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Offline Flyin6

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Hummer H2 SUT Build
« on: September 22, 2014, 12:00:12 PM »
I'll bet you boneheads never knew I owned and built one of these monsters
What I would consider a slightly more capable Tahoe, it does have good angles and when I off roaded it, the thing did fairly well, although it broke parts.
It has lesser than HD parts...things like a semi floater 14 bolt but with an electric locker. Decent ground clearance, but not enough
Lots of chrome (That don't get you home)
a really comfortable interior and a fuel economy sometimes barely in the 12's

The truck badly needs a diesel and real 1 ton axles, then you'd really have something.
Never the less I took a swing at one and here all that is
« Last Edit: October 11, 2014, 05:15:46 PM by Flyin6 »
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #1 on: September 22, 2014, 12:03:18 PM »
The day I bought it
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #2 on: September 22, 2014, 12:12:09 PM »
When building this truck I wanted to stay close to stock since the available lift kits really don't do much except raise the vehicle. They, for the most part do not increase suspension articulation which is exactly what an independent front suspension desperately needs more of. Consequently, I elected to go with chevy "green" 1/2 ton keys, cognito UCAs, longer bilstien shocks, and upgraded steering made by both Cognito and Fabtech. Here's what our stock key (rusty) and the 1/2 ton keys look like...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #3 on: September 22, 2014, 12:12:36 PM »
Here's a look at the difference in the indexing of the hex...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #4 on: September 22, 2014, 12:13:22 PM »
Here's the stock suspension before tear down...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #5 on: September 22, 2014, 12:14:14 PM »
Here's a comparison between the stock and the Cognito UCAs. The cognito arms allow for more "droop" and correct the ball joint angle. Additionally, they allow for stock alignment specs when lifting around 3"...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #6 on: September 22, 2014, 12:15:02 PM »
Here, the Cognito UCA is installed, which is a relatively simple procedure...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #7 on: September 22, 2014, 12:15:55 PM »
Next the Bilstien shocks are bolted in. Notice the totally wimpy stock tie rods which are about to go bye-bye...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #8 on: September 22, 2014, 12:16:41 PM »
Here are the stock front shocks and their replacement rear Bilstiens. Sorry, but the fronts were already bolted on, my bag...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #9 on: September 22, 2014, 12:17:30 PM »
Here are the tie rods, stock and Fabtech. Which ones do you think are stronger???
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #10 on: September 22, 2014, 12:18:36 PM »
When bolting in the Fabtech tie rods, you will need a minimum of a 17" crecent wrench, those suckers are huge! Next comes the Cognito Idler link brace...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #11 on: September 22, 2014, 12:19:29 PM »
Now comes the pitman arm brace...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #12 on: September 22, 2014, 12:20:45 PM »
Here's a better pic of the idler brace. I used the stock idler, since mine is still new, however I will soon replace it with the supplied Cognito monster Idler...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #13 on: September 22, 2014, 12:21:39 PM »
And here's all the suspension goodies installed prior to alignment which was W A Y off until after the rack. The technician was able to align to factory specs!
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #14 on: September 22, 2014, 12:23:05 PM »
Here's a shot of the new ride height
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #15 on: September 22, 2014, 12:24:01 PM »
And a shot from the rear...
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #16 on: September 22, 2014, 12:54:47 PM »
Here's the install of the complete Volant "Cold Air" intake system. It is a quality piece which is well designed, fits well, and is easy to install

Here's the engine compartment prior to removing the stock system. BTW, the stock system unlike AirAid, K&N, and others is actually a real "cold Air" system
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #17 on: September 22, 2014, 12:55:28 PM »
Here's the Volant Kit
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #18 on: September 22, 2014, 12:56:02 PM »
...The business end of the larger air plenum...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #19 on: September 22, 2014, 12:56:38 PM »
...And the air filter element inside the box...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #20 on: September 22, 2014, 12:57:13 PM »
Here's a view of the factory air tube and the cleaner Volant unit...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #21 on: September 22, 2014, 12:57:46 PM »
Here's a side by side of the stock and Volant air boxes
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #22 on: September 22, 2014, 12:58:40 PM »
...And the new Volant MAF alongside the stock one...

New is in my hand

Apologies for the fuzzy picture quality
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #23 on: September 22, 2014, 12:59:17 PM »
...Engine bay with stock everything removed...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #24 on: September 22, 2014, 12:59:56 PM »
The new air plenum mounts with two bolts and washers into factory mount points. The new MAF mounts into the air box using the factory rubber collar.
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #25 on: September 22, 2014, 01:00:36 PM »
The new air tube mounts using a supplied silicon bellows and clamps, and a rubber doughnut on the TB side.
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #26 on: September 22, 2014, 01:01:14 PM »
 installed, clamps tightened, and MAF reconnected, almost done...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #27 on: September 22, 2014, 01:01:52 PM »
View from left side, all done
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #28 on: September 22, 2014, 01:02:39 PM »
Ah, but not quite done! I added the Predator Program for 87 Octane, adjusting for firm upshifts in standard and tow/haul mode.

After a few test drives I noted:

Mileage improved from 11.4-11.7 to 12.3-12.5
The engine makes more "air" noise when acclerating (good thing)
The shifts are indeed frmer, although not as snappy as I would like
The seat of the pants feel seems a little better, but not verified by testing
Satisifaction: Hmm, well, so-so...
Worth the money: Probably not
Would I do it again: Probably, because it lays the ground work for the headers and the 4.56 gears
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #29 on: September 22, 2014, 01:06:43 PM »
Next we'll install a H2O Off Road bumper system
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #30 on: September 22, 2014, 01:07:29 PM »
Here's the stock stuff that gets removed
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #31 on: September 22, 2014, 01:08:38 PM »
...And the stripped front end...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #32 on: September 22, 2014, 01:09:15 PM »
Next the winch bottom plate gets bolted on. There are a total of three thick winch mount plates...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #33 on: September 22, 2014, 01:10:02 PM »
Here, the lower cover assembly is bolted in. It also includes the mounts for the DRLs...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #34 on: September 22, 2014, 01:10:44 PM »
...Next in go the heavy duty "mini-grill" pivot points which also serve as the mounts for the new front tow loops...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #35 on: September 22, 2014, 01:11:22 PM »
...The next step is to bolt in the winch with it's new trick locking plate which tightens from below making it a difficult procedure for a potential thief to steal your winch...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #36 on: September 22, 2014, 01:12:00 PM »
The hause was already installed, but here is a better pic of what it looks like up close...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #37 on: September 22, 2014, 01:12:40 PM »
...Next the "mini-grill" gets attached...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #38 on: September 22, 2014, 01:13:25 PM »
...The tow loops which are the same as the ones in the rear were bolted in place with the mini grill, here's a close-up...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #39 on: September 22, 2014, 01:14:07 PM »
...HereI had to do a custom bracket to install the T-Max control box which I created from 1/8" plate steel and bolted it to the two chrome steel rods above the drum. Here it is installed. Yep, it's tight, but it fits fine after trimming the lower edge of the stock grill...
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #40 on: September 22, 2014, 01:14:43 PM »
...And here it is all installed...
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #41 on: September 22, 2014, 01:15:32 PM »
I wanted to reinstall the stock double brush guard, so I started by cutting off all the stock mounting points, then creating my own angle brackets which I welded to the brush guard, then drilled and bolted all that to the H20 mini grill...
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #42 on: September 22, 2014, 01:16:44 PM »
Here's the front tab...
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #43 on: September 22, 2014, 01:17:39 PM »
...And the rear which made it very strong...
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #44 on: September 22, 2014, 01:18:55 PM »
...And here's the finished product with the cognito/fabtech/bilstien and other parts installed!
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #45 on: September 22, 2014, 01:21:47 PM »
I was tired of lugging that monster of a stock muffler around, so the last time I was home I procurred a MagnaFlow stainless muffler with a straight through design and 3" inlet and outlet.
At first I was reluctant to use 3", since my H2 has factory 3.25" piping, however upon further inspection, I noticed the outlet of the muffler actually necked down to 3" from the factory, so with that in mind I did it anyway.
The new muffler sounds awsome! It has a low note and a rumble, zero resonance, and will sond off with throttle application. I do not believe it made any appreciable power increase, but it does sit much higher up in to the body. All in all, for $150, I think it was a worthwhile mod
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #46 on: September 22, 2014, 01:25:35 PM »
Next, in the search of some power and mileage, I'll install some Dynatech long tube headers

Note: All these posts are a condensed version of this build all consolidated here for convenience. All the chat with other members has been removed so that this reads as a pure build thread
Site owner    IS 6:8  Psalm 91 
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #47 on: September 22, 2014, 01:26:09 PM »
Tear down begins. You have to remove the inner fender liners which is actually fairly easy, then getting to the manifolds and other things is pretty easy
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #48 on: September 22, 2014, 01:27:11 PM »
Here's some of the stuff that has to be removed:
UCP, spark plug wires, O2 sensors (4), front wheels, cross member and other cool parts
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Offline Flyin6

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Re: Hummer H2 SUT Build
« Reply #49 on: September 22, 2014, 01:27:49 PM »
07-08 style old and new Y-Pipes
Site owner    IS 6:8  Psalm 91 
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