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‘91 FWC K5

91 fwc k5 restomod
Look in the classified section here or post a wanted ad for it in that forum. Usually somebody has a set. I’m all for switching to the manual, and I know you are going to pick up a 465, I would keep an eye out for a 4500. If you do plan on road tripping a lot the OD is nice to keep your sanity rather than listening to the 350 buzz along at 3000 rpm or up depending on your hearing and tire size.
A 4500 would definitely be smarter, would be extra nice if the shifter lined up with the factory hole. I had a 3500 in my last blazer with 373 and 35s and 5th was nice to shut it up but my highway mileage went down a noticeable amount, 4th was best for mileage( averaged 14-15 at 75 ish) If it came to it I could always swap it or add an overdrive unit or something in the future
 
That was his last blazer.
Does he have the same setup now?
Yessir, both blazers are 3.73 and 35s, thats where my idea of not needing OD came from. It would run highway speeds fine in OD but mileage suffered, 1:1 on the nv3500 was where I got my peak mileage of 14-15. Not that Im building it as a mileage machine but when I finally get around to restoring the camper getting the most out of each tank would be nice. If the 350 ever lets me down it will likely get my spare low mile 6.2 and that would get even better mileage but id have to regear for peak rpm
 
Anyone have any input on panhard bars? Im going to add bars front and rear to help iron out my handling with the 52s and 64s, my front has pretty noticeable axle sideloading? The crossover drag link will push and pull the axle side to side. Not very noticeable in slow speed town driving but definitely noticeable on “high speed” corners, ill have to take up about 1/8 turn of slack in the steering wheel to get the truck to actually start turning. So my questions are

1: should the front panhard be parallel to the drag link or should it be parallel to the axle at static ride height? My drag link doesn’t have much angle in it with my roughly 4” lift so not sure how crucial it is.

2: im using a heep yj for reference as its leafs all 4 corners with oem panhards front and rear, why is the rear panhard bar opposite of the front? As in front is driver frame rail to pass axle tube and rear is pass frame rail to driver axle tube. This appears to be the standard but in my mind Id think this would cause angled movement of the body driving through a suspension compression as the panhards push the front to the left and rear to the right. Unless Im able to get both panhards pretty close to flat then maybe its not noticeable?
 
Another overall update on the truck. Finally decided to dig in deeper to why it diesels so bad. Did a compression test, 3 was at 130 4 was 25:1zhelp: and 6 was 160. Poked the bore scope in 4 expecting the worst, looked good enough except for carbon buildup. Then noticed that the exhaust valve rocker arm was tight. Backed it off 3 full turns and ran the compression test again. 220 psi. Ran the rest of the valves and they were all tighter than expected. After running all the valves the only low compression hole is 3 at 175. Also noticed casting numbers under the covers while running the valves. 10088113, looks like 87-91 corvette heads or zz4 crate motors 64cc chambers, I was told it was a crate motor, so I read up on the zz4 and saw 10:1 compression…… its been running on 87 the whole time ive owned it with the occasional 93 fillup trying to diagnose other issues. No pinging.

Ran around the block and determined it feels maybe 5% better. Still diesels like no tomorrow, got back from the test drive and shut it off and it dieseled for almost 45 seconds. Ran the ignition timing when I put the hei in doing the carb swap. Decided to do it again to check. 5°…… thats not where I put it, grabbed the lightning whirler and turned it counterclockwise by hand…. Not completely loose but loose enough. Apparently when I set the timing last time I didn’t tighten it down:whistle: So back at 14° actually tightened this time and went for another drive. Noticeable improvement, probably another 10% or so. Except the worst pinging ive ever heard in my life at half throttle. Drove it easy back to the shop and proceeded to pump out 25 gallons of the 87 I put in it this morning, drove back to the gas station for a second time and put 100$ worth of 93 in it. Drove it easy a couple miles to get some good stuff in the bowl and then laid into it, no more pinging. Got it back and shut it off and no more dieseling. Will have to see if that trend continues.

Only other notable diagnosis is mr slippy appears to have let 2nd gear go out on early retirement. It shifts from 1st straight to 3rd. I cant tell if its going into 4th or not, if it is it isnt going into lockup I dont think. Every now and then it seems like it tries to grab a hair of 2nd before it makes it all the way into 3rd but hard to tell. Once I find a set of pedals and 32 spline input for the 241 that headache will be gone. The 465 is already on hand patiently holding my 89 ranger springs down.

Overall there was an improvement, not really excited to find the 10:1 comp I want this rig to eventually be taken on some excursions and I question the availability of 93 in the more remote places. But thats a problem for future me, Ive still got a four wheel camper to work on before I get that far. And some driveline work.
 
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Got the panhard bar in and the Offroad Design sway bar put in today, I knew they would make the truck drive better but I didn’t think it would be that big of a difference. This thing handles night and day different.

Panhard design ideas were robbed from augustdiesels build thread. The base kit was a ruff stuff kit with the brackets cut down, as with. 4-5” lift theres not really that much clearance under there. My angles aren’t perfect compared to the drag link but it seems to work good for the short test ride.

Scored a clutch pedal assembly and it showed up today, 465 reseal kit is here and the 241 reseal kit is in. I need a 32 spline input if anyone has one laying around. Im getting closer to having this thing ready for a camper. With any luck camper restoration starts this winter.
 
Buddy had a 32 spline 243 laying around, snagged it, should have all of the parts to get everything put together. Going to reseal everything in the coming weeks to get that stuff ready, postponing the swap, might be getting a 2 post in the shop.....
 
Your panhard really needs to be a LOT longer. It should attach near the knuckle. Ideally it would be the same length as the draglink (43"-ish?) and it's way short now. The extra length will make it sweep the axle side to side less and get rid of the bumpsteer. Just solidly locating the axle and raising the roll center helps handling but you're forcing the axle to move laterally and the less that happens the better. And, you may not notice it now but it does have bumpsteer with that system. Maybe you never will notice but it's there.

The lateral forcing is the big problem with running a panhard with leaves, especially with a long travel system like your 52s. The panhard will force the axle to move side to side quite a bit, in some examples, well over an inch. Short lift and low travel, it's workable. But it should be longer to minimize it. Get up to a 6" lift with a longer travel system and you're asking the leaves to move side to side a LOT.

Monitor the frame around all the brackets, especially the panhard. Cracking is often a problem.
 
Your panhard really needs to be a LOT longer. It should attach near the knuckle. Ideally it would be the same length as the draglink (43"-ish?) and it's way short now. The extra length will make it sweep the axle side to side less and get rid of the bumpsteer. Just solidly locating the axle and raising the roll center helps handling but you're forcing the axle to move laterally and the less that happens the better. And, you may not notice it now but it does have bumpsteer with that system. Maybe you never will notice but it's there.

The lateral forcing is the big problem with running a panhard with leaves, especially with a long travel system like your 52s. The panhard will force the axle to move side to side quite a bit, in some examples, well over an inch. Short lift and low travel, it's workable. But it should be longer to minimize it. Get up to a 6" lift with a longer travel system and you're asking the leaves to move side to side a LOT.

Monitor the frame around all the brackets, especially the panhard. Cracking is often a problem.
I wanted a longer panhard setup but wasnt able to find any other examples to go off of for my setup, with only a roughly 4” lift I dont have much room, especially with the hight of my spring pack. My untrained eye said there wasnt enough room to run a bar over the leafs, it looked like it would hit the frame, leafs or maybe both on compression . I dont plan to go any taller, and the swaybar was a must, especially for once I get the camper put back on, ill probably have to add a rear swaybar as well. And im thinking about adding a rear panhard with the 64s and 6” shackles but I dont know enough about suspension to know if what I do is going to help or hurt, the universal kits from ruff stuff I have would put my rear panhard going from pass frame to driver tube, which seems backwards to me, that seems it would make the truck pivot under front and rear compression, but maybe thats better than both axles getting pushed the same direction? Right now the truck drives and handles great for a k5 on 35s IMO, but I haven’t flexed it much to see if theres going to be any issues there or not. before the panhard Id have roughly 1/3 turn of the wheel in corners id have to take up to get the truck to start turning from the axle moving over. Im still not completely excited about the front end setup, k5 frames are hot garbage imo, before the panhard I had dad turning the wheel back and forth while I looked at everything and the axle moves, frame bends and twists, with the hoop on my bumper I can see the frame wiggling alot over bumps, alot of that is body mount movement but the whole thing seems flimsy, and I need to find a way to check but I think the rear frame section is bent slightly over the axle from what im guessing was an overloaded trailer setup, theres a bow in the floor id like to get rid of for camper sake. My understanding is that panhards should be equal in length and angle to draglink but with the steering box being on the outside of the frame I would have had to hang the panhard even further off the frame? It seems good enough for me, its way safer to drive now, but im most definitely very worried about the frame cracking. I looked at everything when I swapped to the 2wd box and it looked good, added the brace to it when installing the 2wd box and was thinking about coming up with some way to tie the panhard frame mount to the passenger side frame rail but not sure exactly how. ORD coming up with a panhard kit anytime soon? I like kits that dont make me think too hard lol
 
Why do you feel the need for a panhard? Also they do sell a kit, it's part of the 4 link kit. It is going to require some fabrication regardless.
 
Why do you feel the need for a panhard? Also they do sell a kit, it's part of the 4 link kit. It is going to require some fabrication regardless.
It was needed in my case, the 52s flex more side to side, id have about 1/4-1/3 turn in each direction on the steering wheel taking up slack in corners, back to back corners were slightly sketchy lol. Around town it wasn’t all that noticeable, but curvy backroads and 60mph curves we’re starting to get annoying, and eventually I want this thing ironed out to drive cross country
 
It was needed in my case, the 52s flex more side to side, id have about 1/4-1/3 turn in each direction on the steering wheel taking up slack in corners, back to back corners were slightly sketchy lol. Around town it wasn’t all that noticeable, but curvy backroads and 60mph curves we’re starting to get annoying, and eventually I want this thing ironed out to drive cross country
Yep. I plan on doing something similar on my burb. Going to make it quick disconnect for when its not a street queen
 
Yep. I plan on doing something similar on my burb. Going to make it quick disconnect for when its not a street queen
Thats not a half bad idea… might have to look into that, that would probably take alot of stress off the frame wheeling, but might be kinda hard to get lined back up
 
You guys are all going down the path that led me to round springs.
1: this thing is too stiff. add custom springs and good shocks
2: this thing doesn't turn. add crossover steering
3: this thing doesn't steer precisely. add panhard bar
3.5: panhard with leaf springs isn't easy or good. deal with it
4: this thing doesn't have very good wrap control. F-it, coilovers fix ALL of this!

It is a bigger hairier step, but it does solve the problems.
 
Got the lift in, 4 speed swap in progress, unfortunately I was unaware of an I beam in the ceiling that lines up perfectly with the lift cylinder…. Im going to have to move the lift 6” to get full lift height or buy the optional 2 stage lift cylinder that offers more clearance, while I get the price on that I made taller lift pads that will work for this project. The pic was taken with the short pads, had to remove the running boards for them. IMG_4665.jpeg
 
Well after an inconveniently timed trans jack seal failure we are back in business, 4 speed and crossmember are in, appears the 700 crossmember and rubber mount work with the 208/241 adapter housing IMG_4861.jpeg
The inside of the 4 speed appears to the untrained eye to be in good shape
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This is the second 241 32 spline swap ive done and I find it odd that the 27 spline input bearing is noticeably wider than the 32 spline, I would have guessed the opposite before tearing into one
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Hopefully wont hit any more snags finishing up the bottom side, should have the tcase and shafts back in tonight, then I can get it off the lift so I can put the pedals in, my least favorite part.
 
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