gear and tire was 18.9 combined. The large tire which made the speedo run slower pulled it down to around 16. Given the little bit it was running underspeed, I estimate low 16's consistiently for the lugging engine with the big tire and 3.73.
With the 4.56, I am now cruising with traffic at 1900-2000 RPM and this engine with it's current tune obviously loves it. If the speedo is running 10% over then that means the truck is getting 18.72 MPG with a 4.56 gear and a tall tire! Don't know about you, but me thinks that is pretty darn good. Now imagine how it will be with a couple ten thousand miles on it and all broken in and sporting H20 injection! I may be knocking on the door of the low 20's. It's certainly within the relm of being possible.
After that, the bad news, a seeping pinion seal which I plan to replace tomorrow is small potatoes indeed!
(http://i.imgur.com/v07uV5I.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:16:02 AM
Today was a "Chores" day on the truck. There was starting to be a few things that needed to get tweaked or finished, so I took the day to work off the list.
First, I was not satisified with the total number of hangars on the MBRP exhaust. I felt like I could really use one more near the outlet of the muffler. Really, MBRP supplies enough to get the job done, but if you really slammed it around it will move some and that is putting stress on the joint and the down pipe, two things I don't want any problem out of.
So, I fashioned up a new mount using another stock rubber isolator. If I just welded a hangar to the exhaust it would start to become problematic getting the exhaust off at some future date. So I made an adjustable mount that cinches down tightly then releases again with the turn of either of two 3/8" bolts. Here's what I started with:
(http://i.imgur.com/L3PTTsS.jpg)
An upper hangar and a lower mount slip into the 1/2" square tubing and are held in place by 3/8" "pinch" bolts
(http://i.imgur.com/tGPVHOR.jpg)
Here's the other mount welded to the muffler outlet and coated with zinc
(http://i.imgur.com/r6tqOQs.jpg)
...and the whole mount assembled and installed
(http://i.imgur.com/VQYkYGm.jpg)
(http://i.imgur.com/1bsvWZ3.jpg)
While I was under there and toying with the exhaust, I removed the rust-o-matic hangar, wirebrushed it, coated it with zinc then painted and reinstalled it. I also sprayed all the other welds on the MBRB exhaust which had started to show scale rust. Welders zinc is a great self-sacrificing product that will keep you runt free.

(http://i.imgur.com/0XjMKZo.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:16:16 AM
Exhaust all done and more snug than ever before it was on to the fuel system. When I installed the Air Dog and sump, I did not reinstall the fuel tank skid plate.
II cut a relief in the bottom of the skid plate, missing slightly on the first attempt, but nailing it on the second.
(http://i.imgur.com/SgXwFFV.jpg)
The cover went right on with a minimum of effort and bolted right back up. I relief cut the base below the fuel line so that it would still provide protection, however bend just enough to accomodate the fitting.
(http://i.imgur.com/nuYhB0b.jpg)
(http://i.imgur.com/Fx7HGz4.jpg)
Next, I reinstalled the transfer case skid plate. I never liked the way it stuck downward at a slight angle, so I bent it up and closer to the case to get that all important ground clearance
(http://i.imgur.com/cutbEde.jpg)
Here, I show how neatly the fuel supply line tucked into the skip plate install
(http://i.imgur.com/D5btz7S.jpg)
The last thing on the schedule to get done today was to install the correct Air Dog fuel return adapter. Up to now I had used my homemade fabbed part which worked flawlessly (as far as I know). THe change was a simple 10 minute job. THe AD lines are easy to disconnect by pushing in on the tabs and pulling apart...nice!

(http://i.imgur.com/0k7d9zf.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:16:27 AM
OK, lets get going again. Today was day 1 of the front Eaton E-locker and Yukon 4.56 gear install.
The first thing I had to do was to install the wiring harness, switch and relay.
After searching and pulling the panels off the interior I finally decided the only real area remaining that is not close clearance, hard to get to, or choked with wire was in the overhead console
(http://i.imgur.com/qKb9SjZ.jpg)
(http://i.imgur.com/Hr7wGUD.jpg)
The top stuff had to be partially removed as well as the pillar to make room to pull wires
(http://i.imgur.com/HoXdZgY.jpg)
(http://i.imgur.com/6N1xCmh.jpg)
Here's the lighted switch that controls the locker
(http://i.imgur.com/7b7Nei8.jpg)
The overhead console actually is set up for additional switches as evidenced by the casting. The area inside those protrusions are exactly the right size for this switch.
I drilled a series of holes and cut out the opening
(http://i.imgur.com/f6vYWFy.jpg)
(http://i.imgur.com/AsnpfZb.jpg)
With the hole opened up just large enough, I pulled the wires and drilled a hole in a support panel on the roof to screw the ground wire into.
(http://i.imgur.com/6Uq0B9u.jpg)
(http://i.imgur.com/ScR8gDL.jpg)
Here's the panel reinstalled and hooked up
(http://i.imgur.com/sCNZGHX.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:16:35 AM
After sorting out the wires and making the required connections, I ran the two diff control wires through the firewall and routed the harness to where it will soon connect to the electric diff
(http://i.imgur.com/x2giwrp.jpg)
(http://i.imgur.com/QSx4lsI.jpg)
(http://i.imgur.com/ClzuQEk.jpg)
...All done with the switch and harness install...
(http://i.imgur.com/DSFaNad.jpg)
(http://i.imgur.com/o4w4ldW.jpg)
(http://i.imgur.com/OYK18M2.jpg)
Loaded up with goodies and ready to visit Mr. Chevrolet to make the boxes disappear!
(http://i.imgur.com/H6hDfPR.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:16:47 AM
As per Randy's RIng and Pinion's recommendations, the break-in process requires a fluid change at 500 miles. That will come up in the next few days or so.
I thought I'd make an improvement with the rear diff cover. I had several choices here. I could go with a chrome thing but that would be, frankly hideous! And it would make no useful contribution to the vehicle's prowess. (big word there for an Army Pilot!)
A common change people go for is to the aluminum finned covers that provide additional cooling and increased capacity. You do not, however, see those kinds of covers on true off road vehicles, and there's a real and practical reason for that...they break!
So, considering the purpose for my truck which is a driver, occasional off roader, but with a strong over tones of wanting to be a "doomsday, survivalist" vehicle I went with a cover that can take a lickin' and keep on tickin'
I called Shawn, the owner of Great Lakes Off road inc. and talked to him about his excellent covers. THey are by test, actually bullet proof, no really!
He has an AAM 11.5 cover which is all that and more. It's so strong that he warrantes it for it's life!
He starts with a laser cut 1/2" thick gasket ring and forms and welds a 1/4" plate steel cover to it. It is super trick and it retails for an amazing $110!
Yea, that's $110, not $279 or whatever those pretty covers go for. Not that they are bad, no sir, for towing they are great, but write my requirements into the vehicle mission statement, and they immediately become ash trays!
Shawn welds a 3/8" NPT allen head fill plug into the side of the cover somewhere, and calls it done. I think it's a fine piece and I'm looking forward to painting that sucker up and bolting it to it's new home!

(http://i.imgur.com/5ALeJlU.jpg)
That thing's mongoloid! It was actually a part of a transformer (movie creature thing), the one that was a MH-53J I think!
He also makes one for the AAM 9.25 we have in the front of our trucks, and I'll be installing one of those as well.
The cover allows for 2 extra pints of fluid which is helpful, but also allows for a slight overfill through fill plug positioning if you desire to do so. Dunno on that fine point yet, but I'm betting I'll figure it out!
This pic shows the fill plug a little better
(http://i.imgur.com/LjMAXXM.jpg)
OK...ater a good night's sleep...
Only bad thing is the killer sheperd jumped all over me this morning early AM just to get me up to get his ball which was trapped under the dresser...
Da#$!! dog!
I was talking to Road Armor, I'll leave the gentlemans name out for now. Anyhow the guy who actualy designed that excellent bumper which we use. THe subject was rear bumpers. I was discussing picking up a rear bumper directly from him, but wanted to know if he had something innovative. We talked about this thread and the exposure it has and so forth.
It turns out that they (RA) have a totally new bumper design coming out for the 2500 HD GM. There were some design issues with the earlier bumper that caused them (RA) to have to tweak the models for the various years as GM subtly made changes to their design.
They will come out with a bumper that fits into the bumper recess, retains the towing framework, and mounts a winch! Unlike some other model vehicles it seems we get our cake and get to eat it too!
After some conversation the gentleman decided to allow me to announce the new unit here in this thread, then when they get one built, to bolt the prototype onto my truck where I can show the install for folks to view.
How cool is that?
Anyway, here are the first of the renditions of the new creation. I will show the current model above and the new creation below.
I am asking for some feedback that I may pass on to the RA folks. good/not good, like, don't like, suggestions. This is the time to get it out there and directly interact and influence the new design!!!!!!!!!

(http://i.imgur.com/TMTWAor.jpg)
(http://i.imgur.com/G5us6KI.jpg)
(http://i.imgur.com/YaXWAed.jpg)
The new design will fit better and have recess for the back up sensors which will mount them at the correct angle. Those sensors, I hear are very expensive, something like hundreds, so this design protects their integrity while hardening the back side of our trucks!
(http://i.imgur.com/V5r9TQN.jpg)
Another view.
(http://i.imgur.com/5F2RjYF.jpg)

I think the license plate mounts where the winch goes. I know, I know, but I didn't see anywhere else to fit it in the design. Please keep in mind these are prototype renderings and may not represent the final design, just where they are at the moment.
With regard to the license plate, I was thinking of doing something like I did on my Tundra. With this bumper, I plan to run a rear winch as well as my front. It is always easier to back out of the mess you got in to rather than try to pull up and over against the obstacle that stopped you in the first place. Obviously that does not apply to winching yourself up a hill, but sure does for just about everything else.
Here's a pic of how I mounted the plate on my other truck:
(http://i.imgur.com/owYEFm1.jpg)
I also asked them what will be the bumper capacity, i.e. how much winch can we put in there.
I suggested they look at something really big like this Recon 17.5K model, which I would definately mount up it the bumper can handle it:
(http://i.imgur.com/xn4mlwj.jpg)
Let me explain why I want such a large winch.
I have said in the past that all you really need is a 9K with a pulley. THat gives you 18K worth of pull for a lighter weight unit.

The rear winch can obviously be used to recover your vehicle, however I see a rear winch as a unit dedicated partially to recovering someone else. Perhaps a heavy vehicle downhill. In a position where you need your full length of line. For that, the rear winch is perfect, delivering a full 17.5K pull on 90 feet of line. it could also possibly allow you to position your vehicle in such a way that the heavy, engine, end is positioned over a rise which would serve as a great anchor for pulling such a large weight.

......Got some answers from Road Armor
Does the bumper work with a spare: Yes, it will work with a spare in the stock location up to a 33" tire
Does a winch mounted on the bumper interfere with a spare: No, as long as the spare is 33" or smaller and the winch is not too big in physical size.
Can the bumper mount a 17.5K unit like the recon model I have shown: The winch will fit as long as the winch control box is relocated. He (the engineer) designs around a warn M12000 winch for physical sizing and fitment.
So what other concerns do you have or have questions about with this new bumper that you would like to get answered?
Here's another winch that is cost effective like as in less than $500 and has a healthy line speed.
(http://i.imgur.com/bMoYyLe.jpg)
Here's some more views of that bumper showing a warn M12000 winch. You can see it is right there next to the spare. Another issue to resolve is that it interferes with the spare tire winch access mechanism, so that has to be sorted out
I believe the engineer said the winch clutch lever would have to be clocked slightly to gain clearance from the tow hitch but if you have never done that, it is not hard. I have to do it every time I mount a winch.
(http://i.imgur.com/RWOSLtZ.jpg)
(http://i.imgur.com/aKUfuY7.jpg)
And a better rear aspect pic
(http://i.imgur.com/AXRE9rA.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:16:56 AM
Here it is coming apart and out:
(http://i.imgur.com/H8s9R33.jpg)
(http://i.imgur.com/kBoE3ZO.jpg)
(http://i.imgur.com/Xp0xyki.jpg)
Here's the axle assembly coming out. Tommy (left) and Brad manhandled that serious chunk of metal as best they could whild I snapped away. Piles Chevrolet has a great and caring staff who really "get it" when it comes to knowing guys like us. They are meticulous and Tommy who did the bulk of the work really took his time. I saw him constantly referencing the computerized manual. I didn't once see anyone rushing about, but I often saw them stop to think about how to do something.
Comment here: These Mechanics only get paid book labor time. If for example the book allows 3.6 hours for a ring and pinion change that's what these gentlemen get paid. That would suggest that they would need to work quickly to earn their paycheck. Tommy took all day! He labored 8 hours on this project perfereing to get it done right, in favor of making money. What do you say to that? That really shows character...like I have said before these guys are good, and that attitude runs all over this dealership, so, yes, I am shamlessly giving them a plug!
But more than that. we the people need to patronize places like this dealership who try their best to deliver even if it costs them personally!
(http://i.imgur.com/qOKiGBp.jpg)
(http://i.imgur.com/K2KbzpV.jpg)
(http://i.imgur.com/1GuIJae.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:17:06 AM
Axle is out!
(http://i.imgur.com/JkZQtE7.jpg)
...The cavity left behind.
You don't often see this view
Still all shiney new looking!
(http://i.imgur.com/qt9rJ9x.jpg)
(http://i.imgur.com/ONwEGGt.jpg)
Diff cover coming off
(http://i.imgur.com/1t3s5g4.jpg)
(http://i.imgur.com/7ldFffN.jpg)
Fluid drained
Diff cover removed
Right axle extension assembly unbolted...
(http://i.imgur.com/ueC6Ndk.jpg)
(http://i.imgur.com/zXORl5u.jpg)
Diff cover has a great rubber "O" ring style gasket which we reused later. THe short shaft came out next. It is simply tapped out and set aside
(http://i.imgur.com/ZzxYZPX.jpg)
(http://i.imgur.com/ygUkAdo.jpg)
(http://i.imgur.com/lhXbk3Q.jpg)
(http://i.imgur.com/L3pNt88.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:17:16 AM
Talking about gaskets and sealer, this stuff is the best there is for sealing up things. GM form-a-gasket compound. I elected not to use it and go with the factory gasket, but when Shawn sends me that excellent diff cover he's creating, I will use this stuff to seal it all up.
(http://i.imgur.com/6a6SVB7.jpg)
Here's a shot of the diff just before the side adjusters were removed.
I opened the install kit Randy's RIng and Pinion sent me to start fishing out some of the things Tommy would be using soon...
(http://i.imgur.com/JutawH1.jpg)
(http://i.imgur.com/My3EI6Z.jpg)
Make sure you have a 57mm 12 point socket at this point or you will have to stop work. That's one enormous bolt which is secured in place by a retainer which is pressed into the case into hundreds of mini splines. THe bolts screwed into the three holes "press" the retainer out, which allows one to remove mugo-nut!
(http://i.imgur.com/p9Z05bO.jpg)
(http://i.imgur.com/M95TxGP.jpg)
(http://i.imgur.com/dgcjrmc.jpg)
The 57mm nut has a flange onto which the side carrier bearings are pressed. I have never seen such an arangement. THere is nothing else holding the diff in the case except gravity and good will! THis little fact will soon come home to roost and cause a bit of a problem...
(http://i.imgur.com/8mOjuRO.jpg)
(http://i.imgur.com/cCdg9g1.jpg)
(http://i.imgur.com/P2I4pXB.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:17:25 AM
Here the mechanics are removing the other bearing which is all that is holding in the diff at this point

(http://i.imgur.com/hhYAsPd.jpg)
(http://i.imgur.com/4dAy2oG.jpg)
With that bearing out the diff rolls right out!
(http://i.imgur.com/B9bCZR0.jpg)
Tommy thourghly cleaned, deburred and prepared the new ring gear for installation onto the new Eaton E-Locker
I started unboxing the Eaton unit
The thinner ring gear is the 3.73, thicker one if the 4.56
(http://i.imgur.com/XTZMXEN.jpg)
(http://i.imgur.com/pvACkpl.jpg)
(http://i.imgur.com/MQIrl9N.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:17:40 AM
Those who are observant will notice the new ring gear is reinstalled onto the factory open differential.
You see as I rounded the corner with Mr. Eaton in hand, Tommy immediately gave me the "Rut-Row" look. You see, the Eaton unit I had which fits Chevy and Dodge 9.25 axles, does not actually fit the new much stronger and improved design which we had just taken all apart!
I have to fault myself here. I believe I may have miscommunicated with the folks at Randy's when placing the order for all this stuff. I think I was saying split case or something like that. You see, there used to be a split case front diff arrangement, apparently, but that is not what we have in our trucks today. We have a setup very similar to the rear or a 9" ford, sort of, but without caps. So there was no way the Eaton was going to fit. Apparently the gears still do but, that's about it.
A quick call to Tate at Randys confirmed my fears. He said nothing else was available either such as a limited slip, so I was left with no where to go except to reinstall the factory diff, which we started right away.
.........No use in crying over spilt milk, so with that little wrinkle out of the way, we continued with the install
Tommy torqued the ring gear onto the diff
(http://i.imgur.com/9PTJIrB.jpg)
The factory pinion gear is removed leaving an empty case.
The larger gear is the old 3.73
(http://i.imgur.com/YwUTKWb.jpg)
The empty, soon to be stuffed case
(http://i.imgur.com/ZLVyMkm.jpg)
(http://i.imgur.com/DGhURqW.jpg)
There was a shim behind the bearing which was transfered to the new pinion, and the bearing was pressed back on.
(http://i.imgur.com/1CqDGzj.jpg)
(http://i.imgur.com/KliV3dg.jpg)
Here's some closeups of the factory diff showing the strange bearing arrangement and some shots of the side adjuster recess in the case
(http://i.imgur.com/tUcYfEi.jpg)
(http://i.imgur.com/LuqXe76.jpg)
(http://i.imgur.com/ijUI7mZ.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:17:48 AM
The new pinion bearing race is installed into the case
(http://i.imgur.com/2ZclnBj.jpg)
(http://i.imgur.com/QD710mR.jpg)
The new pinion was installed along with the bearing and the new seal, then the diff was rolled back into the case, and the side adjusters put back into place
(http://i.imgur.com/v8db3t1.jpg)
(http://i.imgur.com/HBunpWE.jpg)
(http://i.imgur.com/xXR3m8n.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:17:56 AM
The tell-tale yellow marking compound was painted onto a couple teeth and we rotated to get a pattern...What do you think???
Can you believe this guys luck, or skill?
Does that look good or what?
(http://i.imgur.com/bGvsuSY.jpg)
(http://i.imgur.com/dZUqPwM.jpg)
(http://i.imgur.com/reY38Rf.jpg)
Not totally convienced, Tommy elected to tear it down again to take a better look. He removed the diff and the pinion gear then sat for quite a long time evaluating the pattern. Several other mechanics came over to consult and everyone agreed that it was pretty close, perhaps a tiny bit too deep. Finally, Tommy elected to reassemble it all again torqued to proper spec, crush sleeve in place and check it again
Here's what we got:

(http://i.imgur.com/2ZXsNod.jpg)
(http://i.imgur.com/HNgE2oo.jpg)
(http://i.imgur.com/xMooUsV.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:18:25 AM
That is satisfactory and on the inside of the ring gear which is a pretty strong position, so he decided to let it stand!!!!!!!!!!!!
OK, time to button this puppy up and reinstall it
Here is the reassembly
(http://i.imgur.com/20cytqe.jpg)
(http://i.imgur.com/kWMVPFw.jpg)
(http://i.imgur.com/RtN5slP.jpg)
Getting closer
(http://i.imgur.com/Rs2lICd.jpg)
(http://i.imgur.com/OAG6Zpz.jpg)
(http://i.imgur.com/VaXceaQ.jpg)
(http://i.imgur.com/16Tn4tT.jpg)
Next came the GM synthetic fluid, just shy of 2 quarts pretty please!
(http://i.imgur.com/uryAL5Z.jpg)
(http://i.imgur.com/Wfi0bk4.jpg)
Ready to come off the rack!
(http://i.imgur.com/TSDOCgs.jpg)
The final step was the test drive. I can promise you none of that was done on any pavement what so ever. We drove down the hill onto a gravel area and checked it out in 2WD, 4WD High, and 4WD Low, then back to 2WD. It performed flawlessly!
I'm telling you with that grizzly rear locker this truck is not playing around. THe traction and the power is really there. There was no hint of traction or power shortages, and no unusual sounds. THis was a terrific end to a good day. My compliments to Steve, Tommy, Brad, and the rest of the staff of the Piles Chevrolet service department who made this all come together and in such a positive way. THey are friendly, professional, are easy to work with and a pleasure to be around.

On the drive home mileage increased to 73MPG!!!!!!!!
OK, not really, still sitting at 19.3 with a 13% speedo error, so 17ish real world.
This is a super duper mod and I highly recommend it to all!

So I ended up going to church smelling like the liquid in those GM botles, I wonder if anyone noticed???
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:18:36 AM
I currently have a bunch of balls up in the air in the build/juggling act I find myself positioned at right now.

1. I will soon get the rear cover from Great Lakes Off Road (GLO), and swap that bad boy onto the truck with a fresh fluid change

2. Shawn (GLO), and I have a cool part and kit coming together for our trucks which will appear right afterward and kick off another round of mods to improve off road-a-bility. I think you all will want one of those kits once we get it all figured out...cool stuff

3. Rock rail/step thing is in it's early stages

4. The rear Road Armor bumper is in que, looking at sometime in June

and no. 5
which is
the 1st oil change

I didn't want to do just an oil change, I wanted to step it up some so, here's some foreshadowing of things to come in the next couple/few days:

(http://i.imgur.com/2h7dKHk.jpg)
Inside those boxes:
(http://i.imgur.com/kqFZLuF.jpg)
(http://i.imgur.com/SgcbT4c.jpg)
I'm going to do some other cool stuff as well to include a custom mount and a oil sampling valve/drain valve in lieu of the standard drain plug.
Should be a nice day long project taking things slow at first, then tapering off from there!

OK boys and girls
Ready for another one?
Today we are installing the Amsoil dual bypass filter system
Here's what you get in the box:
(http://i.imgur.com/VGRyzSl.jpg)
(http://i.imgur.com/3NJWCXx.jpg)
I will also be installing a fumoto drain valve in the oil pan
(http://i.imgur.com/WiYkNdx.jpg)
Here's a better pic of what's in the box
(http://i.imgur.com/UZP2Zad.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:18:45 AM
The filter base is one high quality chunk of aluminum. In fact everything is top of the line stuff!
(http://i.imgur.com/Hucrx6t.jpg)
(http://i.imgur.com/m6TGZIA.jpg)
(http://i.imgur.com/c5FbMp4.jpg)
(http://i.imgur.com/5FRqABb.jpg)
First the old oil gets drained and the factory filter is removed
(http://i.imgur.com/nT1XsoO.jpg)
(http://i.imgur.com/tNQ7ZE3.jpg)
Here's the Fumoto drain valve that will be replacing the drain plug of old
(http://i.imgur.com/lJpurx5.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:18:53 AM
Here is the block adapter showing its component parts

(http://i.imgur.com/MIN6vmn.jpg)
(http://i.imgur.com/NX77b9c.jpg)
Here's a closeup of the line, fittings, and the instructions showing just how all this makes sense.
Really, it is a straight forward install, easily done!
(http://i.imgur.com/YHaoRGY.jpg)
(http://i.imgur.com/Cpoifpb.jpg)
I wanted to plug up that big leaky hole somewhat so I started reassembly with the installation of the block adapter along with the 90 degree fitting that is the pressure out (dirty oil)

(http://i.imgur.com/TIHMUv6.jpg)
(http://i.imgur.com/JshipHq.jpg)
I preassembled the filter block somewhat to try to figure out where it should be placed
(http://i.imgur.com/TL7qB1C.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:19:02 AM
The spot I selected to mount the filter unit was festooned with wiring bundles. I pryed the loom off the frame, then drilled a 1/4" hole overhead in a stiffner and reinstalled it overhead out of the way

(http://i.imgur.com/yQgDpK2.jpg)
(http://i.imgur.com/Sq20Xae.jpg)
(http://i.imgur.com/KYBJ7Gm.jpg)
This is that spot on the frame along side of the torsion bar all cleaned off and ready to fit some custom adapter I have yet to figure out!
(http://i.imgur.com/zMu80et.jpg)
At this point, the oil finally stopped dribbling out so I installed the Fumoto drain valve
(http://i.imgur.com/m4w08nV.jpg)
(http://i.imgur.com/gh3uZcS.jpg)
When I drain the oil, I want it to be mess free and I want to be capable to drain into a milk carton, so I installed a length of clear plastic tube. To secure it from dangling in the slipstream, I talled an existing hole in the bottom of the Allison with a 5/16" tap and bolted a #8 Adel clamp that holds the clamped off line, all done with that!

(http://i.imgur.com/x6d9psb.jpg)
(http://i.imgur.com/kHlDWno.jpg)
(http://i.imgur.com/vh2FosB.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:21:29 AM
Next I started attaching brackets to the fliter unit to try to figure out how to fit it to the truck
I noticed right away that one of the bolts was too close to the filter, so I ground it back some. At this point I hadn't realized I had the filter unit turned around backwards
(http://i.imgur.com/W1Q92VV.jpg)
(http://i.imgur.com/eLM5Zho.jpg)
(http://i.imgur.com/acP53Rf.jpg)
Now the line fittings go in as well as the plugs for the opposite side
(http://i.imgur.com/sv42YXS.jpg)
(http://i.imgur.com/wUE0AyE.jpg)
(http://i.imgur.com/ylzLQvO.jpg)
Next, I added a sampling drain valve for those future oil samples
(http://i.imgur.com/trD7loE.jpg)
(http://i.imgur.com/qUhT66g.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:21:44 AM
The adapter to enable me to mount the filter head to the frame was as simple as taking a short section of box steel tubing. I used an existing hole in the frame and drilled another 1/2" hole forward of that. I used two frame bolts I had removed earlier, 7/16" diameter super strong and coated. I then tack welded their nuts inside of the box section

(http://i.imgur.com/FRBm9zl.jpg)
(http://i.imgur.com/OUTXm4g.jpg)
(http://i.imgur.com/QI48IXv.jpg)
The mount turned out to be simple, sturdy and plenty strong enough
The filter unit bolts to it with 4ea 1/4" bolts
(http://i.imgur.com/AbMvACU.jpg)
(http://i.imgur.com/DNQ4Pgs.jpg)
(http://i.imgur.com/J19NR6x.jpg)
After painting the mount, I permanently installed the filter mount assembly onto the frame
(http://i.imgur.com/X7OEYcC.jpg)
(http://i.imgur.com/Qth9aOD.jpg)
Next I started assembling the new oil lines. I think this is #10 hose which has a 1/2" ID and flows a lot of stuff
(http://i.imgur.com/QvCbsow.jpg)
(http://i.imgur.com/kxrPXvd.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:22:03 AM
1st line is installed
(http://i.imgur.com/r5hrAMx.jpg)
(http://i.imgur.com/NLqQpBn.jpg)
...and the second line is installed
(http://i.imgur.com/nsl41we.jpg)
(http://i.imgur.com/0jv17cU.jpg)
(http://i.imgur.com/jEzLulE.jpg)
I filled the filters with the fresh Amsoil
(http://i.imgur.com/s2zhHPE.jpg)
...and installed both filters onto their mounts. Even the lables came out in the right place. This project just went well from start to finish!
(http://i.imgur.com/D96NYPW.jpg)
(http://i.imgur.com/w3bTeUr.jpg)
(http://i.imgur.com/XgLUFW3.jpg)
(http://i.imgur.com/dbMV9pt.jpg)
I topped the engine off with the remainder of the three gallons of oli I had, and started it up.
I had pressure almost right away, and not a single leak!
Now that's how to cross the finish line!
(http://i.imgur.com/uq2lBCy.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:22:12 AM
Jumping around here a bit,
Although we are still on the oil discussion for the moment, I just got an eamil from Road Armor.
The engineer designing the new Chevy HD bumper responded to the requests you made earlier.
He says it is very difficult to get another two light ports in there. Not impossible, but difficult. Same-same with the license plate relocate. Complicating factors have to be structure both seen and behind as well as the back up sensor cutouts that are inclusive in the new design.
He sent me this side view pic to share:
(http://i.imgur.com/MPGzcCj.jpg)
Here's a good pic of a Taco that took a rear impact from a 3/4 ton service van. THe aft road armor bumper was apparently still useable, whereas the van was not
Conversation continues about license placement, but no news at the moment. THe issue is to keep it trim and not overly bulky so plate placement turns out to be something that is difficult to design around. the other pic shows the overall bulk and size of the current design that could reach production.
(http://i.imgur.com/xEGTC5O.jpg)
(http://i.imgur.com/SRZQu87.jpg)
I know down the road I am going to want to install a Dana 60 up front. That will get the front end close to indestructable, however I'll have to say bye-bye to my nice ride.
I need to do something to prevent that from happening.
Maybe if I sink a chunk of change into the front, I won't be tempted to mess with it
Something like these:
(http://i.imgur.com/iikz8gp.jpg)
(http://i.imgur.com/GVh8f5U.jpg)
Those magnificient puppies are RCV lifetime CV axles.
They are two things, well three actually
1. Uber expensive $2500 a pair!
2. Unbreakable
3. Lifetime warranty, you ever wear them out or break them, you get another one!
and
4. Really kool
OK, that's four things, but I'm only an Armee Pilut, but you get the picture!


Quote:
Originally Posted by *********
"Is there a picture of the completed truck on here somewhere. I read 55 pages, but I can't keep searching. Thanks"


Don't want you to go looking all over, so I'll post one up for ya.
Not current, the truck is changing every few days with the addition of more parts. It currently looks like an Army Mrap!
(http://i.imgur.com/7zqGieA.jpg)
(http://i.imgur.com/Bt8ti8f.jpg)
(http://i.imgur.com/P3xfHby.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:22:23 AM
The mail man delivered the rear axle cover made by Shawn over at Great Lakes Off Road in Indiana.
It is a raw steel, no-excuses part that not only looks cool, but it's priced at half of what the aluminum covers cost, increases fluid capacity, has a lifetime warranty, provides protection against anything short of an IED from damaging that costly Grizzly and 4.56 gears, and adds strength through stiffening up the differential housing.
This is a great part and a quickie project for anyone wanting something cool and easy to do.
Here's some shots of it:

(http://i.imgur.com/yAoaMyf.jpg)
(http://i.imgur.com/jLkl9qy.jpg)
Here's some floor shots of it:
(http://i.imgur.com/sasWnKy.jpg)
(http://i.imgur.com/wGjSSQ1.jpg)
(http://i.imgur.com/J22A3qb.jpg)
The flange is laser cut from 1/2" steel, and the rest is from a single piece of formed and welded 1/4" plate.
(http://i.imgur.com/8bmmCBG.jpg)
The fill plug is located up higher so you can opt to bring the fluid level a bit higher if perfered. I will do that and see how it all works out. That fill plug is 3/8" NPT (big)
The bolt holes are factory sized
(http://i.imgur.com/MBVGFCo.jpg)
(http://i.imgur.com/1dBrkRi.jpg)
Tomorrow I'll acid etch the thing and paint it, then install it when it properly dries.
You have to appreciate great little products like these coming out of entrepreneurs in the good old US of A. An everyday guy gets and idea and executes on it and creates a product and a business. That is the engine of this nation and I just feel great supporting folks like him and his wife as they work long hours (at multiple jobs) to make this thing a success. It's a privilege to get a part like this, aside from the fact that it is, well, a great part!
(http://i.imgur.com/4pw89PN.jpg)
(http://i.imgur.com/Qyeinum.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:22:33 AM
This is STLASER'S original intro into Don's build thread (the guy that built Don's diff covers and a member on this site):
Here is the original link to the JP Mag article (yeah I realize they drive Jeeps but it is what it is...). Which is basically some knuckle heads shooting various cartridges at our covers, the main point is however we won the independent review. Note: please disregard the non scientific testing procedures that allowed us to win.
http://www.fourwheeler.com/how-to/transmission-drivetrain/154-0708-bulletproof-test/photo-01.html
In all honesty we were not the first to build a fabricated differential cover. Wagoners Machine Shop was the original to the best of my knowledge. Please realize if you know who I'm talking about you are doing two things, one showing your age and two you are a hard core wheeling guy.

We were the first to build a true two piece fabricated cover the correct way with state of the art machinery at a realistic price point. We have since been copied by no less than ten different manufacturers (it is my opinion imitation is the sincerest form of flattery). One thing to note is we still have more options available and in all honesty the best welder that I know finishing these up for our customers. We are family owned and all the parts are built here in the US by true craftsmen. Lastly there are endless modifications you can incorporate into these units and that sets them apart from anyone in the field.

Finally a little on our background, I am a general manger of one of the largest production laser fabrication companies in Indiana and have been for the last fifteen years. My wife is a registered nurse working towards her masters degree and we are raising three daughters the correct way with lots of hands on experiences involving shooting sports and a variety of four wheel drive vehicles. In all we have operated GLO for the last ten years, which started as a good reason to get me off the pavement more often. Thanks Shawn & Tonya


OK, I painted the cover today, although after seeing what it looks like now, I may be painting it again tomorrow, still thinking about it...
Here's the raw cover, then the same one after being treated with Muriac acid which is pretty powerful stuff
(http://i.imgur.com/36ZIM5j.jpg)
(http://i.imgur.com/gVpythW.jpg)
I thourghly washed with very hot water, dried it, the sprayed it with Zinc Phosphate. THis is the primer used on aircraft where corrosion is a berry berry bad thing. First coat was a light one
(http://i.imgur.com/TsWxhse.jpg)
(http://i.imgur.com/CD8UmQf.jpg)
Two more coats gave me the coverage I wanted. Zinc is a self sacrificing metal. If there is ever a scratch this deep that exposes parent steel, the zinc molecules will actually flow into and over the scratch to prevent oxidation.
(http://i.imgur.com/1izDpZf.jpg)
(http://i.imgur.com/gMjUjZR.jpg)
Next it got a coat of high temp primer, then a brush on coat of Hammerite textured gray metallic paint.
This is weird stuff if you haven't ever seen it. No matter how you smear, brush, or spray it on, it reacts and flows all crazy like creating a hammered metal texture. I sort of like that because it doesn't show nicks or scratches and is very thick going on.
(http://i.imgur.com/3JvdC5B.jpg)
(http://i.imgur.com/tMn7vk5.jpg)
(http://i.imgur.com/mgxqILk.jpg)
I gave it a second coat and at 1700 it was still not completely dry, so I guess I'll do the install of the cover tomorrow. No worries since I need to purchase longer bolts. I was going to install with the factory bolts, then upgrade in a week to something cool, but those tiny factory things just won't be long enough. I might do what Shawn suggested and install studs, seems like a good idea, and lookes no-excuses rugged!
I'm not completely sure I like how that dude turned out. Not as uniform as I was expecting, so giving it the night to sleep on is prudent!

(http://i.imgur.com/U13OUY1.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:22:51 AM
(http://i.imgur.com/YABcWFN.jpg)
(http://i.imgur.com/lSCDWOp.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:23:03 AM
(http://i.imgur.com/7dkvLn5.jpg)
(http://i.imgur.com/XwVwpxb.jpg)
(http://i.imgur.com/iFshasv.jpg)
(http://i.imgur.com/CuVLr0z.jpg)
(http://i.imgur.com/PyYWzIB.jpg)
(http://i.imgur.com/ZftrR39.jpg)
(http://i.imgur.com/imO9ds8.jpg)
(http://i.imgur.com/44bEXtQ.jpg)
(http://i.imgur.com/PMf6p30.jpg)
(http://i.imgur.com/4WnFNB0.jpg)
(http://i.imgur.com/GD18zAL.jpg)
(http://i.imgur.com/6A7XPmB.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:23:12 AM
(http://i.imgur.com/UKmnpyF.jpg)
(http://i.imgur.com/Yyqkqbi.jpg)
(http://i.imgur.com/y3KA14x.jpg)
(http://i.imgur.com/tjqpgkb.jpg)
(http://i.imgur.com/CKMkHQ2.jpg)
(http://i.imgur.com/JT4DhlN.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:23:25 AM
(http://i.imgur.com/qjoGHi7.jpg)
(http://i.imgur.com/qEbA290.jpg)
(http://i.imgur.com/yZwxYe9.jpg)
(http://i.imgur.com/qmDmjZ3.jpg)
(http://i.imgur.com/pEmkUPE.jpg)
(http://i.imgur.com/ZpMsx2V.jpg)
(http://i.imgur.com/zrzaNDn.jpg)
(http://i.imgur.com/egVU6Fh.jpg)
(http://i.imgur.com/2zzo28m.jpg)
(http://i.imgur.com/jGEzz3t.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:23:34 AM
(http://i.imgur.com/WOGUwuT.jpg)
(http://i.imgur.com/79TeMCO.jpg)
(http://i.imgur.com/vKPQLct.jpg)
(http://i.imgur.com/zT1Jcys.jpg)
(http://i.imgur.com/iqSZ51E.jpg)
(http://i.imgur.com/TUlVpzm.jpg)
(http://i.imgur.com/1ahBADm.jpg)
(http://i.imgur.com/0bR5T4Z.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:24:03 AM
(http://i.imgur.com/W2IZvxh.jpg)
(http://i.imgur.com/0m8TbgM.jpg)
(http://i.imgur.com/HJFtKsn.jpg)
(http://i.imgur.com/cZqwBcP.jpg)
(http://i.imgur.com/1Tpq6qi.jpg)
(http://i.imgur.com/hZgbErX.jpg)
(http://i.imgur.com/3FEMsP3.jpg)
(http://i.imgur.com/QBr6zZT.jpg)
(http://i.imgur.com/JU2OdjJ.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:24:26 AM
(http://i.imgur.com/jG9KkI1.jpg)
(http://i.imgur.com/f7ppTgZ.jpg)
(http://i.imgur.com/Wb01FiU.jpg)
(http://i.imgur.com/tw0kCWK.jpg)
(http://i.imgur.com/vXeEQfh.jpg)
(http://i.imgur.com/RnWE2cY.jpg)
(http://i.imgur.com/67qyw6J.jpg)
(http://i.imgur.com/ITmsQlE.jpg)
(http://i.imgur.com/zXxEkfx.jpg)
(http://i.imgur.com/uUkEMqr.jpg)
(http://i.imgur.com/gS6e9vi.jpg)
(http://i.imgur.com/y0kGqy7.jpg)
(http://i.imgur.com/SO693YB.jpg)
(http://i.imgur.com/LQWqOfK.jpg)
(http://i.imgur.com/GDG95ul.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:24:44 AM
(http://i.imgur.com/dL21KRJ.jpg)
(http://i.imgur.com/Ufyc59T.jpg)
(http://i.imgur.com/MXGBBns.jpg)
(http://i.imgur.com/jyxmEOV.jpg)
(http://i.imgur.com/Q4K2W90.jpg)
(http://i.imgur.com/0Sf8oos.jpg)
(http://i.imgur.com/x3h1b7x.jpg)
(http://i.imgur.com/SF8CxfJ.jpg)
(http://i.imgur.com/dfv6Slv.jpg)
(http://i.imgur.com/MicE2TS.jpg)
(http://i.imgur.com/wPb1153.jpg)
(http://i.imgur.com/BaSYmAx.jpg)
(http://i.imgur.com/MEkoFCI.jpg)
(http://i.imgur.com/QMSOvb1.jpg)
(http://i.imgur.com/wYUgXBh.jpg)
(http://i.imgur.com/V3cNPLs.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:24:59 AM
(http://i.imgur.com/bnzNzYp.jpg)
(http://i.imgur.com/ES2Jk9w.jpg)
(http://i.imgur.com/nXrKiqp.jpg)
(http://i.imgur.com/XFAJW1g.jpg)
(http://i.imgur.com/PeqV7FF.jpg)
(http://i.imgur.com/3PcpEMI.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:25:14 AM
(http://i.imgur.com/yHQuTjA.jpg)
(http://i.imgur.com/wpuR86E.jpg)
(http://i.imgur.com/nuR8UNT.jpg)
(http://i.imgur.com/aXJWMVw.jpg)
(http://i.imgur.com/4aZlUln.jpg)
(http://i.imgur.com/417ktv4.jpg)
(http://i.imgur.com/HV7jH15.jpg)
(http://i.imgur.com/C6BvD3r.jpg)
(http://i.imgur.com/KrDknn2.jpg)
(http://i.imgur.com/Os8VVlB.jpg)
(http://i.imgur.com/lfbkEKX.jpg)
(http://i.imgur.com/1piujdW.jpg)
(http://i.imgur.com/XAMYWxM.jpg)
(http://i.imgur.com/kRqgHq5.jpg)
(http://i.imgur.com/PLN0Pqn.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: OVERWATCH_09 on September 26, 2014, 11:25:31 AM
(http://i.imgur.com/tjrabV1.jpg)
(http://i.imgur.com/xTRtKdM.jpg)
(http://i.imgur.com/kZeUYqN.jpg)
(http://i.imgur.com/cz1cVxC.jpg)
(http://i.imgur.com/uylQDAP.jpg)
(http://i.imgur.com/R5FFudU.jpg)
(http://i.imgur.com/Ko9WJgQ.jpg)
(http://i.imgur.com/ElXUwDB.jpg)
(http://i.imgur.com/WHq3hrW.jpg)
(http://i.imgur.com/0nnkhLv.jpg)
(http://i.imgur.com/fzE0ct6.jpg)
(http://i.imgur.com/yWUjT2g.jpg)
(http://i.imgur.com/88YHZJR.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 18, 2014, 01:03:53 AM
save
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: rcampbell on October 19, 2014, 05:50:04 PM
Love what you are doing with the truck! I saw a miller 212 welder in a pic, if it's yours how do you like it? Hoping to upgrade mine soon.
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: Flyin6 on October 19, 2014, 06:23:40 PM
Yes it's mine

The Miller 212 is a great Mig

It continues to serve me well to this day

If you haven't seen this build, the part copied over here is maybe a tenth of what that truck goes through.

Unfortunately, I don't believe we will ever get to copy the 8,000+ posts on its build thread, but all the new stuff will happen here.
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 27, 2014, 10:58:52 PM
(http://i.imgur.com/o9bqIB9.jpg)
(http://i.imgur.com/3HWgwvY.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 27, 2014, 11:00:57 PM
(http://i.imgur.com/gzPIO5q.jpg)
(http://i.imgur.com/M7qp5nI.jpg)
(http://i.imgur.com/ZiiA6wC.jpg)
(http://i.imgur.com/UQTclVM.jpg)
(http://i.imgur.com/Ebs1M9I.jpg)
(http://i.imgur.com/EiglWvM.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 27, 2014, 11:08:48 PM
(http://i.imgur.com/zUuLUal.jpg)
(http://i.imgur.com/VQ1iLtU.jpg)
(http://i.imgur.com/K4wrnmG.jpg)
(http://i.imgur.com/coKuJrF.jpg)
(http://i.imgur.com/sNsXJ6o.jpg)
(http://i.imgur.com/MiO4eyh.jpg)
(http://i.imgur.com/IQp8koK.jpg)
(http://i.imgur.com/LRssFxS.jpg)
(http://i.imgur.com/Z0OgaLK.jpg)
(http://i.imgur.com/WuwN4bd.jpg)
(http://i.imgur.com/BdkFele.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 27, 2014, 11:13:14 PM
(http://i.imgur.com/aqsCaIS.jpg)
(http://i.imgur.com/kexCCu9.jpg)
(http://i.imgur.com/D8P154E.jpg)
(http://i.imgur.com/TEGCS3p.jpg)
(http://i.imgur.com/6TFao9o.jpg)
(http://i.imgur.com/alZBr19.jpg)
(http://i.imgur.com/qWRXZEd.jpg)
(http://i.imgur.com/AhmTBXu.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 27, 2014, 11:15:08 PM
(http://i.imgur.com/XcjqcP0.jpg)
(http://i.imgur.com/n1E5a7g.jpg)
(http://i.imgur.com/CYbxgSm.jpg)
(http://i.imgur.com/tC3pqzI.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 27, 2014, 11:15:51 PM
(http://i.imgur.com/ZQkaNAY.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 27, 2014, 11:52:15 PM
save
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 27, 2014, 11:54:30 PM
(http://i.imgur.com/HAvoiyW.jpg)
(http://i.imgur.com/wvVGm3i.jpg)
(http://i.imgur.com/AFeddtX.jpg)
(http://i.imgur.com/DKpzdyc.jpg)
(http://i.imgur.com/1sb973Q.jpg)
(http://i.imgur.com/nzReiKD.jpg)
(http://i.imgur.com/AnXEjXm.jpg)
(http://i.imgur.com/j7MkvQQ.jpg)
(http://i.imgur.com/5CVIJTu.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 27, 2014, 11:56:07 PM
(http://i.imgur.com/8WB2Q55.jpg)
(http://i.imgur.com/mflaD1c.jpg)
(http://i.imgur.com/i15m5jN.jpg)
(http://i.imgur.com/C0KzViL.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 12:01:59 AM
(http://i.imgur.com/71CnK5E.jpg)
(http://i.imgur.com/bMjt9Pd.jpg)
(http://i.imgur.com/eswn2cc.jpg)
(http://i.imgur.com/SmHalrD.jpg)
(http://i.imgur.com/43rMvAX.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 12:04:08 AM
(http://i.imgur.com/LZacSID.jpg)
(http://i.imgur.com/5capM4h.jpg)
(http://i.imgur.com/C2ZaGG1.jpg)
(http://i.imgur.com/dGQyDY0.jpg)
(http://i.imgur.com/JDlfuCR.jpg)
(http://i.imgur.com/T8U0pyh.jpg)
(http://i.imgur.com/OI5btNx.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 12:10:11 AM
(http://i.imgur.com/iHZXDsW.jpg)
(http://i.imgur.com/itGDAmi.jpg)
(http://i.imgur.com/AkwXT6f.jpg)
(http://i.imgur.com/nGpjRot.jpg)
(http://i.imgur.com/Ddza0ji.jpg)
(http://i.imgur.com/Qxlzh9i.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 12:11:10 AM
(http://i.imgur.com/7dYuD1c.jpg)
(http://i.imgur.com/Ehnsxwc.jpg)
(http://i.imgur.com/J3epl8q.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 09:49:53 PM
(http://i.imgur.com/ppdAgmW.jpg)
(http://i.imgur.com/bT8mGyF.jpg)
(http://i.imgur.com/slbABwY.jpg)
(http://i.imgur.com/32aHYeL.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 09:51:31 PM
(http://i.imgur.com/uXbP6Ct.jpg)
(http://i.imgur.com/rqXcAeI.jpg)
(http://i.imgur.com/ydW6WzA.jpg)
(http://i.imgur.com/9Jq7mj7.jpg)
(http://i.imgur.com/gnh0RX8.jpg)
(http://i.imgur.com/uIoEJtU.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 09:56:40 PM
(http://i.imgur.com/JKn1dsL.jpg)
(http://i.imgur.com/CclAQwW.jpg)
(http://i.imgur.com/FmKWzgq.jpg)
(http://i.imgur.com/NDbmTkh.jpg)
(http://i.imgur.com/DDppYH4.jpg)
(http://i.imgur.com/kEqU8ud.jpg)
(http://i.imgur.com/d7Najis.jpg)
(http://i.imgur.com/unNpHqJ.jpg)
(http://i.imgur.com/pG2YYAQ.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 09:59:40 PM
(http://i.imgur.com/GQr4s5b.jpg)
(http://i.imgur.com/FJUHTR1.jpg)
(http://i.imgur.com/YFx2L8s.jpg)
(http://i.imgur.com/B8bcl6r.jpg)
(http://i.imgur.com/mlxIv4V.jpg)
(http://i.imgur.com/SSOTjzr.jpg)
(http://i.imgur.com/jmcGyvr.jpg)
(http://i.imgur.com/TFyx9Qg.jpg)
(http://i.imgur.com/7v6Gh2O.jpg)
(http://i.imgur.com/Zr174CF.jpg)
(http://i.imgur.com/no09GKZ.jpg)
(http://i.imgur.com/bEk2Kzz.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 10:01:57 PM
(http://i.imgur.com/Hg8Lggz.jpg)
(http://i.imgur.com/Og7mo3A.jpg)
(http://i.imgur.com/lcD3Jsq.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 10:14:19 PM
save
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 10:46:32 PM
(http://i.imgur.com/EopTh0i.jpg)
(http://i.imgur.com/JoEyzgG.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 10:46:58 PM
save
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 10:51:48 PM
Here's Don's favorite part of the cmax build (insert sarcasm face here)
...truth be told, he probably would want this left out, but we're putting here anyways !
(http://i.imgur.com/H64YGZP.jpg)
(http://i.imgur.com/kqkcJSX.jpg)
(http://i.imgur.com/spNqGuD.jpg)
(http://i.imgur.com/cX7YmsE.jpg)
(http://i.imgur.com/BQgba5M.jpg)
(http://i.imgur.com/bdYOCoX.jpg)
(http://i.imgur.com/ziqx1fT.jpg)
(http://i.imgur.com/1v4T5zn.jpg)

Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 10:54:40 PM
(http://i.imgur.com/Ol1SrdG.jpg)
(http://i.imgur.com/8V7IVAm.jpg)
(http://i.imgur.com/vXkZEGJ.jpg)
(http://i.imgur.com/L5jkX7p.jpg)
(http://i.imgur.com/ekpr79M.jpg)
(http://i.imgur.com/wnf1G3o.jpg)
(http://i.imgur.com/JLy8U5L.jpg)
(http://i.imgur.com/V22i8SK.jpg)
(http://i.imgur.com/X5boTIC.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 10:56:34 PM
(http://i.imgur.com/9x7bPHO.jpg)
(http://i.imgur.com/5sV8QQ0.jpg)
(http://i.imgur.com/UdtHPDu.jpg)
(http://i.imgur.com/IUstZEF.jpg)
(http://i.imgur.com/IUstZEF.jpg)
(http://i.imgur.com/fy0MDnl.jpg)
(http://i.imgur.com/TUlEyS5.jpg)
(http://i.imgur.com/7NQmZ5E.jpg)
(http://i.imgur.com/wUrm9vX.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 10:59:50 PM
(http://i.imgur.com/n41Kbe9.jpg)
(http://i.imgur.com/Hr4BJMH.jpg)
(http://i.imgur.com/NETVuUZ.jpg)
(http://i.imgur.com/yNgVNy1.jpg)
(http://i.imgur.com/Mr7Dpbk.jpg)
(http://i.imgur.com/Mr7Dpbk.jpg)
(http://i.imgur.com/3qB7347.jpg)
(http://i.imgur.com/3qB7347.jpg)
(http://i.imgur.com/TNNirjA.jpg)
(http://i.imgur.com/GiG6cqb.jpg)
(http://i.imgur.com/lfAQxdY.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 11:04:06 PM
(http://i.imgur.com/ep4PIEV.jpg)
(http://i.imgur.com/vLzxqUU.jpg)
(http://i.imgur.com/S2aAMlw.jpg)
(http://i.imgur.com/f5bUqIg.jpg)
(http://i.imgur.com/k06tj0u.jpg)
(http://i.imgur.com/VANQo7B.jpg)
(http://i.imgur.com/6afX3nZ.jpg)
(http://i.imgur.com/39yATQS.jpg)
(http://i.imgur.com/MeajybH.jpg)
(http://i.imgur.com/bcQeDwT.jpg)
(http://i.imgur.com/jmHPknQ.jpg)
(http://i.imgur.com/mbekLCn.jpg)
(http://i.imgur.com/VPQDHC9.jpg)
(http://i.imgur.com/gu3gCx0.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 11:35:24 PM
(http://i.imgur.com/zjpvrZj.jpg)
(http://i.imgur.com/cNNZGMM.jpg)
(http://i.imgur.com/vjRsAao.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 11:44:39 PM
(http://i.imgur.com/o4N8Xqp.jpg)
(http://i.imgur.com/ToUUGOP.jpg)
(http://i.imgur.com/FexmDKu.jpg)
(http://i.imgur.com/8Swt5LP.jpg)
(http://i.imgur.com/F59Fobf.jpg)
(http://i.imgur.com/gEcam7p.jpg)
(http://i.imgur.com/dlmyfFZ.jpg)
(http://i.imgur.com/g55DO6o.jpg)
(http://i.imgur.com/YBc3K72.jpg)
(http://i.imgur.com/InLoFOH.jpg)
(http://i.imgur.com/Nqtqr4Q.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 11:49:36 PM
Posted by Flyin6:
OK, I have some totally inflamatory stuff to post up. Wierd how my brain works, but you all know I am now writing my second book which spans the innerspace between biography, musings, philosophy, and who knows what. Anywho, for some wierd reason (I hope there aren't any psychologists reading this!) I actually wake up early in the morning with something swimming around in my head, which I immediately write down to capture. Well, not immediately, first I put on that pot of Java, then start writing. I don't know what is going to pop up, or why, I just write it down. Normally I can have up to 5-7 pages of stuff that just comes pouring out and I write until the hunger pains begin, or lack of coffee wain until the need for sweet tea later on. Does all that make sense? For your sake, I sincerely hope not!
Well, anyway my CIEMR this morning is as follows:
I woke up with this definition of what I believe a Liberal to be all clumped together in the gray matter...Lord help me!

Liberal: A person who is committed to an idea or concept despite logic, common sense, history, evidence, or proof to the contrary. A person who is so convinced of the correctness of their position that they demand others change their views, beliefs, convictions, and way of life to comply. Finds accommodation with all beliefs and ways of life despite how farfetched they may be, and demands the 99% change their views to accept this skewed position through the constant creation of laws, regulation, policy or procedure. One who is not satisfied with the natural order of things and believes more control is inevitably necessary for happiness, although a true liberal is never happy, cannot achieve happiness, and has become embittered and hate filled because of their constant failure to change the natural order of things. People who mostly believe there is no God, that somehow randomness and human intellect has produced the world as we know it and willingly accepts utterly fantastic explanations for how things came to be. Someone who does not love freedom and through their zeal to control things in a manner consistent with their beliefs, actually destroys it and becomes its enemy. Lacking of real courage but totally convinced that because of their zeal and ability to argue their point that somehow they display courageous characteristics. A person whose beliefs are generally only found to be acceptable to like minded people and fringe elements of society. Seldom seen on a battlefield or other places where real courage and self sacrifice are required. Willing to benefit and prosper from the labors of others without having a negative effect on their own conscience. Believing that despite how successful some people have become through their personal labor, sacrifice, and brilliance, that the fruits of all that effort should be shared by everyone. A fan of the grasshopper, and truly believes the ant was treated fairly and perhaps even shown leniency
......BTW...No offense to any liberals who might read this, I have to admit to actually knowing some of you, and fondly looking forward to our bantering back and forth!
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 11:51:17 PM
Quote:
Originally Posted by ***********
"Awesome progress Don! Looks great! It was nice to catch up on your work."


Thanks!

I just picked up the fiberglass, tight weave which I will soon use.
Here's how that top will come to completion:
1. Next I will build the hinge system
2. Then run the wiring and mount interior and exterior LED lights.
3. Do some sanding, countouring, shaping and body filler work.
4. Cover the exterior with the heavy and tight weave fiberglass mat and resin
5. Fill interior spaces with structural and fire retardant foam
6. Install interior panel, switches, and assundry items such as a inside roof cargo net
7. Build interior ribbing for lower half of the enclosure
8. Finish the wiring and connect
9. apply foam insulation
10. apply aircraft flame retardant carpet
11. Paint upper extending lid assembly
12. Apply vinyl digital camo to lower half and upper edges, vehicle roof and hood
13. Mount topper to vehicle
14. Attach the fabric material to the two upper sections and work out the bugs on that
15. Invade Iran...oops, I meant persuade uncle stan to let me check it out on the farm!
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 28, 2014, 11:57:02 PM
Day 8 of project chop top.
I wanted to be able to erect the top to it's full upright position by COB today, but the construction of the hinge mechanism is a bit more involved than I first estimated.
I decided to wrap the strongest part of the new roof frame with steel which was bonded, screwed and through bolted in place. THe creation of the hinge brackets took me the whole afternoon. but I'm ready to go on the lifting mechanism tomorrow.
To build the aft hinge attachment point, I started with a 3/16" thick 1.5 square tube. I cut it to length, then using a plasma torch, cut one side off forming a U-channel
(http://i.imgur.com/bluRIBU.jpg)
(http://i.imgur.com/MOAWqgP.jpg)
(http://i.imgur.com/316ldoU.jpg)

Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 29, 2014, 09:28:01 PM
(http://i.imgur.com/xp9LQvu.jpg)
(http://i.imgur.com/OhwJVZV.jpg)
(http://i.imgur.com/wPgdzVW.jpg)
(http://i.imgur.com/V12xB3K.jpg)
(http://i.imgur.com/nqYzIhz.jpg)

Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 29, 2014, 09:31:35 PM
(http://i.imgur.com/ENIPs7o.jpg)
(http://i.imgur.com/U2xrqfy.jpg)
(http://i.imgur.com/E9OopNU.jpg)
(http://i.imgur.com/vPe3FQe.jpg)
(http://i.imgur.com/rz0sb9s.jpg)
(http://i.imgur.com/JDpWOPc.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 29, 2014, 09:33:28 PM
(http://i.imgur.com/LJS84vl.jpg)
(http://i.imgur.com/PT6uaKG.jpg)
(http://i.imgur.com/Zsrg6Nl.jpg)
(http://i.imgur.com/qYt3nSP.jpg)
(http://i.imgur.com/6OgAIDt.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 29, 2014, 09:40:56 PM
(http://i.imgur.com/cv3VPW1.jpg)
(http://i.imgur.com/IQ1yxUM.jpg)
(http://i.imgur.com/wnHU2S5.jpg)
(http://i.imgur.com/WXCSmNr.jpg)
(http://i.imgur.com/ZAH03Jq.jpg)
(http://i.imgur.com/XuxBjTU.jpg)
(http://i.imgur.com/EG2Vo2n.jpg)
(http://i.imgur.com/U2qbgmI.jpg)
(http://i.imgur.com/w1SkLqb.jpg)
(http://i.imgur.com/xgrpWHw.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 29, 2014, 09:41:38 PM
First I got some news from Road Armor. They experienced some difficulties building our new rear bumper. They moved locations and there was a loss of information on the hard drive, specifically this new bumper design. That is apparently cleared up and the gentleman at Road Armor has the design completed. He said he will do prints over the weekend and send that to the shop for actual construction. shouldn't be too long.
Here's two sketches of it he just sent me showing the back up sensor holes

(http://i.imgur.com/J2i3XpA.jpg)
(http://i.imgur.com/ptPeLGW.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 29, 2014, 10:19:45 PM
(http://i.imgur.com/eCqow9k.jpg)
(http://i.imgur.com/yLRuaBd.jpg)
(http://i.imgur.com/xU9KoNs.jpg)
(http://i.imgur.com/GGtS4dP.jpg)
(http://i.imgur.com/Vh9WNUb.jpg)
(http://i.imgur.com/A8rAyks.jpg)
(http://i.imgur.com/3SBe2mF.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 29, 2014, 10:22:45 PM
Various shots showing the forward hinge folded in carry position, another shot of the back end sky high, and another of my able bodied assistant
(http://i.imgur.com/mGybrKW.jpg) (http://imgur.com/mGybrKW)
(http://i.imgur.com/Dq26c1M.jpg)
(http://i.imgur.com/bU8Aylx.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 29, 2014, 10:29:06 PM
Posted by Flyin6: (all previous posts by myself or Overwatch are from Flyin6, other than quoted posts)

I have been researching pneumatic cylinders, which is my first go to idea to raise the top. Apparently very easy to construct, and even can be made out of 2" PVC! The working pressures of those things are low enough for them to be very safe, but durable???
I think I am looking at a redesign of the project since I don't have room for full length cylinders.
I have 21" of debth in the bed. I have another 21" of topper height, so 42" total to work with. I need 8" length inside the cylinder for piston, stop and things like that, so I have 34" of stroke available. The top extends 42" so that does not compute.

I will need to:

1. Redesign the hinges to raise the top to a lower height
2. Build a compound cylinder with dual/triple rams that telescope from inside each other
3. Redesign the topper into a hard shell camper unit
4. Abandon this project and purchase some sturdy slide in camper unit like an Alaskan or similiar.

I don't make big moves quickly or without lots of good information (One of Sun Tsu's principles) so I am thinking this thing through at the moment.
Meanwhile, I think I'll press forward with other projects, focusing initially on the suspension and trying to get some movement out of the guy who is supposed to be designing a custom digi-camo vinyl wrap for the truck
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 29, 2014, 10:33:31 PM
Quote:
Originally Posted by Stlaser
"Don't ditch the original idea, it was good. The execution of it just needed some help.

Good plan to move on to something else and sleep on this project for a little while........ Again if I can help with parts or components let me know. The scissor idea is solid though......"


Thinking about that top, I think I could get away with two lift cylinders considering the top won't go anywhere with the linkage holding it more or less in place. If you think about it, about half of the cabin area will be taken up by a flat sheet which will be used to sleep on, so having the cylinder/pole there just might not matter all that much or interfere with movement.
Anyway, that's the direction I am thinking at the moment. Next step would be to build a telescoping cylinder with two rams, one inside the other...
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 29, 2014, 10:40:39 PM
I decided to fab up those telecsoping air cylinders just to see if it could be done and to have something to work with to see if I can integrate it into the top.
For those of you who are waiting for "Normal" kinds of modifications, those are all coming, some are even in the mail as I write this, but I need to press on with the project chop top just to see if this thing is going to materialize or get chucked.
Reading about how some folks make cheap air cylinders out of PVC, I decided to see what I could do. THe max pressure on that stuff is 280psi which is a bunch and a lot more than I will ever need so I moved ahead.
Needing a more compact size because the interior is already cramped, I went with a 3" cylinder that telescopes with a 2" ram, then another 1.5" ram telescopes out of that. The purpose is to keep it compact, but get the long reach I want.
Here's the three cylinders/rams
(http://i.imgur.com/Z59NuSo.jpg)
(http://i.imgur.com/0sr9ACe.jpg)
(http://i.imgur.com/UF4Y5vw.jpg)
(http://i.imgur.com/lUcgSmF.jpg)
(http://i.imgur.com/qMXC8bt.jpg)
(http://i.imgur.com/epMf2u2.jpg)
(http://i.imgur.com/4iTpyMX.jpg)
(http://i.imgur.com/LajLFVN.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 29, 2014, 10:42:29 PM

(http://i.imgur.com/PkFtCYT.jpg)
(http://i.imgur.com/19CJFQu.jpg)
(http://i.imgur.com/gARZdWc.jpg)
(http://i.imgur.com/HJ6I3n4.jpg)
(http://i.imgur.com/f3JjiON.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 29, 2014, 10:46:29 PM
Quote:
Originally Posted by Armalite View Post
"I like the new idea. Never seen anything like this done before. It just might work!"

I read about some guys building haloween props. That gave me the idea. The double ram is new, or at least I haven't found an example of it, although I'm sure someone out there has tried it
I'll know tomorrow if that is going to even be a possibility.
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 29, 2014, 10:49:07 PM
I've been playing with the lift scissors design.
I'm going to scrap my first design and start fresh with a simpler mechanism. No matter what I come up with it will probably never be easy to just lift the top to the full up position. There just isn't room for bulky lift mechanisms and a bunch of cylinders.
I may use the cylinder I created because the darned thing works great! Maybe (and I'm not sure about it at the moment) I will use that cylinder to raise just one end. That will make it easier to manually press the other end to the open position.
The top is getting heavier all the time. Ashley was kind enough to send me yet another solar panel, a larger one. Now I will be competing with the Hover Dam as far as power output! I will mount that sucker up there, the gel coat the outside, fill the inside up with foam, install lights and an interior finish panel. I'll easily have the whole top section minus the tent fabric up to around 150 pounds. I guess it will provide incentive to keep lifting weights!
That's it for now. I am also carefully considering option #2 which is to purchase something like a used Palmino Bronco collapsing camper and just mod that thing into my mobile survival habitat.
We'll see...
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 29, 2014, 10:50:51 PM
N2BRK gave me an idea...And you thought the only thing that came from Jersey was great pizza!
I have now constructed two seperate lift systems and by themselves, I don't like either one...
So my apologies for all the build pics of engineering experiments that were just, well, experiments
Maybe I'll go back and have John clean up the thread, or maybe just leave the stuff there to show the evolution.
Anyway the New Jersey connection gave me the idea to go back and review the gear options, which led me to review the cable lift systems and that's when the light bulb came on.
By using a simple hand crank winch some cable and pulleys and two steel lift jacks, one piece of square tube inside a piece of C-Channel, mounted to a pivot on the lower frame, and to a swivel or pivot hard point on the top will allow me to keep the scissors linkage and allow me to crank the top up.
I thought I could mount the winch inside of the top and allow the hand crank axle to poke through to the outside, say at one of the back corners. Then, all I would have to do would be to walk up to the back of the topper, attach the hand crank or even a powerful drill/driver and raise the top while standing on the outside. Then climb up inside and extend the scissors linkage to their over center/locked upright position and voila' (that's french) I'd be living in shangri-la (no idea what language that is!)
So, I'm off on a buying frenzy...gotta get a winch, cable, pulleys, turn buckles, steel, and kitchen sink parts...
CYA soon!
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: Flyin6 on October 30, 2014, 08:42:33 AM
Note from Big Don:  Ken and Overwatch09 have posted all this up so far. Had I done it, I would have left this part out, but I guess it shows some design and progression toward the current end state of that truck...
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 30, 2014, 09:43:19 AM
I know it's a sore spot, but it shows some great design and fab....and it's part of the story.

.....you do have the power to remove it btw. lol
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: Flyin6 on October 30, 2014, 08:47:48 PM
Naw, it's history...and tells part of this story
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 30, 2014, 10:53:46 PM
I'll take that as a your blessing.....so here we go:


Brother Ash...
Here's a couple pics of both of those solar panels you sent me.
The first was a 55 watt unit and the second unit is a 65 watt panel. THat means I will be able to generate up to 120 watts on a sunny day to help recharge/feed batteries which in turn will operate the coffee or sweet tea maker!
Yippee!

(http://i.imgur.com/CPIHgXk.jpg)
(http://i.imgur.com/v0PacHN.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 30, 2014, 10:54:26 PM
save
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 30, 2014, 10:55:20 PM
Had another cool part show up on the back of the brown truck

Thanks to Holton at Alligator!

I will be installing this Alligator down pipe in the near future.
(http://i.imgur.com/DhyIsdA.jpg)

Quote:
Originally Posted by Armalite View Post
"Its not too bad on the new lml's. Did mine last week. You need at least one other person to help you, but two is better. You dont have to remove the transmission dip stick or anything else, other than the fender well. Only hard part is removing the rear factory heat shield. And then getting a good "seat" at the turbo and getting a good fit with the clamp. Other than that, its not bad at all !!

I'm sure Don will have no problem installing it. I'm not going to say it cant be done by yourself, lol, because Don will prove me wrong, and make it happen. So, I'm interested to see his approach". 

You just laid down the gauntlet!
I was planning on starting it one morning around 0800 and working by myself. I think I still will and see how it goes, That gives me up to noon when I call in the Cavalry, who will also bring me a sub sandwich and tea. Since he's just a Black Hawk pilot, I usually give him all the difficult/dirty/dangerous tasks! (and complain the whole time about his poor quality workmanship!)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 30, 2014, 10:59:34 PM
Quote:
Originally Posted by .............
"When is the last time someone has called you McGyver? I mean this thing has gone from a stock LML to something that will be in the next transformers movie! Im waiting for voice control and a red light bar to pop up now. Then the truck will introduce itself as Maximus Modded and Ill kick your trucks butt! haha "

That's funny!

Serious note though, just think about it. You get into a situation where civil unrest goes into mahem. I'm thinking the larger the vehicle the better off you will be. If it's a diesel, then it has all the HD stuff which means while you're flooring it to smash your way through stuff, drive axles and control arms and things like that will stay intact.
Remember I cut my teeth with these kind of vehicles in places like Baghdad and Kabul. I wasn't doing the driving, but the guys who were did whatever was necessary to get through. jumping curbs, pushing cars out of the way, driving over debris, going opposite direction against traffic and knocking walls over were just some of the tricks I watched and learned.
By my reckoning, you need big heavy powerful vehicles to get through all that. You need big torque engines to move all that. Diesel fuel is not as likely to catch fire if you are driving through burning vehicles. Bullets will do less damage or you'll simply have more of a built in reserve to get you out while your truck is dying. And it can carry more stuff and people. Arguably, a HD truck is a terrific survival vehicle and takes much less in the modification department to be reuseable afterward.
All the while it is giving you that capability, it still works out well as a driver, camper, grocery getter, and mall cruiser. Win-win-win the way I see it!
But, yes it is going to morph quite a bit more before I call it sort of done!
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 30, 2014, 11:01:59 PM
(http://i.imgur.com/rMohDPu.jpg)
(http://i.imgur.com/zjp745b.jpg)
(http://i.imgur.com/q0VJS4X.jpg)
(http://i.imgur.com/WnbVo1a.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 30, 2014, 11:06:21 PM
(http://i.imgur.com/jZHPUcd.jpg)
(http://i.imgur.com/CbVhs6V.jpg)
(http://i.imgur.com/FhPB1XU.jpg)

(http://i.imgur.com/JcYgL6Y.jpg)
(http://i.imgur.com/sR5mtso.jpg)
(http://i.imgur.com/KF7CHv2.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 30, 2014, 11:11:20 PM
(http://i.imgur.com/GKIq4EV.jpg)
(http://i.imgur.com/nMaCpOf.jpg)
(http://i.imgur.com/6WixOOX.jpg)
(http://i.imgur.com/EzzPKlk.jpg)
(http://i.imgur.com/AdT2K0G.jpg)
(http://i.imgur.com/DtgjBe7.jpg)
(http://i.imgur.com/etP6sWL.jpg)
(http://i.imgur.com/pWBKyD3.jpg)
(http://i.imgur.com/HeMLXNq.jpg)
(http://i.imgur.com/f92fhi3.jpg)
(http://i.imgur.com/f92fhi3.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 30, 2014, 11:13:30 PM
(http://i.imgur.com/BCkOQBt.jpg)
(http://i.imgur.com/vRzuVTf.jpg)
(http://i.imgur.com/KIEC4K1.jpg)
(http://i.imgur.com/TsLUyuE.jpg)
(http://i.imgur.com/Iw44YrJ.jpg)
(http://i.imgur.com/UixGoJ0.jpg)
(http://i.imgur.com/Q3mvDD8.jpg)
(http://i.imgur.com/1Zme5nr.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 30, 2014, 11:15:31 PM
(http://i.imgur.com/hw5ewTg.jpg)
(http://i.imgur.com/veOkOUo.jpg)
(http://i.imgur.com/4q2Be67.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: cudakidd53 on October 31, 2014, 02:09:27 PM
Ohhhh, the TAC-Topper......wait till you see the Pre-Rangers make the final modifications! :o
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on October 31, 2014, 02:29:54 PM
You're probably one of those guys that tells details about a movie to someone that hasn't watched it yet!
lol
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 03, 2014, 09:05:15 PM
(http://i.imgur.com/1McYOnI.jpg)
(http://i.imgur.com/SZy1zyr.jpg)
(http://i.imgur.com/gtKimjW.jpg)
(http://i.imgur.com/MRjXKXD.jpg)
(http://i.imgur.com/8ZhTb4L.jpg)
(http://i.imgur.com/hg22Eml.jpg)
(http://i.imgur.com/O5vzBTB.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 03, 2014, 09:07:23 PM
(http://i.imgur.com/4BuCgVi.jpg)
(http://i.imgur.com/apvyi2L.jpg)
(http://i.imgur.com/AoR34KP.jpg)
(http://i.imgur.com/DzZtMSz.jpg)
(http://i.imgur.com/wEZm31g.jpg)
(http://i.imgur.com/PBjkmec.jpg)
(http://i.imgur.com/5GjUSuv.jpg)
(http://i.imgur.com/6lZXD7m.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 03, 2014, 09:08:33 PM
(http://i.imgur.com/A25VAoL.jpg)
(http://i.imgur.com/QZFk5Oe.jpg)
(http://i.imgur.com/ZagXZr7.jpg)
(http://i.imgur.com/iquj23o.jpg)
(http://i.imgur.com/Dm2caKN.jpg)
(http://i.imgur.com/Dm2caKN.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 03, 2014, 09:13:48 PM
Originally Posted by Armalite
"Get that lowering kit installed yet !!"

Yep, sure did!
No pics, camera batteries died!
I cut about 8" out of the legs, 4" each side of the hinge and rewelded the thing.
After reassembly it cranked to full height well enough but at this point in the design, it's anything but stable. So that's issue number next. See if I can find a way to get that thing locked in place and not wobbly.
Like I have said all along, this is a slow running game. I hope after all this work that I don't fumble on the 1 yard line. Well if I do and the thing comes up short, I'll only be out around $600ish. On the flip side if I can get it worked out, I have a pretty cool camper shell.
Back at it tomorrow! ........

............The work proceeded again today on the chop top project. After some reinforcing of the base of the topper and adding links to make the lifting poles rigid, the top finally goes up and down without flopping around. I came up with a cover for the lifting poles which is a simple piece of 3" PVC. I will paint it some interior friendly color later on, but the idea is to "clean up" and hide the mechanical linkages.
Next I will fashion up some retaining pins and a couple braces to slide into place when the top is up to keep it there and the weight off the lifting mechanism.

Maybe I'm ready for a pure truck modification project. Something simple but fun, about half a day's worth. You guys ready for one of those write-ups?

Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 03, 2014, 09:19:22 PM
OK, as promised here's a "normal" truck project.
In this installment, I will be installing the Silastic rubber bushing, hinged, nice on your bottom ride enhanser thing-a-ma-jigs.
Was that enough adjectives for ya?
These beauties are a nifty contrivence that replace your steel shackle with a rubber twist bushing that is designed to soak up normal road harshness and will react before the springs.
I wanted them because with my whole planned package which consist of a rear sway bar, Deaver springs, Firestone air bags, and maybe, just maybe some off the hook King custom 3" shocks. Anyway, these shackles are a planned part of that modification process, and I wanted to get some seat of the pants time on them before all the utter (mispelled on puropse) changes are ah takin' place.
Many thanks again to Holton Guyton of Alligator Diesel Performance for his help in this project.
Here's the box and what you get:
(http://i.imgur.com/AZlUZPF.jpg)
(http://i.imgur.com/Hc1Osr2.jpg)
(http://i.imgur.com/O2GaTS5.jpg)
(http://i.imgur.com/OBuP1Hp.jpg)
Most notable, of course are the all important decals. They can be used in many ways, to plaster all over your tool box and cabinets for example. Or perhaps to cover a recent rock ding while doubling as making your truck appear as a class 8 desert racer. Or perhaps they can be applied over a noisy spouse's mouth piece if she is saying totally crazy stuff like, "Why don't you mow the grass instead of working on that truck!"
Anyway, enough with the suggestions, here's a closeup of the good parts
(http://i.imgur.com/v6h3l4i.jpg)
(http://i.imgur.com/dPxYBzz.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 03, 2014, 09:23:34 PM
And here is where it all starts...
(http://i.imgur.com/CCuW7xj.jpg)

OK, a quick read over of the instructions and I could see this was going to be a breeze, a simple 10 minute job.

WRONG

It wasn't quite a satanic ritual, but let's just say there are other steps required to actually put these things on that the instructions neglect to mention. Additionally for those that have purchased a copy of my book I will be adding to Chapter 22, which is titled "Wisdom."

First off, of course you need to remove the factory shackles. A quick zap from my new 600+ ft lbs impact wrench and the bottom nuts are off.
Next comes the top bolts.
First go get a couple gallons of gatorade, some asprin a really big hammer and a steel pole 2 feet long. You will use the latter to alternatively beat on the truck and your head.
To get the top bolt out, you need to disconnect the bottom bolt completely, then jack up the axle until the spring tops out against the body. THis is the moment when you first notice GM placed a steel body flange exactly there where it stops this process about 1/4" short of where it needs to be.
Your choices at this point are 1. bend that flange up and out of the way, or 2. remove the bed of the truck to the point where that bolt will clear.
I chose option 1.
So out comes the RBFH (Really big flippin hammer) and a 2' section of steel pipe. On the first swing of my hammer I did indeed hit the pipe. THat jolt loosened about 7 pounds of dirt which acted in acordance with the laws of gravity. Luckily none of it got on the floor, because my face and mouth stopped it all.
Road dirt does not taste good. OK a good rince and a quart of gatorade to remove the taste, and a see through face shield, and I continued to beat on the steel pipe.
This is the first pearl of wisdom we will pencil into my book:

Whenever you are holding something heavy above your head, you will invariably drop it.

Write that in please...
Here's the area of pain, err, bending:
(http://i.imgur.com/61j9b2h.jpg)

That bottom bolt is a vacation in the Bahamas by comparision. Set the impact to off with your best 24mm socket, get a wrench of the same caliber and let her rip!
(http://i.imgur.com/XbKc5fK.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 03, 2014, 09:25:52 PM
So you beat the living shot out of your truck which used to like you, and you, it and finally after some choice french (small "F") the thing comes out!

Ah, think you're done??

THink again!

Here's where you will add yet another pearl of wisdom to your copy of the book of Don.
When sitting uncomfortably under your vehicle with an air hose rolling about directly under L5/S1 what ever you need will be just out of reach requiring painful extra movement.

Pencil that in as well please...

When you try to position the sulastic shackle in place to push in the upper bolt, you discover that the back bulkhead, just barely interferes with proper alignment. Mind you, just barely! It's close enough for you to  with it for 30 minutes before you realize that two pieces of matter actually can not occupy the same space at the same time!
So back to choice 1. RBFH or 2. Remove the truck bed.
Again I opted for choice #1.
And for a third amazing time I will once again ask you to pick up the pencil and write another pearl of wisdom into my book.

"If a heavy steel pipe has previously hit you on your forehead, and you drop it yet again, then it will strike precisely the same spot again."

Pencil that in there also, please...

The left side has some electronic control panel bolted in there. It effectively blocks everything. THis is my answer to actually get to that bolt once I beat on that bulkhead and injured my head.
(http://i.imgur.com/R7XCmXL.jpg)

The knife is pictured because at this point I realized I still had one side left to do and was considering suicide!

Ok, so after a L O T of swear and using of ancient hebrew blessings, I finally got the things in there, bent bulkheads, flanges, and all!

Here's a side by side of the new and the old
(http://i.imgur.com/WzerEG1.jpg)
(http://i.imgur.com/GGl33iO.jpg)
(http://i.imgur.com/uanbfjf.jpg)

Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 03, 2014, 09:29:20 PM
The sulastic shackle has a resting position of 3" between the bolt hole centers.
The factory dumb iron piece has a C to C distance of 4 3/8"
(http://i.imgur.com/9mXfxSR.jpg)
(http://i.imgur.com/67EzH1Z.jpg)

Obviously suffering from the brain damage from the multiple concussions, I no longer cared about focusing the camera, so this is the only shot I have of the sulastic piece fitted in there. It is out of focus as is my life at the moment, but hey, just roll with it.
(http://i.imgur.com/OQseqWK.jpg)

The sulastic shackles raised my unladen truck about an inch. It has not been driven at the point of this picture. I plan to get to that after a long shower and a visit to the emergency room. Following all that, I'll report on the ride changes if any...Till then BE Good
(http://i.imgur.com/VZMdgrm.jpg)

....Edited

I wanted to say a couple words after the test drive. Really, there isn't a lot of difference. There is, however a decrease in ride harshness from driving over expansion joints and when bottoming out in long smooth dips. That experience just turned into a glide instead of an abrupt event.
I didn't see any difference in cornering or with braking. During light, moderate and hard accleration, again, it's about the same. The truck did break traction accelerating up a country hill at lower speeds, dunno...fluke.
Overall, considering the quality of the part, the injuries and the ride for lightly loaded driving it seems like a wash. I'll re-evaluate once the topper is back on with the quad .50 mount!

Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 03, 2014, 09:46:11 PM
We will be inventing and installing a shotgun mount in todays installment of what the heck is Don up to next???

THe plan is to get a functional non intrusive mount for a 12 gage shotgun into the cab of my truck making the weapon easily deployable from a seated position. That means the weapon should be coarsly oriented in the direction you will grab it, located on the side of your grabber device (hand) and more or less ready to go to work in an instant.
The mounts that fit overhead have you scrambling in the dark for something that is back there somewhere. The mounts that stand the thing up on end are a long reach, have a funky retention device and block that exit.

Considering all that stuff the only place I can see to mount it is thusly:
(http://i.imgur.com/jU4RZHN.jpg)

The weapon of choice here is the newer Mossberg 930SPX. This mount also fits my M500 SPX, Mossberg Persuader, and the range of Remington pumps and autos which I do not use.

So to keep the weapon in place it needs to have the muzzle and the stock retained somehow. I started by finding some steel tube and cutting about a 1.75" piece

This small cylinder fits loosely around the magazine extension tube of the shotgun
(http://i.imgur.com/mTmGiNp.jpg)
(http://i.imgur.com/OVN3yqj.jpg)

I found some 1" X 2" rectangle tubing and sliced a piece off about that long. Percision is not in play at this point. Well to be honest Percision was never in play. Ever heard of Kentucky Windage? Well, you're seeing the concept in action!
I pushed the various pieces together hard and got a tack weld in place. Next I welded that sucker up like it was the single retention bolt for the Hoover Dam!
(http://i.imgur.com/3y4Futg.jpg)
(http://i.imgur.com/kc5efyb.jpg)

After grinding I applied gun lube paint. Otherwise known as John Deere black, according to the book of Don, it also lubricates the end of barrels of guns
(http://i.imgur.com/n8ruLSn.jpg)
(http://i.imgur.com/XmjVux7.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 03, 2014, 09:52:43 PM
I didn't have my BlackHawk Pilot friend handy, so I enslaved my 8 year old, having him tighten the two 5/16" bolts while I held the nuts from the underside. THe bolts come out just beside and above the PTO cover of the transfer case.
(http://i.imgur.com/lFM3OSl.jpg)

The butt stock retainer is gonna make you angry or happy depending on whether your wife just went shopping or not.
Starting with 3" Aluminized muffler tubing, I cut off a 1.75" piece and split it along itis seam weld.
THen with careful shaping with various dollies I formed it into the clip like shape you see. I also coated it with the John Deere gun lube, then wrapped it with 1" wide electricial tape to help the gun lube.
(http://i.imgur.com/obFiEmp.jpg)
(http://i.imgur.com/OrPQ880.jpg)
(http://i.imgur.com/EuMdhEu.jpg)

I slipped it down over the lower console section then screwed it in place from inside the console so no screws show at all
(http://i.imgur.com/H7LH1np.jpg)
(http://i.imgur.com/Dr5EUYN.jpg)

Here's some shots with the Mossberg held in place in it's new home
(http://i.imgur.com/A5OVll8.jpg)
(http://i.imgur.com/RMyAET5.jpg)

I tried the mount on a couple other weapons and found that they fit in a gravity retention fashion, however not as planned. In a gitty up-gone dity-mau I could drop a 5/8" right handed ice maker in there for a short drive, but not as a planned move sort of deal.

Pic #1 is a M4 with a double 30 mag.
Pic #2 is an AK-47 with a 40 rd mag and a collapsing stock
(http://i.imgur.com/ODRFTJk.jpg)
(http://i.imgur.com/b0WnrnL.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 03, 2014, 09:55:17 PM
One of the tenants of survival anything is hide in plain sight. Another is low observability. I think I might have achieved both with this mod. You have to be taller to even see inside the windows. Then you have to really be looking to catch that gun part that just doesn't jive with the styling LTZ interior. All in all, I think it's a pass.
(http://i.imgur.com/k2F65dN.jpg)
(http://i.imgur.com/7bw7HCE.jpg)
(http://i.imgur.com/zjtCreL.jpg)
(http://i.imgur.com/UwfE0zJ.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 04, 2014, 09:13:52 PM
save
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 04, 2014, 09:18:08 PM
So here is the next of an endless series of modifications and improvements.
Looking at the dual fuel filters and dual oil filters, along with excellent filtration, I see four big leak points. SHould a rock or piece of debris poke a hole in any of those components, you will be able to follow the line a couple hundred meters to my broken down truck.

I have long wanted to get started on skid plates or at least protection for vital components, so today I decided to fix the filters.

In this installment you will see how to "Armor-up" thise liquid filled thin wall cylinders fairly easily.

Here's what we are starting with:
(http://i.imgur.com/zoTaKIa.jpg)

The concept here is going to wrap the filters with a steel jacket. For the two fuel filters, 3.5" aluminized muffler tubing is perfect. Cut two sections the length you need. ON the air dog, that will equate to two different lengths
(http://i.imgur.com/zeMC7mp.jpg)
(http://i.imgur.com/PGwm4KN.jpg)

One cylinder required some relief cuts near protruding bolts.
TO hold the shields onto the filter, a simple clamp will suffice. I cut some picture window slits into the sides of the shields where a stainless band clamp could capture both the shield and the filter as well.
(http://i.imgur.com/h0VaYZr.jpg)
(http://i.imgur.com/G64tdMa.jpg)
(http://i.imgur.com/WEXNA9b.jpg)
(http://i.imgur.com/8sGTdsy.jpg)

The plan is to come back to this at a later date and fab up an actual skid plate. With that in mind, I attached the new shields, then welded some threaded tabs as future attachment points

I know, nasty looking welds...well not really, just a lot of heat to get max penetration since those anchor points might take a serious wack at some future point. THe high heat setting set fire to the oils, the aluminum, and my right hand (glove)
(http://i.imgur.com/d67ICbj.jpg)
(http://i.imgur.com/f7RInSE.jpg)
(http://i.imgur.com/R0dyniU.jpg)
(http://i.imgur.com/PzKglfN.jpg)


Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 04, 2014, 09:24:47 PM
A little time with the wire cup grinder, and some clean up with laquer thinner and we're looking pretty spiffy
(http://i.imgur.com/H9WIZYs.jpg)


Flat black paint and decals hide lots of welding spatter and sloppy work! You will note that I am using a lot of both elements here
(http://i.imgur.com/bS29RmW.jpg)

OK, good, those need to sun themselves for some time to bake on that John Deere paint/gun lube stuff.
Next on to the front (Oil) filter unit.
I used 3.5" for the fuel filters. The oil filters are a whole different animal. The smaller filter takes 4" Steel tubing and the large main filter takes 5" tubing. Luckily, I had both laying around so with some measuring and cutting I had my next two parts.
I decided to use the band clamp technique for the smaller tube, but wanted to up my game for that big 2-quart main filter. I ended up cutting the 5" cylinder along it's long axis and using bolts welded to either side of the cut to draw the segments back together forming the clamping pressure I needed.
(http://i.imgur.com/it1D23w.jpg)
(http://i.imgur.com/io2dHxW.jpg)
(http://i.imgur.com/ZBQ4ZlH.jpg)
(http://i.imgur.com/Rf5vPSP.jpg)

The smaller oil filter got the same treatment as the fuel filters
(http://i.imgur.com/Kce0saq.jpg)

I bolted the biggin' onto the biggin' and the smaller one was clamped onto the, well, smaller filter.

I created two more larger nut plates for addition of a future skid plate and tack welded it in place, then removed it and finish welded the assembly
(http://i.imgur.com/tKdhaNa.jpg)
(http://i.imgur.com/26hIfXP.jpg)

I applied more paint/gun lube to the new creation.
Here's both filter shield units resting happinl on what has now become my spare painting table
(http://i.imgur.com/4n8ffUr.jpg)
(http://i.imgur.com/4n8ffUr.jpg)
(http://i.imgur.com/cf8wHdQ.jpg)
(http://i.imgur.com/iTNxKRR.jpg)



Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 04, 2014, 09:26:59 PM
With the addition of the band clamps, installation was a snap (that's fast and easy)
As promised I applied a decal over one of the sloppy areas!
(http://i.imgur.com/FE6AuAa.jpg)
(http://i.imgur.com/VbtQjTA.jpg)

Ditto on the oil filter shielding and just like that I'm all done...happy me!
(http://i.imgur.com/KmnHRMG.jpg)
(http://i.imgur.com/5i8Vljk.jpg)
(http://i.imgur.com/2hBlPEq.jpg)
(http://i.imgur.com/NSnlV3a.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 04, 2014, 09:40:38 PM
Quote:
Originally Posted by *******
"Your fabrication skills and used still amaze me! Damn nice job!"


Well Thanks!
seems the protection of all these diesel filters is just plain overlooked.
Do you think this is a decent enough solution to provide some basic protection?
I think some folks will be able to use this idea on their trucks if they want.

Quote:
Originally Posted by *******
"I think its a great idea! The only thing I would worry about is if something could get jammed between the filter and shield and the ground. U said u was considering a skid plate though so that should solve that."

Yessir, this shield as it is may be obsoleted in the future by a skid plate system. I may cover the bottom of the vehicle with plates, some of the bottom, critical areas...??? I haven't given that a great deal of thought yet, but I did want something under there for now just in case.
One thing I was considering was a steel frame mounted on the underside which held composite panels in place. THe goal being light weight while retaining strength and the ability to glide over debris such as junk strewn in the road or a rock field. I played with that idea in the past. THere are some dynamite plastics which are light and blue ox strong. They also are "slippery" so when the truck is crawing over a Nissan, the poor quality jap parts wouldn't hang up my truck but the plastic panels would allow me to slide over the junk.

Quote:
Originally Posted by ********
"I think its a great idea to have a full skid plate system. Light weight is the key in my opinion.

I will suggest something though. From my Experience with my quad. I have installed a full set of aluminum skid plates. Not the lightest but it has been extremely durable and lasted through what I've put it through! I know aluminum is a little soft though."

Aluminum comes in many different hardnesses, check it out. Most automotive stuff would be softer grades because of cost and ease of forming.

HDPE (High density Polyurethane) sheet in 1/2" thickness has an impact resistance of 120 lbs/inch! So as you roll over the A-pillar of a Hyundai, naw forget that, iKorean junk will fold up under any pressure. As you roll over a newer (not rusted through yet which will be hard to find) Korean SUV roof pillar, the force of that structure crushing should easily be accommodated by the plastic HDPE sheet.


Posted by Armalite:

Quote:
Originally Posted by flyin6
".......HDPE (High density Polyurethane) sheet in 1/2" thickness has an impact resistence of 120 lbs/inch!...."

Now you're thinking. That's some pretty bad stuff. What we use to cover the bottoms of our bowfishing boats. Glide over any stump, log, or beaver dam in the lake. Never had it puncture before either.


Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 04, 2014, 09:41:08 PM
You know, I was thinkin (mispelled on purpose) which is not a normal or safe activity for me sometimes, (most of the time lately??)
This is supposed to be a build thread. Heck I even named it my build thread. But it is a bunch of things. We get to Faith, traction devices, guns, lift kits, patriotism, more gun stuff, survival, young guy counselling, military and combat, the book thing, my girls and boys, fuel additives, philosophy, and a host of other things.
Maybe I should rename all of this. Call it the Don show. Not because I want anyone to know or remember my name, heck every third guy in America is named Don. No we should call it the Don show simply because I probably won't forget my own name and then the title won't be misleading any longer. What did Mr. "T" say. "Pity the fool" well I do pity the fool who spends what, a week, reading this thread thinking it is a build thread only to have gone down so many side streets that it could actually develop symptoms of early mental illness. Of course, one could logically argue that anyone who followed all this, for this long, might actually suffer from some mental disorder.
You know what, all that was a dumb idea, forget it, The Don show, what was I thinking?
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 04, 2014, 09:44:06 PM
Got a bit of a hangup here
I keep wondering if the topper thing I am building is too little.
It doesn't provide much space if you have to do much more than overnight in it which I have already done. Not enough room for very much at all
I almost have to expand outward and I could do that in a variety of ways.
I could relook the design and perhaps do something with that to gain some room. A flip-Pac tent thing would do something there, but just not be that durable. I could perhaps buy an surplus Army trailer, the larger one and build that out with a cooking area, tent of some form of a habitat and develop the supported site concept with that. With an articulating reciever hitch it could be all terrain.
Another option would be to just buy a fold down truck camper unit that cranks up to the full height living position when stationary, but provides a lower CG and drag profile while on the move. I could of course modify that to fit my exact needs.
That's why I have been a little slow in the topper build out at the moment.
Here's some pics of what I am talking about, which are of the Palamino camper system:
(http://i.imgur.com/mmkINPM.jpg)
(http://i.imgur.com/CGxEkR6.jpg)

Quote:
Originally Posted by GreatLakeOffRoad (stlaser)
"If you haven't go look at one in person, I doubt you'll like the quality of them. Not very durable, nor will they take the abuse you intend to put it thru possibly........ (note: I live near and supply the RV industry of the world aka Elkhart, IN. with steel parts) just my 2 cents"

Coming from you, that's all I need to hear!
I trust your judgement so I'll rule that one out...But what if Dr. Don did his stuff to one?
OK, Shawn, got anywhere else I should look? How about the Alaskan? That's supposed to be a sturdy camper?? .......

.........General comment here:
I am not giving up on the tactical Topper concept, just revisiting the concept before I get any deeper in the idea with bucks. As I move forward on that project, the cost is going to go up rapidly so this is a good point to see what I have so far, and where I could divert to.

OK, onward and upward!

Posted by Armalite:
Don, if I can be honest here for just a sec. I wanna give you a couple of my thoughts, and that's all they are. Just my opinions.

For anyone else here, just wanna clear up something first. Don and I have had numerous conversations, on this forum and in private. We are just about on the same page, so I dont want anyone thinking I'm being negative towards Don. He knows exactly where I'm coming from...

You need to ultimately decide where you want this topper to get you, and what purpose it needs to serve for you in the end. For an overnight stay, or even a few, it will serve it's purpose just fine. If you're looking for an extended stay, I feel that you're not going to get the results you want. That's a small, cramped space. I got in the back of my truck and walked around today, trying to see what kind of space you're dealing with in the back of that truck. It's CLOSE quarters for sure. Especially if you get ready to add a fridge, sleeping arrangements, generator, ect. Now, don't get me wrong. I know you can figure out mounting solutions and ways to make the small space work. But heck man, you're a big guy. You need more than a 6' bed. I'm not downing your concept in anyway. It's the most inventive feature i've ever had the pleasure of seeing brought together. Heck, that's why I'm trying to send you whatever I can that will help, because I wanna see that sucker work. It's truly remarkable. I just feel, personally, that this is a one of a kind concept, that will serve it's purpose for grabbing a cat nap, or catching a few hours rest, then moving on. It will not serve as a weekly, or monthly, overnight camp out. You will run out of room. I feel you will get frustrated with the lack of, well, everything. Space, equipment, ect. I mean, you're only going to be able to fit so much, then that's it. No more room.

Again, there are two sides to every coin. Same with this situation. You need to figure out what your end goal is. And shoot for it. I was given some very good advice the other day. It fit my personality perfectly, and it will fit yours as well.

"Don't make fun of those that dream, because those that don't dream, dont have anything."

Get after it big Don...



Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 04, 2014, 09:59:52 PM
Gents,
Just ordered some parts to keep all this going.
Read along but pay attention to the last item.
1. Just ordered the 4" LML Deaver springs to get rid of that lift block I mentioned a couple thousand pages ago.
2. Ordered the turbo resonator block off plate from Alligator. The idea is to clean up the under hood area some more in prep for something, actually a couple of things which is coming soon
3. Since I desperately need an EGT and boost, I ordered the Edge CTS monitor with the dash mount kit and the rest of the stuff to make that all work.
4. Finally, as of tomorrow there will be an EGR block off kit coming!!!!!!!! Yippee!!!!!!!!
Yep, Alligator has them finally. Give Holton Guyton there a yell and he'll get one for you as well!
I guess there was a reason I was waiting to install that Alligator down pipe! I would have had to remove it anyway to pull off the EGR junk!

Quote:
Originally Posted by Armalite
"Why did you decide to go with the edge cts? Thought you were more of a gauges type guy? Just curious".

You know, I was thinking of the multi tasking ability of that unit. If it takes video input, then a simple rotary switch could use the same screen to select from multiple cameras, perhaps even a remote wireless one!
I flew aircraft with steam gages and with tv's. Have to admit I like the technology mo-better......

......I'll know more PDQ on this EGR thing.
Talked to Holton just now. He is sending me a complete kit with which I will remove both coolers, reroute the coolant lines, and will include a new up-pipe to make the job easier??? Holton wants everyone to see what comes with the whole kit so that's why I'll be doing the complete removal.

On the Deavers, here's what we just found out:
The LML springs are in fact not available. They are, however, in testing at this very moment. That is a complex process as I have been informed and could be nearing completion or mid stream. I do not know that. I was told I could expect an ETA of my springs by mid week. Now that word might be that the springs will be available in 6 months, or it might be that they are enroute. I am at their will at the moment, and that's OK
So everyone is up to date on this next phase of project "who knows what's happening!"
Stay tuned for updates!


 
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 04, 2014, 10:05:09 PM
OK boys and girls, time to fire up the mods again and stoke the fires a little more.
This time I will install an Edge CTS with an EGT probe.
Overall this is a pretty simple task by comparision to much of the other stuff I have done as of late.
It is a bit tedious when you're routing the cables and drilling the exhaust manifold. But, just lean into it and you'll get it done just fine.

I decided to install the dash pod to make the installation more of a permanent addition. Here is what I purchased, again from Alligator with the help of Holton.
(http://i.imgur.com/o5rRClW.jpg)
(http://i.imgur.com/ez0EsyE.jpg)
(http://i.imgur.com/k5C44is.jpg)
(http://i.imgur.com/SljD5o4.jpg)

The gage pod came in a natural gray color which I painted with my favorite John Deere Blitz black a day or two ago.
The first step is to gain access to the right side of the engine with the removal of the right fender splash guard
(http://i.imgur.com/Je1HVCp.jpg)

All nice and stock for now, but that my friends will change!

I selected a spot, then center punched and drilled it with a 5/16" bit
(http://i.imgur.com/ZlhFFXS.jpg)
(http://i.imgur.com/P1lMYDz.jpg)

The manifold is a pretty thin wall casting which was easy to tap with a 1/8" tapered pipe thread tap

The fitting was installed and tightened, but not over tightened.
(http://i.imgur.com/6trFNHy.jpg)

Next the EGT bi-metal probe was inserted carefully with the aid of some spray lubricant
(http://i.imgur.com/w9sanen.jpg)
(http://i.imgur.com/X16lEVr.jpg)

Having read of the mysterious sound created by the vibrating cable I isolated that sucker with a clever trick one of my crew chiefs taught me many moons ago.
First you cut a short section of hose. 3/8" fuel line works fine.
You then wrap a zip tie around the stationary mount object and thread the two ends through the hose section. Now simply zip the loose ends around your cable and voila' (French word again) you have an isolation mount!
Here's a quick demo of what I did on the truck:
(http://i.imgur.com/XQf1zbi.jpg)
(http://i.imgur.com/ZMYvNb6.jpg)
(http://i.imgur.com/sA83wJR.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 06, 2014, 09:37:36 PM
And here it is on the truck:
(http://i.imgur.com/2XFZVK0.jpg)
(http://i.imgur.com/nMCHzvL.jpg)

Next I did something else and here's a picture:
(http://i.imgur.com/PqlVSY8.jpg)

 routed the cable through the rubber gasket surrounding the steering corner at the north west position.
That cable was secured under the dash and up through the side of the dash with the fuse box access removed.
THen it was time to fit the pod to the dash. I used tape to mark it's final resting place and where the tabs would be glued in place.
(http://i.imgur.com/k2Rbn5Z.jpg)

With the dash washed several times with prep-sol and alcohol, it was time to permanize the pod. (That's Don speak, means stick the thing on for good)
(http://i.imgur.com/DdjPiDA.jpg)

With the pod in place I stuck the CTS in for a test fit
So far, so good!
(http://i.imgur.com/MzYKnoh.jpg)

Rutt-Row,
No pic of the CTS, what happened to the darned thing?
Well, here's another pic, stare at it while I go figure out what happened to the other pic.
(http://i.imgur.com/X2vlV5z.jpg)

OK, couldn't find it must have deleted it. Funny, I did that without being under the influence of coffee!
OK, so here it is going together for the final time:
(http://i.imgur.com/X2vlV5z.jpg)


And here's the thing with a stream of really fast excited electrons (electricity) being applied.
We pilots can appreciate all the pretty colors. Now I have more stuff to stare at and distract me from the task at hand, just like flying!
(http://i.imgur.com/u8lXAeV.jpg)
(http://i.imgur.com/LLRNHVu.jpg)
(http://i.imgur.com/cycInys.jpg)
(http://i.imgur.com/KqdnIrX.jpg)

Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 06, 2014, 09:45:17 PM
Quote:
Originally Posted by G****** D****
"Thought of something you might like and it is not an expensive mod. I added all of the Retro Solutions LED lights for my interior (front map lights and dome lights) as well as the 5 watt reverse lights. It's like having your headlights on in reverse. I can see backing up my driveway at night and have 155 window tint.

Just a thought for you. "

I'll look into it!
Danka! ......

Quote:
Originally Posted by Armalite
"The back up lights are a definite help over the factory lights. Love mine. I'm not so sure you will want the interior lights though. I have them and they are crazy bright. Wont go well with the NVG's you're planning on running." 


Well, I won't use nods all the time, just when I need them.
Wierd thing about those devices, They can't see blue green light. If those bulbs could be tuned to that frequency, then on a dimmer they would give low illumination to the areas you wanted to see looking under the nods, and not reflect off the windshield at all.
Now, conversly even a tiny bit of red light will wipe you out. THat light will put such a glare on the windshield that you can't see anything!

.......Oh, and an update on pieces parts:
Holton out at Alligator has shipped the EGR delete kit, it's enroute.
I will be eliminating the coolers, up-pipe, EGR motor and who knows what else. THat should clean up things nicely making it more ready for the twins...there I go day dreaming again.
I am also going to replace that downpipe, so everyone can anticipate more accident prone injury inducing parts changing for the better. I think I'll set aside 2 days for that one!
Finally, the initial data I am getting from the Edge CTS is about what I expected except that the EGT's aren't as high as I suspected. Today under a short full throttle 3 second stab, the motor hit 922F and 20 something psi boost. It all seems low, but I'm not sure the thing is actually reading the probe I installed.
I think I will follow the advice of several members now and make double sure my device is updated on the computer while linked to the fusion software.


.......I went to the site and looked at the back up lights. I can't find them. If I'm correct I need a replacement for a 3047 bulb but I'm not finding that number for the B/U's
I'm betting I have that number wrong, what part number or factory bulb are you showing? .....

.......Quote:
Originally Posted by G****** D****** 
"Bulb # 3156 is what you will need. Here is a link to the thread. It has the number in the first post. There is also a link to the Sylvania site in this thread that talks about part numbers for other bulbs. I haven't looked, but wouldn't be surprised at all if you could get different colored interior lights.

My map lights and dome lights are 212-2 and I got the 6 led version instead of the the 3. Works great and very clean light. I also put the 194 license plate bulbs in. That may not be the effect you are going for though. I just figured when I replaced mine, I would do them all and get the cleanest light I could. Love it on mine, but they are bright.

Super Bright LED Reverse Bulbs! "

Thanks for the info!



Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 06, 2014, 09:59:36 PM
Thanks to you for the idea, and to you and Ashley for the links. (He sent me links to everything as well!)

OK, so I ordered the LED back up bulbs with the radial illumination option.
I also ordered the 6 LED dome light
Additionally I ordered the low beam 55w HID replacement headlights and the wiring harness to bring voltage directly from the battery and skip the headlight harness.
Everything pictured increases vision, can you tell which one is different?
Should be a nice little one day mod
(http://i.imgur.com/VRWvXmU.jpg)
(http://i.imgur.com/Xei8RXL.jpg)
(http://i.imgur.com/UOHyKdv.jpg)
(http://i.imgur.com/8TRKtPo.jpg)
(http://i.imgur.com/emRSxf1.jpg)



Quote:
Originally Posted by G*******D******
"If you decide to change out the map light festoons, it will be the same bulb as well. Look forward to hearing how you like the HID lights. I have been curious on those as well. I thought about the 6000K for my low beams only. However I was looking at the 35 watt kits. What did you like about the 55 watt versus the 35 watt? I worried that it may melt the housing. I haven't ordered mine yet, as I have a few other things on the table first I must get."


I retrofitted 35w HIDs to an earlier truck. 55W is a new technology and mo-better. There is no significant temp increase going to HID's over Halogens. In fact, the halogens put out a lot more (volume of) heat. HID's are using less amperage so other than out right positioning, I can not see how they could add any heat, in fact I believe the opposite is actually true.

The only advantage I see to using the 35W kit is less money

Those dome light kits include 2 bulbs, so I may very well stick one of the bulbs into my map light. I will use them in the back end when ever I decide what I am going to put back there (camper shell).

Quote:
Originally Posted by r********** 
"Don, i'm looking forward to what you think of having the HID's in a stock housing. I have been holding off just because i don't want to be blinding people all the time and i usually don't need the extra light. Although it would be nice everyonce in awhile lol "

Admittedly, it is of some concern to me, but most people these days drive jap or Korean cars, so I don't feel so bad about it after all.
Funny, but even now I get the folks approaching me flipping on their high beams while I'm cruising on my lows, so the practical difference approaches zero!


Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 06, 2014, 10:05:22 PM
Man, you guys were having a party on my thread last night! Sorry I missed it. As for the sleep, plenty of time to do that when you're dead. As for the tallieban, well, in a crazy way I'd like to be out there chasing them across those hills. Mostly though I just turned a lot of jet gas into noise and wind. Now I do miss just flying along and for no reason at all, shouldering the M4 and squeezing off a few bursts just to see if I could hit a rock or something doing 130 knots at 1000 feet. Funny but at that speed and altitude you have to aim something like 20 feet or more behind your target, not in front of it as with bird hunting. Did I ever tell you guys about the day I was messing with a gunner over this lake in Iraq?

Funny as all get out.
He was new, his first flight with this battle hardened group of airborne warriors. Well north of Baghdad on this training mission we threw a blue 5 gallon plastic drum into the water to serve as a target. flying along at 300 feet at about 60 knots in a slow pass by the target I watched him squeeze off a few shots which were hitting past the target a few feet.
On the next pass the rounds were on target...he had figured out that he needed to aim behind the target since it was stationary and we were moving.
So on the next turn I increased the speed to around 90. Again I watched as the rounds splashed past the drum again. I knew I had him when he muttered a curse word over the intercom and I saw him sling the empty magazine out into space!
The next run he had made the adjustment and again the rounds were on target...cool, and I knew I had a big fish on the line, time for some fun.
The next run I slowly crept up to about 105 knots and increased my altitude to about 500 feet. Once again the bullets splashed a good 5-10 feet past the target and this time I get a good "" over the intercom. That's when I start piping in, "Yo dude, what's up, you're not consistient, now let's see some rounds on target!" I get a "Sure, I'm trying, I don't understand what's happening!" I reply, "Well I do, you claim you were once a good gun, but today you suck, that's what I understand!" I have to cover my mic so he can't hear me laughing!
So on the next run I approach at 90 knots at about 300 feet and as he is shooting I bump to 500 feet and slow to about 60 knots. Watching his shot group, I'd say the only safe spot down there was in the immediate vicinity of the drum! He got mad and threw his empty mag down at the drum. I quickly interjected, "Hmmm, best shot so far and you didn't use your rifle."
This was when the other pilot figured out what I was doing and started in as well. "You know don, with this guy, maybe we should just issue him a box of rocks, seems he's better with them than the weapon!" THen I ask a question." Say dude, you were in the military, right?" That was answered with a deafening silence.
THat day was day one of new gunner try out. Most of these guys were ex-rangers, SF and Seals. THey knew their stuff. Another Night Stalker was flying in the left seat with me, and these guys had worked with us in the green machine. They wouldn't dare say anything to us, knowing our history (Which is somewhat fable, somewhat folk lore, and somewhat true).
You see, the thing we had to do is to see which one of these knuckleheads would be able to seamlessly integrate into the flight crew and which ones were Rambo's. THe latter does not work. So in Special Operations fashion, we were psychologically loading him up and seeing if he would give up.
THis one was a bit angry but he never gave up. Later on I and others would spend hours with him teaching him how to drive tacks from 300 feet while in a break over a target, but for now, I just wanted to see if I wanted to go "downtown" with this guy.
THe next maneuver was a killer. We would fly directly over the target at 1,500 feet then do a crazy sprilling dive over and around it. We would purposly take the aircraft way out of trim so that the wind blast would be right in his face instead of streamlining past. The bank angle was crazy, so I had to fly while looking over my shoulder so that he wouldn't perforate my rotor blades. As we entered this death spiril I heard the guy open up with controlled single shots. I steepened the dive into something I'm sure he had never seen and frankly only a very few helicopters could safely do. But in our mighty little bird, well, just move the stick. If you can stand it, so can the machine. At the bottom after a couple sickening turns, he had reloaded and as he started a mag dump, I did a hard pull out and the rotor blades bit hard. The "G's" built but he kept shooting. Then his stomach also did a dump. Admist the fierse flapping of those poor abused blades, the screaming engine, the crushing push in the seat and the snap roll to the opposite side this guy was puking all over himself, his weapon, and my aircraft and still pouring out fire on that blue drum.
Did we hire him? Darn right we did. When we came back, I landed at Liberty LZ right next to the US embassy near a garden hose. I told him to wash himself and the aircraft off, slapped him on the back and welcomed him to our crew. I wasn't the guy doing the hiring, but after all that, I knew this gunner was a keeper.
BTW, that rant was all coffee inspired...On this Yuban kick lately. THat stuff gets ya goin'
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 06, 2014, 10:13:51 PM
 have a quickie little project to post up before the useless and irrevalent chatter proceeds!
As we all know I am preparing to perform an EGR delete and down pipe installation on the tactical chevy, which now and forever more will be known as the Survival based tactical urban area disturbance avoidance vehicle, or simply as, "My truck."
Holton supplied me with a simple device used to block off the hole when one turns that turbo resonator into a frisbee. I have just discovered the thing is not aerodynamically efficient as it flies in a crooked parabolic flight path over a relatively short distance although a great amount of power has been used. In that sense it would be much like an Army Black Hawk.
Anyway, here is the little gem of a part in all it's glory:
(http://i.imgur.com/i8jPK72.jpg)

And the part it will soon replace:
(http://i.imgur.com/E9gV53q.jpg)
(http://i.imgur.com/VD6SDiy.jpg)

Three bolts later, 2-10mm and one 13mm and this is what you're looking at:
(http://i.imgur.com/6Lqw9MJ.jpg)
(http://i.imgur.com/PqCMl5J.jpg)

The block off is a high quality machined aluminum piece which is held securely by two allen head screws.
This one part removes the transonic inversion pulse which immediately adds 26 horsepower and 55 ft/lbs and 1.5 mpg. It removes approximately 86 pounds off the front axle which now allows the truck to corner in excess of 1 G!
Well, actually none of the second paragraph is true, but don't you wish it was!
What it does do is essentially nothing except to get rid of that boxy top hat thing and make it easier for me to take it all apart in the near future. OK, on to the next thing....
(http://i.imgur.com/ownJvF0.jpg)
(http://i.imgur.com/hffGe9O.jpg)

Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 06, 2014, 10:20:41 PM
Sticking the HID's in at the moment...
Darned company didn't send me any instructions, have to hunt the net for some. Who knows, might have a good fire before the night's over!......

.....Success!
No fires, smoke, leaks, minor loss of blood and skin, but all in all the HID's fired up instantly!
OK so for today we will discuss the installation of 55W high performance super duper HID headlight replacement. Then after all that you'll see LED tail lights and dome lights going in.
I ordered all of this stuff on some of your recomendations, and I'd have to say, am quite pleased with the cost, quality, bang for the buck, and ease of installation.
Here's what I purchased from RetroLighting.com:
(http://i.imgur.com/IJI20Bx.jpg)
(http://i.imgur.com/PI3aZD8.jpg)

Unknowingly, I purchased a wiring harness without realizing one already came supplied with the 55W HID's. THe harness allows you to pull voltage directly from the batteries.
I decided to remove the radiator bulkhead cover and the front grill. The use of these 90 degree needle nose makes the front grill removal a snap!
(http://i.imgur.com/GaEy6pX.jpg)
(http://i.imgur.com/ydiQyNO.jpg)

The headlight assemblies are held in place with 3-10mm bolts shown here:
(http://i.imgur.com/glLe7Fv.jpg)
(http://i.imgur.com/LKRJtwh.jpg)
(http://i.imgur.com/dTT0K5m.jpg)

With the headlight assembly loose, wiggle it forward and out, then remove the top lamp which is the low beam, assuming that is the bulb you are replacing.
The HID bulb is taller and thinner and enclosed within a plastic shipping container.
(http://i.imgur.com/cydZRzJ.jpg)
(http://i.imgur.com/KVA6yc2.jpg)
(http://i.imgur.com/HNkQg7q.jpg)

The HID bulb is simply pushed and turned back into place. Next you will have to start hooking up the harness and the ballast after it is mounted.
(http://i.imgur.com/3AEj2gJ.jpg)
(http://i.imgur.com/JfpWZKh.jpg)
(http://i.imgur.com/lPWGomf.jpg)

I mounted the ballasts to the core support gussets at the north east and north west corners. I secured them with a couple of stainless screws and nylon lock nuts .
(http://i.imgur.com/GEwb7vi.jpg)
(http://i.imgur.com/s5n6mUR.jpg)

With the ballasts securely mounted, I drilled another hole, then sanded the area around it and bolted my ground wire to the stud. I did that for each ballast. There are a few connections to make and they are not idiot proof, so pay attention. I got lucky and got it right on the first attempt. ONce everything is plugged together, I taped the exposed unused plug, zip tied everything securely and zip tied the right headlight harness under the radiator guard as shown.
(http://i.imgur.com/2mF7zLO.jpg)
(http://i.imgur.com/FfAahMv.jpg)

A simple turn of the headlight knob produced these results
These are HID's in the 6000K heat range which produces a cool white light with just a hint of blue, much the same as my driving lights.
(http://i.imgur.com/SxwgACV.jpg)
(http://i.imgur.com/G5BOTpW.jpg)
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 06, 2014, 10:25:12 PM
All righty, on to the next project. This is the simple installation of interior 6 bulb LED dome/map lights.
Here's what they look like:
(http://i.imgur.com/augVlso.jpg)
(http://i.imgur.com/eB4Gd2e.jpg)

The cloth is my old flight suit left sleeve full of bullet holes!
Well, not really, it's a paper shop towel!
The lens pry's out from the bottom, lower point.
(http://i.imgur.com/70fTZlE.jpg)
(http://i.imgur.com/mXUad8H.jpg)

Taking care not to touch to "bulb" after you take the stockers out and throw them at your dog, simply press in the new LED's and replace the lens, that's it...Super simple
(http://i.imgur.com/2vmACno.jpg)
(http://i.imgur.com/txUuDoH.jpg)
(http://i.imgur.com/G8XX7LX.jpg)


Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 06, 2014, 10:32:22 PM
OK, now for the back up lights.
We will be installing LED's with both rear focusing light and radial illumination into the stock location.
Here's the new LED's:
(http://i.imgur.com/ZTyuCQ7.jpg)

Two screws are all that hold the tail light lens assembly in place. Remove them, then with the lens balanced precariously on the lip, pull out the stock bulb.
(http://i.imgur.com/Jzereqp.jpg)
(http://i.imgur.com/EMDeDIJ.jpg)
(http://i.imgur.com/U5QkaSC.jpg)

Old and new side by side
(http://i.imgur.com/hxoVr8I.jpg)

Now reverse the procedure
(http://i.imgur.com/OGUVlDq.jpg)
(http://i.imgur.com/efXPjLj.jpg)

And here you go. a mini rear defense photon torpedo!
(http://i.imgur.com/HktNLRh.jpg)
(http://i.imgur.com/De0ufYO.jpg)

....Just finished my night drive. THise 55W HIDs are amazing. 6000K is the perfect temp as well. Very clear clean crisp white light. Good cutoff as well. An approaching driver will have to get pretty close, probably less than 50 feet before the light might cause problems. No one at all flashed their lights at me, and oddly enough I was getting flashed when driving with my stock halogens!
The back up lights are many times more light output than what I had based on overall scene illumination. Those are the overall best bargain of the day for less than $16 and that much extra light.
The interior dome light is overkill. Definitely no areas not brightly lit when those map lights are on.
All in all, this was a great mod. I think I'll go farther and install the LED's in the bed illumination light and maybe add some to the underhood and in some other places....

 Quote:
Originally Posted by f*******
"I'm assuming you mean Retro-Solutions.net, as retrolighting.com isn't a site?

Also, I'm searching what I presume to be the place you got these from. I'm guessing either you got a deal or swapped the price of the festoon bulbs and the backup LEDs, because the listed price is $40, not $16. What am I missing? For $16, it's a no-brainer."

Wow, I got that one all turned around!
You're correct on just about everything
The company is Retro solutions
The back up bulbs are $39.99
The dome lights are $11.99

I Stand corrected!

Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 06, 2014, 10:34:10 PM
Quote:
Originally Posted by Armalite 
"Don, few questions...

Why did you not go ahead and swap out the high beams to HID as well?

What about the turn lamps also? Did they offer those?

After all the work of tearing out the front end and getting in there, wouldnt it be easier to just do a full replacement? "

Good questions Ashley, I'll ask Don and see if he is here today.
Ah, yup, I'm here!
OK about the high beams: The HID's broadcast a yellowish light. I already have HID driving lights wired into that same circut. So, in my truck, when I switch up to highs, I actually have 4 lights burning, two halogen with the yellowish tint, and two HID's in cool white to slightly blue. A scene is best illuminated by a multitude of colors blended together as in "natural sunlight". So by retaining the halogens I get some yellow , and white, and with the HID's, white to blue. Different objects in the observable scene react differently to different colors of light so I actually get to see a tad bit more of what I'm looking at.

The turn signals are offered in LED as well, but I see no purpose. THey do not provide light to illuminate the scene, simply a blinking light source to signal your intentions. THe amperage draw of the stock bulb is intermittient, and my electrical circuts are not taxed so no advantage there. Finally LED's would cost a lot and again not make any difference as the stock turn signals show up fine. If you were working with something like a 67 VW beetle with 2" tail lamp lenses, the something much brighter would perhaps be worth it, but not with our well designed trucks.
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 06, 2014, 10:36:49 PM
I actually did another install yesterday, given the ease of the lights. I'll post that one up in a day or so.
I built some cool work platforms that hug the tires of the truck and have you standing about beltline to top of fender. I built them with a 15 degree splayed leg setup so they would be super stable. I figure with the way I'm banging myself up lately, I needed to incorporate a little safety into the follow on projects. We seem to be digging deeper and deeper into this build. Not long before I'll be doing stuff inside the frame at this rate! You know, come to think of it, inside the frame would be a good place to store some more fuel...hmmm...


Quote:
Originally Posted by Higher Caliber
"What are your plans for mounting your spare or spare*s*?"


That is going to be one cool project!
It all hinges on the Road Armor bumper build.
I have been in contact with the folks down there and our bumper is actually going to be built today for the first time. Yep, today. It won't be long before I have it and bolt it up.
They know what I plan to do with it and are good with it.
I am going to build a swing away rear tire carrier. I plan to mount the spare up high along with a fuel can and water can rack. I am going to support all that weight on that excellent road armor piece. Again, we have discussed how much weight I am hanging off the bumper and from where and the engineer there feels it will be GTG. I will probably get a tiny bit anal and reinforce it even more.
Now There is a problem with the carrier.
I don't know exactly where to position it.
You see, if I add the tactical topper project onto the truck, I can build it in close to the tailgate.
However if I decide to add a larger camper, the collapsible roof type, then I might have to space it out aft a tad bit to accomodate. I am still considering plans to upgrade to a unit where I could go anywhere off grid for awhile and hunker down while all of you figure out who survives and who goes on to, well, just goes on!
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 08, 2014, 10:25:06 PM
Quote:
Originally Posted by Higher Caliber 
........"Now I need to see this mod that I inspired Don, That way I can rip mine out and re-do it the right way! "

All right I'll post it up
Inspired by the good thinking of Mr. Higher Caliber, I had been carrying the flashlight and extra mag in the console. He, however had a great idea, so I just moved the location somewhat and added it as well. So with full credit going to it's rightful owner and acknowledging that I DID SHAMELESSLY COPY HIS IDEA, here goes:

Using some old duty magazine holders, I cut off the tops and drilled 6 holes into the backing, then installed 6 sheet metal screws
(http://i.imgur.com/Oyzh1fo.jpg)

I'm using the exact same concept because it is a good one and we both apparently roll the same way. I will be keeping a spare 15 shot Glock 19 magazine and a surefire flashlight in this holder
(http://i.imgur.com/dk6vHJc.jpg)

I differ from the earlier installation only in location and with regard to the type of pouch. Not sure but The one I used may be an "Uncle MIke" double glock mag belt pouch. I never wore all that crap on a belt, mine was always MOLLEE installed in my vest somewhere so this sucker survived in good shape from the Baghdad and Kandahar days.
Here's where it will be going:
(http://i.imgur.com/qqnL3Zk.jpg)

Actually after I thought about it some It would work better if I angled it toward me, so that is what I ended up doing.
TO install the pouch(s), I first removed the plastic trim piece from under the console lid:
(http://i.imgur.com/T4Afogy.jpg)

Then by laying the plastic piece on the bench and press firmly, I screwed in the 6 sheet metal screws. Afterward, using forces approximating subducting continents, I cut off the screws nearly flush with wire cutters.
(http://i.imgur.com/YxrNWL7.jpg)
(http://i.imgur.com/KcHePGH.jpg)

When I closed the lid, I realized there is a reason we measure twice and cut once. The pouch interfered a little bit at one corner with the console, so I trimmed it to fit and reinstalled the trim to the console lid.
(http://i.imgur.com/b0fh5vt.jpg)
(http://i.imgur.com/iTOXqYu.jpg)

Nothing really to see here, other than showing that the lid actually closes once again
(http://i.imgur.com/h4luwZU.jpg)


Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 08, 2014, 10:29:17 PM
Have a lot os stuff on the burner at the moment.
Thinking about the build, this group, and still writing the second book. Wrote all morning...fingers are putty!
Anyone want to read some of the junk from book #2?

Quote:
Originally Posted by G*****D******
"Always up for some of your writing. Have enjoyed everything you have written so far."

OK, here's a little something.
Happened many moons ago...
If you read my book, you know it jumps around a bunch but is mostly about stuff that happens in the last two wars.
One of my publishers asked me to write a bio sort of thing. Keeping it all in order, so that's what book #2 is all about. I write something for it almost every day. THis is from today:

The training to become a night stalker was pretty intense. There was PT all the time, running then weight lifting, more running and some more weight lifting. Back in those days there wasn?t a formal system of training yet so a new guy like me just reported to the hangar and started training with the instructor pilots. I worked with some good ones. Al Wilson wasn?t much older than me, but had a lot of experience in the Chinook which I had only just learned how to fly. Then there was Eddie Hill a slow talking Louisiana boy who wasn?t a boy at all. Finally there was John who was our senior instructor pilot. He was all business and operated from the premise that with everything we do we need to strive for perfection. Landing a foot right of centerline on an emergency running landing on a runway was not satisfactory, on center was. I don?t think there was much distance between satisfactory and perfect with John. The thing was, that on any day, he could back it up with performance. He wasn?t one who couldn?t walk the walk, no sir, he set the pace.
I would alternate between the IP?s as they flew me nightly in our modified Chinooks, teaching me mission tasks. You see training in the Army is broken down into levels. Obviously the first step would be the actual aircraft qualification which in most cases took place at Ft. Rucker, Alabama. That?s where I had learned to fly those leaky, starving for love orange paneled Chinooks. Once I had qualified but not yet mastered the tasks they required of me, I was released to my next unit. The Night stalkers would first assess my abilities to see where I fell in the proficiency ladder. In my case all that was pre determined as I had been a former Aeroscout pilot and knew nothing of the Chinook or how to operate it. Additionally, I had never flown the Chinook in a regular Army unit like the 101st Airborne for example, to get some time under my belt with the airframe. Nope, I was skipping college and going straight for my masters directly from high school. I didn?t only have to learn to become a proficient Chinook pilot hauling sling loads and flying assaults, but I had to learn special mission tasks as well.
That?s where the rubber meets the road with the 160th. Everything they do is special. Almost nothing is normal. Whereas my newly qualified Chinook pilot brothers in the 101st were honing their skills hooking up sling loads in dusty LZ?s, I was learning aft wheel landings on buildings, and fast rope approaches and a host of other things. All of that required quite a bit of practice, hence all the flight training I was currently receiving.
On this fateful night I would be flying with Eddie Hill. It would be a good flight. Eddie almost never became flustered when a newbie like me fudged up something. He would just show you the error of your ways and send you along to do it again. We were going out to a place called ?Golden Eagle? which was a cleared off area on the south side of Fort Campbell. He wanted me to practice hooking up and carrying heavy sling loads and there was a doozey sitting there. The 101st had rigged up an old M114 armored personnel carrier with cables which a crew in training could hook onto and fly around with. It was a big load which was quite heavy. At that particular point in time our unit was flying an odd assortment of Chinooks. The Army had cobbled together several modified CH-47C Chinooks, but added all sorts of miss-matched parts to improve performance, albeit at the cost of longevity. Our company of around 16 Chinooks was constantly wearing out airframes and requiring new aircraft. As a consequence, we had quite a few of the newer unmodified CH-47D?s and some of those were also being modified in various places around the country while we tried to figure out what a heavy lift Special Operations helicopter was going to look like.
Eddie and I arrived at LZ Golden Eagle, landing beside the M114 which was sitting in a field of shoulder high weeds. Lowering the ramp, the flight engineer scrambled off to check out the load rigging and prepare it for us to lift. I busied myself with the various performance calculations to determine if we actually had the power to lift the load. The numbers came in close, but we could do it. We would only be in danger for a short time immediately after takeoff and prior to landing where we would not have single engine capability. All that meant was that if the engines so much as hiccupped during those times, myself, Eddie, or the crew chief watching the load would quickly create some very expensive air mail.
I briefed procedure to Eddie?s satisfaction and we hovered over the load for a short time while the crew hooked it up. This is a very nervous and high concentration time. The pilot is maneuvering a 50,000 pound aircraft which is effectively 100 feet long making very small movements in response to the crew chief?s directives. ?down two, right one, hold what you got, your drifting right, come back left two, hold your up, you?re centered over the load, hold your drift, hold position, clevis is in hand, clevis is on the hook, you are cleared to come up, bring it straight up fifteen, ten, five, four, three, two, one, slings coming tight, slings tight, bring it up ten.?
All of that is very intense. When the guys are calling that load they have a 100+ pound sling in their hands. They are hanging out of a hole in the belly and any sudden move in your part will immediately cause a heinous injury to them. Then after the load is all hooked up and as you bring it up, you can take a breath because they are out of harm?s way for the most part. When the slings come tight the Chinook magic starts to happen. That darned thing comes to life and shows the world why it is such a magnificent aircraft. Now you have 8 tons coming to bear on the airframe and those engines and rotor blades. A Chinook hovers at about 40% of its available power. The Hueys and scout helicopters hovered in the 80% range! This CH-47 was one powerful machine. Increasing power the engines started to roar as the gas producer section spun way up to produce all the extra power. Coming out of the back of those motors was a spectacle of surging hot gasses, fire, sparks, burned vegetation and small animal parts. Viewing it through the night vision goggles, it looks like a small crack had opened to the interior workings of the molten planet?s core.
The thing was that the aircraft could actually do it. We were hovering at some eighty feet not moving, just hovering with 16,000+ pounds of cargo hanging from our belly. H O O A H! that is a cool feeling! I did a takeoff check and pushed the cyclic forward. The giant beast tilted nose down and crept forward and almost instantly started to accelerate rapidly. In seconds I was a 70 knots indicated. We weren?t going to climb, but fly a low level route. So with the load flying maybe twenty feet above the trees, we left the cargo hook in the armed position just in case the engine quit or exploded as they sometimes do and we flew away across the reservation.
Had we been paying attention we might have noticed that the 101st was also playing that night. They were out on a FTX (field training exercise) in about the same place we were. At one point along our route they had also set up a headquarters section replete with all the stuff headquarters sections need, like communications. Now when you are sitting under a bunch of trees you can try to transmit through all those trees which doesn?t always work, or just stick up an antenna. This headquarters section being just like every other one that has ever existed chose option number two. At that time the Army was integrating a new quick erecting radio mast called a 292 (Two niner two) antenna. To make sure no aircraft flew into the thing they had affixed some green chem. Lights to the parts that stuck above the trees. The thing about green chem. Lights is that although they are very visible to the naked eye, they are completely invisible when viewed through Night Vision Goggles.
Some folks on the ground heard our mighty Chinook approaching so were looking up as you would expect when we smashed into the tower, raining tower parts all over the ground. From inside the aircraft I felt nothing at all. The flight engineer, a seasoned sergeant said over the intercom, ?I just saw sparks coming off the load.? ?Sparks, what?s up with that Eddie?? I moved my pinky over the cargo hook release switch not knowing what was going on. In his soothing southern voice, he said, ?It?s just the clevis moving around on the hook up points, happens all the time.? Eddie always had the right answer! As the ground fell away, I dove forward down a ravine as we continued on our training flight.
The rest of the night went pretty well. Eddie made me do several approaches and landings with the load, then pick it back up and accelerate back to forward flight. Satisfied that he had accomplished the training objectives, we set the load back into LZ Golden Eagle and flew back to the airfield, parked and shut the thing down. There seemed to be a lot of helicopters flying all over to the south west, seemingly combing the forests there, probably just some 101st field training thing. I gathered up the goggles, my helmet, vest and other junk and headed off to operations to turn it all in. We walked into a beehive of activity. Standing at the counter, I handed the goggles over while a specialist grabbed them then went back to what seemed like an important phone call. Something was up so I asked. Mostly the guys would just tell me it was none of my concern and not answer, but the specialist covered the mouth piece and said ?A Chinook is down!?
Holy crap a Chinook has crashed, wow, that?s terrible I thought! ?Where?? I inquired. He stabbed a finger at the map then made a circle gesture. Looking at Eddie who was showing grave concern I said ?Heck man, that?s where we were!? He said ?yea? slowly while rubbing across his chin with his free hand.
?What happened?? I continued. The phone call had ended so the specialist gave us the run down. A Chinook ran into a tower about here and was seen going down about here. ?Dam Eddie, wasn?t that where we were?? ?You were there?? asked the specialist as suddenly everyone in operations started to look toward us stopping what they were doing. I heard the Captain say, ?Hold on, I think we know something,? as he covered the mouthpiece. ?Exactly when were you there, and what were you doing?? Eddie was rubbing his chin a little faster and starting to look up and around. ?Sir, about 2200, we were carrying that M114 sling load,? I responded. The sergeants were now standing there also and Williams slapped his forehead and looked at Eddie then me. I hadn?t figured out what was going on, but everyone else was starting to.
?Sparks,? Williams said, ?I saw the sparks.? Captain bellows asked, ?Sparks?? Williams now with his head turned away from Eddie and I in disgust and peering out a window which was actually painted black to prevent exactly that. ?We did it, we knocked down the Freaking tower. New guy here flew right in to it and knocked it down, that?s where the sparks came from. I bet if you go out to that sling load, you?ll find antenna parts sticking in it.? Captain Bellows looked at Eddie who had stopped rubbing his chin and was slowly nodding up and down. Bellows walked back to his desk, picked up the dormant phone and said, ?Sir, it looks like it was one of our birds. No sir, no one is injured. No sir the aircraft is OK. Yes sir, yes sir, yes sir, I will, I apologize, OK, sir I will.? Looking at us with a beet red face, he told us to go the the hospital and give blood and urine samples. We had just been involved in an aircraft accident and an investigation would be ensuing.
?Whew, Eddie, is this how Night Stalker training goes?? It was not the correct thing to have said. At that moment I was reminded that I was a lowly CW2, where as Eddie was a veteran CW4 used to biting the heads off rusty nails and inquisitive CW2?s. It was not a good night!

Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 08, 2014, 10:32:33 PM
Quote:
Originally Posted by D********
"Great read... Next chapter? "



Not chapter, but story. here it is:

Finally out of training it wasn?t long before I started flying actual missions as a BMQ (basic mission qualified) co-pilot. Eager to get me on the schedule more to give relief to some of his pilots who were being over worked, than to give me actual experience I would fly a ten day training support mission in Florida for some of our Navy friends. They trained all the time the same as we did and had a team wanting to play in the Eglin Air Force Base ranges.

I would be flying with an experienced crew in a new CH-47D Chinook under the command of a Vietnam veteran, a CW4. I have to switch up the names so I?ll try to find suitable ones, however you guys actually in these stories know who you were. OK, so let?s call this guy ?Bill.? To the real you, I hope you approve, and I do this out of respect for your privacy.

Bill had been in the 160th since the day it formed from a single CH-47 company in the 101st. I believe at that time we were still technically a part of the 101st Airborne as we were yet to be assigned to and come under the direct command of 1st SOCOM, or First Special Operations Command. In my earliest days in the 160th we sewed 101st screaming eagle patches to the left shoulder of our dress greens and maybe our BDU?s (Battle dress uniform) but to be honest changes were coming fast and I am not 100% sure of that.
Anyway A company of the 159th Aviation Regiment kept its name from the days it was created in Vietnam, the ?Pachyderms.? I?m sure about that, because someone way back then had some Vietnamese carve a pachyderm head bust out of a chunk of very dense and heavy teak wood. That sculpture adorned the desk of the company commander of the pachyderms and on occasion would actually be hand carried on the morning PT three to four mile runs. Ask me how I know about that!

Outside the door of the barracks building where the company also had its headquarters offices was a woven rubber welcome mat that didn?t say ?welcome?. On it instead was emblazoned the phrase ?Pachyderms, tougher than woodpecker lips!? That simple phrase often haunted me. I realized wood peckers don?t actually have lips, but I used to speculate about just how hard their beaks might be. Then I?d get to thinking if it was possible for a wood pecker to suffer from a concussion from all that pecking? That led me to think about how their brains might actually be suspended within their skulls? Perhaps by elastic chords, or in a vicious liquid, I mean how exactly did all that work? Weird, but I?m thinking about it right now!

OK, back to the mission, navy guys, training, OK, here we go. We were to meet up with this team of navy surfer dudes at Hulbert field, home of Air Force Special Operations. It is located along the scenic Florida coast right beside Destin and Panama city. I was going to have some fun finally. I was dreaming of flying, and getting some beach time in, it was going to be good!

We packed up early one morning into our Chinook which was fitted with two 600 gallon internal fuel tanks. With all that gas, we would be able to take off from Ft. Campbell and fly all the way to Florida, nonstop. We did so during the morning and into the early afternoon cruising across the US of A at 300 to 500 feet along a predetermined route which we followed exactly.

Arriving there we parked the aircraft on the hazardous cargo ramp at Hulbert, found our Buick Regal rental car, packed up our personal belongings and headed off to the hotel. Operations had reserved us rooms at the Howard Johnsons, or Ho-Jo?s. As we carried our bags inside I noted Bill as having two duffle bags instead of my single bag. I nodded toward the heavier and bulkier second bag and Bill said ?It?s my ?B? bag.? Oh, B-bag hugh, I hadn?t brought any B, C or D or any other letter bag. I guess I missed that one during training. ?Bill, what?s a ?B? bag?? ?Tell me you didn?t bring one? You don?t have it with you? What if we get deployed from here? Dammed new guys!? Hmmm seemed I hadn?t learned my lesson yet, note to self: Do not speak until having first been spoken to!
We checked in, Bill and I got single rooms, but the two crew chiefs were rooming together. They dumped their bags and disappeared. Bill told me to come to his room after I settled in. I assumed it was for the butt chewing to continue, and I was correct.
The room was cheesy, sorry, Mr. Ho-Jo. I stuffed my clothing into some drawers and in the closet and went next door and knocked. ?Enter? so I did.

Bill was dressed in what I would describe as a black Ninja suit! I was a bit surprised, not knowing what to think of these Night Stalkers yet, a group which I considered myself a part of only by the thinnest of threads. ?B? bag, it?s what you need if we get deployed to go to war. You carry it with you whenever you go somewhere. Has your weapon, ammo, uniforms, stuff like that.? ?Weapon? I asked. Surely I shouldn?t have missed that, I was supposed to bring a weapon? ?You don?t have a weapon?? ?Err, no, no one told me.? ?No one told you that you are supposed to buy your weapons and carry them with you?? ?Err, no, I have to buy a weapon, what kind?? Bill flipped open the bag and handed me both halves of a Car-15 assault rifle which I stared at dumbfounded. ?And one of these,? he dug a little deeper and pulled out a modified .45 automatic pistol. To my mounting surprise I watched him pull out a drop leg holster, put it on and drop the .45 into it. He then picked up the Car-15 which I had laid on the bed and fitted it together snapping the two pins home. He threw the weapon over his shoulder and adjusted it to cross to one side with the muzzle down and the butt stock sticking out beside his ear.

These night stalker dudes are one weird lot, I was thinking as he donned a black hood. Yep, ninja, that?s the look he was going for. OK, for those of you who think this is a fantastic fabrication, well only the second part of that statement is true. This all really happened. Think that?s it? Sorry to disappoint, but this story gets better!

Bill moves over to the window of his second story room at the smallish balcony and railing. My face must have been twisted up in one of those ?what the heck? expressions as he slowly opened the sliding door. I noted it opened with a rump-rump-rump sound. One of the rollers must have had a flat spot. I watched with utter fascination as he moved out into the early evening light and peered over the aluminum railing. ?They?re next door.? ?What, who is next door? I inquired somewhat dumbfounded by this unfolding scene. Bill jumped up and over the railing and clung to the outside, with the weapon swinging outward. At that exact moment, as I moved over to lean on the railing, I watched an elderly gentleman in a huge Cadillac pull into the parking spot one floor below where Bill was hanging. I could see that the gentleman was looking up through his windshield at the ninja hanging on the side of the building. I saw him place the gear shift back into reverse and watched him back out and leave. Good move I thought.

?Go knock on their door.? I focused back to the crazy conversation Bill and I was having. ?The crew chiefs, they are rooming next door. Knock on the door, and when they answer it, I?ll come in from the balcony.? What, are you serious, you want to attack the crew chiefs?? ?Not attack them, just give them a good scare.?

Since I was a new guy and no one felt compelled to talk to new guys, of course no one had briefed me on the antics of brother Bill here. But I would later learn plenty. I later found out that he often did this and on one occasion had interrupted a crew chief and a local girl in the middle of the throws of passion! But this was now, I didn?t know, so I just went along with it. ?OK, give me a second? I said as I left.

I gave it about a three count and began knocking. The voice inside asked ?Who is it?? ?It?s Harward? A moment later the door started to open then I heard a crash and Bill screaming ?Down on the floor, get on your face, N O W!? I watched the spectacle. The sergeant at the door was on his face in the entryway to his room as commanded. The other sergeant a more senior staff sergeant was laying flat on the bed with a huge bottle of Jack Daniels resting on his chest, thumb covering the mouth of the bottle. Bill stood over him all ninja?d up pointing that Car-15 carbine at the staff sergeants face. Both sergeants were saying don?t shoot sir, don?t shoot. What I thought was a gag carried a bit too far was actually much more. Bill a veteran from Vietnam with some baggage from that war would lapse into his Huey Cav days back in ?the Nam? on occasion and had everyone pretty nervous. Would this the time he might lose it and drill these gooks, err that?s right, crew chiefs full of holes by mistake? That was one of those surreal moments in my early life as a night stalker. These guys were actually really crazy, it wasn?t just rumor!

The next couple days we were supposed to support the surfer dudes doing whatever they wanted. The first morning when we drove back out to the hot cargo pad to meet them, Bill says watch this. He is driving. The crew chiefs are in the back seat and I am in the front, right side. Bill guns it and yanks the steering wheel setting up a power slide on the grass covered white sand. The surfer dudes were standing all alongside the Chinook and are watching our approach. Bill slides the Buick up to about 50 feet from where they are standing, throws open his door and rolls out on the ground opposite of the car from them. The crew chiefs actually looked scared and I just watched in amazement yet again. Bill comes up from behind the left fender with his hands raised as if he is holding a weapon. He makes mock recoil gestures as he goes from surfer dude to surfer dude. All the while this is happening they didn?t budge, not one flinch of any muscle. Hmmm cool customers, these surfer dudes. They still didn?t move at all as Bill walked up to one of them and shook his hand. All of them were wearing Oakley sunglasses just like all of us. No one else on that base wore Oakley?s so we secret agents weren?t all that secret in retrospect.

We made a critical mistake that day. We departed with half of their team, leaving the other half on the ground. I would learn later on,that, that was not a good choice, but hey I was new to these Night Stalkers and surfer dude communities.

The mission was to fly them at altitude over a drop zone and let them jump out of the back. We were up pretty high requiring me to wear an oxygen mask. We flew toward the drop coordinates and was looking at a pretty big thunder storm which appeared to be right over the DZ. Bill called the jump master up into the cockpit pointing out the thunderstorm. The surfer dude told us to fly to the coordinates, then turn the green light on and he and his team would go!
I was actually flying and I think that guy just told Ninja Joe here to fly into a thunder storm! You don?t have to be an officer, a college graduate, a pilot or anything else to know not to fly into thunder storms. It?s one of those things right up there with sticking your face in fire!You know what thunderstorms and hail do to your car sometimes? OK, well, it?s ten times worse on the airplane when flying into one of those things. ?Bill you really want to go into that storm? We can?t do that, right?? ?I?ve flown Chinooks for a long time, we?ll be OK!? ?You sure, are you sure you want to do this?? ?Two point five miles.? ?What? I asked ??two point three miles, that?s how far to the drop point.? He flipped the red light on and In the mirror I could see the surfer dudes lining up at the back end. I was looking out the windscreen at an impossibly tall wall of violence right in front of us that I couldn?t see into a single foot.

Three, two, one, Wham! We were in and started to be slammed around by all the turbulence going on inside that vertical airborne volcano. ?Point three, point two, point one, go, jump, jump jump,? Bill said as he flipped the green light one. Like one big fishing net full of tuna, then just sort of poured out the back end of our aircraft, then they were gone!

Get us out of here, he yelled now directing all his attention to me as a sergeant said, ?Jumpers away, aft clear, ramp coming up? I?m sure he was worried about being thrown out the back end. I placed the aircraft in a standard rate left turn, now flying on instruments. In a quick minute (less than a New York minute) we popped out the side of that monstrosity. Bill said circle around. Let?s see if we can see them. Continuing left back toward hell, all I could see was a column of cloud extending from the ground upward a couple of million feet. ?Anyone see anything?? Bill asked. ?See what sir, a couple of our rotor blades or some of the fuselage that got ripped off??

?Very funny guys, one four one.? ?What, are you talking to me.? I asked as I finished thanking the Lord for just saving my life. ?Turn to one four one degrees, your heading back to Hulbert field? Bill said, let?s go back and get the second group. Eglin approach Army copter 2-4-3-4-1 is a single Chinook one four thousand, twenty miles north west inbound for landing Hulbert.? Taking a moment to turn around and look aft, I immediately saw the staff sergeant standing in the narrow companionway and staring at me. We locked eyes for a second. He shook his head side to side and nodded toward Bill. He wasn?t a happy camper. Ditto, neither was I, although being new to the game I was ignorant to the fact that I had been in serious danger. Contrarily, these guys had been living with it for some time.

We flared on the runway near the end and landed. Using a ground taxi minimizes the super strong rotor blast the Chinook produces. We taxied back to the hot cargo pad and shut down. Only one of the surfer dudes was standing there. I overheard the conversation between him and Bill. It seems the team we let off in the middle of that thunder storm had been scattered all over hell and back and had lost most of their equipment. They were not injured, but the guys who had been here had rushed off to try to find and pick them up. That would be it for us for the day?s flying.

After helping the crew chiefs tie down and service the aircraft we grabbed our day bags, mine still containing a sandwich I had made from the breakfast layout, and headed toward the parking lot where the Buick was.

Remember I had mentioned why you never leave your car unattended with half a team of Navy surfer dudes standing around? What we walked up on was not exactly what I?d call a car. Well it was a car in pure terms of mass, weight, approximate shape and the ability to transport people, but only barely. They had jumped up and down on the roof until it was all caved in. They had also smashed in the trunk lid, which no longer worked and the hood. All three depressions were holding water from a thunderstorm which had passed overhead there earlier. The hub caps were kicked in and the grill was missing, we later found that.

Peering inside we discovered that everything that could be quickly removed, had been. We found out later that all those things like door handles, switches, radio, lights and yes, the grill were buried. Buried you ask? Ah yes, after final disassembly of the interior and parts of the exterior, they had placed all the parts inside of the car. Then they had filled the front and back seats of the car about 1/3 of the way up with popcorn!

While taking inventory of the totaled wreck of our rental car, we noticed a few of the surfer dudes standing nearby. All of them were motionless but had the same silly smile which the Oakley?s only partially masked. Not to be beaten, Bill tried to unlock and open the door. That was difficult since the door handles were gone, so one of the sergeants using a screwdriver, wiggled the mechanisms inside the holes where the door handles used to be and got all four doors open. Without saying a word or acknowledging the wreckage at all, Bill climbed in crunching down heavily on the pop corn as he wiggled, or rather burrowed down into the cornels and looked around for the ignition switch. It was hanging out of it?s hole by the wires. Using the skill of a master thief, by holding the cylinder with one hand, he got the key in and cranked the car, which started! Ah, cool, I thought, they left us the engine. While I brushed some corn off the seat and sat in the front seat, my knees came up to about chin height. The popcorn was preventing me from lowering my legs. A couple of Air Force airmen walked by just about then, both starring at the wreckage and at us. One said, ?Nice car!? then the other, ?Clown car, Barnum and Bailey circus must be in town.?

We all squeezed into the car and Bill drove off, all without saying a word or looking anywhere except for straight forward. We scored big points with the surfer dudes who thought it was cool that we had kept our cool through that little ordeal and had never said a single word about it.

After getting back to the hotel, we went to work removing the pop corn and reinstalling most of the parts. The crew chiefs, thought, that the grill ought to remain in our possession as a trophy and in memory of the event. Bill thought about turning in the car to get a new one, but since we had pushed the roof out far enough to actually use the thing for transportation, we did, He and the Sergeants decided to turn in the car as the last thing we did. That?s what we did a week or so later. By the time we landed back at Campbell, National rental car company had already called reporting that our rental car had been vandalized and was totaled. Captain Bellows wanted to talk about that as well. All in all, a single rental car is not too bad of a price to pay for some good joint Army/surfer dude training wouldn?t you say?
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 08, 2014, 10:46:39 PM
Several of the random posts in this build thread are associated with Don's (published) book "Distant Thunder", and some of his posts are from material he may use in a future book. The following is just one of many positive reviews he received from his fellow interweb friends, better known as DOTS (derailleurs of threads).

This was written by STLASER:
Don, you asked for it so here is my review after sleeping on it for a couple of days.

OK, so I finished Don's first book last weekend. Note: that this is the first book I have started and actually finished (could not put down btw) in the last eight years. As with all of his writing the book was extremely well written and read like us normal gear head types actually converse in a shop type setting. Do not take that statement lightly nor any offense as there was plenty of job specific lingoes & various terminologies that kept me on my toes throughout. This in my opinion was the best part of the book. That being regardless of his larger than life job and career he definitely put the hooks into the average reader so that you desire to know more and more. Which is what any good author should do for a reader and that is to actually tug you thru from one point to the next. I would go as far to say that by the end of his first book you will end up feeling like you were in the jump seat behind him. It really is that well written in my opinion.

Now in order to do my job and be thorough I must also address the negative side of purchasing and reading any of Don's works. My ongoing prevalent thought while reading this book was that I end up with more questions about him than I had prior to reading. But then again if you try to form a friendship with Don the same can be said about him on a personal basis as well. Regardless & as frustrating as it can be, my viewpoint is that for whatever reason it happens it flat out works for him and those of us who are able to experience it in the end are better because of it at least on a personal basis. Regarding his writing I believe it will lead him to selling a lot of books, which as a result will benefit exponentially that many more people. Unless you know him, this last sentence probably did not make alot of sense for that I am sorry.

Oh, and if you?re on a budget forego purchasing this book because I can guarantee it will be habit forming. Seriously, you think he bought two hundred of his own book for nothing? You think he gives us little blurbs of his next book on this thread for no reason? You are all fools; the guy is a master marketing genius. The guy is the like the local crack dealer, give you a taste and you will be back for more. Sorry, if this last part was offending I just shot from the hip Don!  Great Book, God Bless.
Title: Re: LML Duramax Silverado Build Thread [Part 1]
Post by: KensAuto on November 08, 2014, 11:15:14 PM
Posted by Higher caliber to Don:

Found this the other day and thought you would appreciate it.

(http://i.imgur.com/Kazczro.jpg)
Wasn't yours was it?

I wasn't a dustoff guy, but I know of one
Dustoff 35 is a regular reader here but chooses to remain in the background. Considering that catfish lookin blackhawk he flew, I can't blame him. I'd be ashamed too!......

Quote:
Originally Posted by Higher Caliber
"I just saw "helicopter"... You know us play it dumb infantryman... I got it from my bro-in law. He was a medevac guy. His last assignment at Fort Rucker was OIC over an air ambulance unit there. I never realized they flew out for civilians as well! I'm not sure if I had just got ate up in a car wreck if I'd want to see a Vietnam era huey coming for me... unless of course it was playing some CCR over a PA system, and there was a guy hanging out the door with cut off fatigues and a head band sporting a 240. I'd prolly just as soon take the *ground* ambulance."


You know, when the last space age helicopter is put to rest at the bone yard, the flight crew will be picked up and flown to the airport in a Huey!......

Quote:
Originally Posted by Dustoff 35
"Big Don,

There you go, trash-talking the "Mighty Sikorsky Blackhawk" again... Not good, my friend...

Particularly when one considers your preferred method of rotary-winged-transportation; the Chinook?"


I rest my case:
(http://i.imgur.com/y6WCXwv.jpg)
(http://i.imgur.com/LeKXfAj.jpg)

Where as The chinook is obviously a creation of beauty. Notice the striking similarities! The graceful lines! The understated sophistication! The commanding presence! The not so subtle timeless beauty!
(http://i.imgur.com/yozxJTB.jpg)
(http://i.imgur.com/zYjteir.jpg)