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CK5
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I ground the housing smooth with some flappy discs, helped with cosmetics I guess. Added a little clearance too mabey.

I ground the housing smooth with some flappy discs, helped with cosmetics I guess. Added a little clearance too mabey.

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I started with a nice straight 10 bolt from my diff pile. I started by shaving the bottom "ears"

I started with a nice straight 10 bolt from my diff pile. I started by shaving the bottom "ears"

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I knew it would be a bit of mall crawler, He wanted me to build up a very nice set of 1/2 ton 6 bolt diffs. all new components inside

I knew it would be a bit of mall crawler, He wanted me to build up a very nice set of 1/2 ton 6 bolt diffs. all new components inside

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My WIFE LOVES when I put truck parts on the table...My brother bought a real clean 89 Jimmy, but wanted all new suspension

My WIFE LOVES when I put truck parts on the table...My brother bought a real clean 89 Jimmy, but wanted all new suspension

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89 Jimmy with BDS 4" suspension lift....springs not blocks

89 Jimmy with BDS 4" suspension lift....springs not blocks

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hhhhhh

hhhhhh

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My 90 3/4 ton 4x4 suburban cost me $ 150, was totaled, but I got another 90 2wd thrown in for free. For a total of $1650 cad I got it to this stage

My 90 3/4 ton 4x4 suburban cost me $ 150, was totaled, but I got another 90 2wd thrown in for free. For a total of $1650 cad I got it to this stage

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repainted the jerry cans while I had them off

repainted the jerry cans while I had them off

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drivers side kicks. I also cut a drain notch in the rocker to floor rail on both sides so water can just drain out, just cut the weather strip back

drivers side kicks. I also cut a drain notch in the rocker to floor rail on both sides so water can just drain out, just cut the weather strip back

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passenger front kicks

passenger front kicks

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it turned out nice out back. I was still going to install tool boxes out back later

it turned out nice out back. I was still going to install tool boxes out back later

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It looks good to me. I left a 3/8" gap along the bottom so it can drain after deep water crossings.

It looks good to me. I left a 3/8" gap along the bottom so it can drain after deep water crossings.

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fastened the panels with stainless self tapping screws

fastened the panels with stainless self tapping screws

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The aluminum cuts easily with a jig saw if you keep the blade wet with soapy water to prevent aluminum from sticking to the saw

The aluminum cuts easily with a jig saw if you keep the blade wet with soapy water to prevent aluminum from sticking to the saw

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decided to replace the water damaged side panels with diamond plate aluminum

decided to replace the water damaged side panels with diamond plate aluminum

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sprayed up front. I thought I might reinstall the carpet so I did not grind the welds... But decided to just leave it sprayed out in Rino Guard

sprayed up front. I thought I might reinstall the carpet so I did not grind the welds... But decided to just leave it sprayed out in Rino Guard

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spray liner out back

spray liner out back

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rear welded up ready to be sprayed

rear welded up ready to be sprayed

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some of the front metal work

some of the front metal work

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sprayed with Rino truck bed liner

sprayed with Rino truck bed liner

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from the back before welding in place...I have a hose clamp keeping the front hoop up

from the back before welding in place...I have a hose clamp keeping the front hoop up

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fits nice and close to windshield frame and a pillars

fits nice and close to windshield frame and a pillars

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the front hoops are way better

the front hoops are way better

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Ready for a roll cage install

Ready for a roll cage install

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