Project mega Cab

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   Just found this site and was impressed with the knowledge of everyone with these trucks so I figured I would share a project I am working on. It's a spare time project. Anyways Plan is to build a Daily driver that will be an all around good truck.
   The Lowdown, I have two young kids so a back seat is a must, It snows up here in CT so 4wd would help, Gas prices are just rediculous so it has to get good fuel mileage. Also I don't like being like everyone else.
   So with that being said I had a 87 R30 that I drove a few years ago. Cam went bad and it got parked.

Started by ripping off the front end Pulling the 454 and TH400


The truck that was going to give it's drivetrain


Picked up a short bed.

[zieg85]

Looks like a fun project, welcome to the site from NW Indiana

[thirsty]

Welcome to the site from your northern neighbor in NH.
I love to see an old square get a second chance!
When you mentioned that you wanted 4wd and that the dodge was giving up parts, how much of the drive train are you swapping? I assume the dodge has a diesel but are you swapping the front end in too?
Nice score on the shortbed too!

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Entire drivetrain from the Dodge will go in. Down the road after it is all together and the bugs worked out I will start upgrading the drivetrain with a built tranny and swap the unit bearings for Ford knuckles, spindles, hubs.
Right now the Dodge  truck runs and drives fine

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Last Monday I got started. Being a holiday I was able to work all day on it without getting interupted or the phone ringing.
Lifted off the cab

Took off the bed and moved the cab and bed outside

Removed front and rear suspension

Bare frame ready to shorten

Ground the rust away and layed out where to section. I am taking out 10" instead of the normal 14 to fit a shortbed. You'll see why later in the build

Frame cut

Cleaned the inside of the frame also for a good weld

Fit the two frame peices back together, got them perfect needed to trim a bit on one side to get it square

After it measured up I tacked it together then ran a 1/16 cut off wheel back through the cuts leaving the tacks so i could get the propper penetration.

All welded up Back ground the inside and welded that up also. I then ground it smooth

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Got the frame back from sand blasting now the fun begins

Have to look hard to see where I cut, ( yes it's getting fish plated on the inside)

Made some rear shackle hangers

Moved the rear crossmember up 6" welded it in and vut off 6" from the frame

Started building some front spring hangers, Plasma cut out, and bent.


Front hangers almost done

I want a nice ride so I figured my buddys 05 Silverado 2500HD rides nice. So I got a set of springs from one
Big difrence compared to the old ones.

[79k30guy]

looking forward to seeing the progress..    awesome so far!

[bigchevyc30]

talking about progress one day we see just a truck with no front to now a bare frame sandblasted and starting on getting new suspension on it great job man cant wait to see it all together. Also when u do get it done maybe you should get a video of it so everyone can see and hear what you did

[bake74]

     Welcome from California, going to be following this build, if my suspicions are right it is going to be one of a kind.

[mikek20]

Welcome from ohio. I'm loving the build already, I look forward to following your progress. Keep up the good work and keep us updated!

[69byrd]

That is a great looking project that you have there.  I will follow this closely

[DustyRusty]

Welcome from Alaska.  Great looking work and fabrication.  Looks like you are on a fast track to get this completed.

How long are the Silverado springs you are using?  Are you using them on both the rear and the front?

Chevy/GMC 4x4 trucks of this era had a passenger side drop transfer case/front axle.  Your Dodge donor truck has the driver side drop transfer case/front axle.  That really doesn't matter but you will get some strange looks from the GM crowd until they hear the Cummins. 

My neighbor has a 1990ish Chevy 4x4 crew cab dually that is in great shape for an Alaska truck.  I would really like to have it.  I'd put in a Duramax and Allison, and go!

BTW, are you aware of the "killer dowel pin" issue w/ the Cummins engines?

Rusty

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The rear springs are 2005  Silverado 2500 64" leafs. The front will be coils not sure what coils to use yet. Have to get the drivetrain installed I will weight the front axle and get some progressive wound springs. The kdp will get tabbed when I reseal the engine.

[Engineer]

I approve.

[ehjorten]

Are you the guy on Pirate4X4 that everyone was rippin' on about the powertrain swap and stuff?  The pictures look awefully familiar.