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76 k5 Wheeler build-GIT ER DONE

gotblazers

1/2 ton status
Joined
May 19, 2010
Posts
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Location
Vermillion,SD
I just finished a wheeling trip and broke a stub shaft/u joint in this poor old half ton k5. Since i got a 87 dodge ram to DD now i can really tear into this thing and im starting by beefing up the front 44 since my dad has agreed to buy it off me for 80% of whatever i got into it when i go to 1 tons as long as help him get it into the 73 k5 :deal:.

Heres some history on the truck
warning its pretty long as it was my first truck and includes my life story in it :D

It was used as a chase truck/DD for a nephew in a score desert racing family. He got a Girlfriend who he married and had kids with and after letting it sit around the shop for 10 years and visiting it infrequently he told his uncle to sell it. My dad bought the truck as a parts truck for the 73 k5 for $1850 and it had been sitting for 10 years.

My dad drove it home and realized this thing ran too damn good to tear apart. So instead of finishing the 73 k5 with it as my first truck he decided to have this be my first truck. He brought it home on a tuesday afternoon and he had told me a week prior something was coming home on tuesday but wouldnt tell me what. He handed me the keys and hopped in the passenger seat and told me to start er up. I cranked it a little and she fired right up, I hadnt driven anything in my life except for the jeep once or twice around the neighborhood, Sure as hell never drove anything loud like this with torque like that. I had a grin from ear to ear as i chugged it all over the neighborhood. As inexperienced as i was it felt like driving a boat on land especially with the power steering these things got but that must have been one of the best days of my life. I didnt have my license yet but i was only a few months off.

I wanted to get the new gas tank in ASAP as the old one was smashed in and rusty so it could only hold 4 gallons but my dad wasnt in the same rush so with 0 mechanical experience i went out and dropped the old tank disconnected the lines and put the new sending unit/lines/straps on the new tank. It took me a few trys to get the filler hose right :rolleyes:. I went out and listened to the radio in it every other day until i got my permit with only 2/4 speakers working and scratchy as ever with those old paper cones. My dad taught me how to do everything else in the engine well. Even got me some planks of wood to lay across the front fenders so i could work on the distributor easier on that old boat.

I started driving this thing to school the beginning of my senior year since i had slacked a little on getting my license. After driving it around for a few months a few guys in my truck mechanics class invited me to go to Hollister with em. First time i went it was with a single other guy i met there who had a 80's bronco 2 all stock shot to hell and we wheeled for 3 hours straight and drove home. After that i was hooked. I got a job petsitting and it was paying so good i was going whenever i wanted. I left all my gear in my truck so i could go on a whim. Most the time i didnt decide whether i wanted to go or not until the school bell rang and i left from school and picked up the food in hollister drove on in and called my dad to tell him i would be back sunday :haha:. I've only got more ambitious and more dangerous with my wheeling so its time for the truck to adapt since my first serious breakage finally occured. I'd always call my dad on the way back from hollister to tell him i was on the way home and he'd always answer with a ''whatd ya break?'' Up until now i didnt have anything to tell him i was starting to feel bad, Fortunately i didnt break anything until i got my new DD a little stock 87 dodge ram 4cyl 2.0 5 speed. And that brings us to the beginning of the build. Kudos to you if you actually managed to read my life story :thumb:.

Basic specs are
400SB/350TH/np203 fulltime ( i learned the hard way :doah:)
44 front/12 bolt rear both open with 3.73's

Heres what came with it
.4'' suspension lift
.all new bushings/transmission mounts
.dual exhaust
.A body with a little rust but 0 body damage (until i got to wheelin :whistle:)
.10x15 chrome rims with 12 year old 33x12.5x15 BFG A/T's
.new smog air pump

Heres what i've done to make it reliable as a DD and now a wheeler
.new gas tank/rubber lines
.thermostat
.ignition module,coil,cap,rotor,spark plugs
.vaccum modulator on tranny
.vacuum advance
.Single exhaust with a cat to pass smog :doah:
.New dash bulbs
.Head unit with cd player and 4 eclipse speakers
.33x12.5 Gdyear Mt/r Kevlars new
.driver suspension corbeau off road racing seat
.brake pads and rear wheel cylinders
.bleed brake system
.starter

And Finally PICS!!!
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Looks like a great start. What are your plans? Sounds like you've got a good place to wheel frequently. I've heard a lot about Hollister.

You should thank your dad for all his support and understanding (if you haven't already). I've been off roading for 15 years now and I probably would have given it up long ago if it weren't for my dad's help and support. Shout out to all the dads out there!:bow::woot:
 
Looks like a great start. What are your plans? Sounds like you've got a good place to wheel frequently. I've heard a lot about Hollister.

You should thank your dad for all his support and understanding (if you haven't already). I've been off roading for 15 years now and I probably would have given it up long ago if it weren't for my dad's help and support. Shout out to all the dads out there!:bow::woot:

I definitley appreciate it. He asked me what i wanted for christmas and i said nothing you've already given me way too much lol. He's been beyond supportive. He bought the 76 k5 and recently the 87 dodge. With the dodge as my DD i can focus on building the wheeler. Oh and he still pays my insurance and gives me allowance even though i have a job. I think im spoiled :doah:but im not hating it.

The plans are somewhat in this order
.Beef up 44 with chromoly,crossover steering,traction aid (havent decided which yet since this will be going into the 73 when im finished playing with it which has stock rear posi and isnt a serious wheeler so idk about putting a locker in it maybe a lunchbox locker.)

.14 bolt FF in rear with locker (yes i realize ill have 6/8 lug for a while)

.swap in a 60 after rebuilding it

.Full cage,fuel cell,4 or 5 point harness for at least driver and maybe some rock sliders or a boatside and narrow the front and rear.

.Rebuild 400SB with TBI (its got 175k miles on it :eek1:)

.Get rebuilt th400 install floor shifter

.203/205 doubler triple sticked

.Wheel the focking snot out of it

Oh and be mindful i have to get the 73 k5 running soon since we are probably moving and its been sitting for a focking century.
 
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Sounds like a great long-term plan. You know you can get 8 lug knuckles off of a 3/4 ton truck that will go right on the D44 front axle. They're probably about $20 a piece used. Check on the classified forum and if you don't see what you want, start a wanted to buy thread. I did that a few months ago and Kenny W responded with a used knuckle that was in great shape. You may want to PM Kenny W. He has lots of axle parts. Be sure to ask him to make sure the studs for the spindle and the steering arm are in good shape. If you need to replace them, I've found the entire stud, cone washer (adapter) and lock nut kit on amazon for about $20. Don't reuse the locknuts that attach the steering arm! They will come loose and cause the studs to break! Get new ones. It's no big job to change the knuckles out. I don't even fork around with a pickle fork, just a 4.5 lb. sledge hammer and about three blows on the axle yoke beside each ball joint is all you need. It would be a good idea to replace the ball joints before you put the "new" knuckles on too. That will cost $15-$50 per knuckle, according to how good of ball joints you want. I know this sounds like a lot of work, but it's worth it to have your wheels match.
 
Since you're going to beef up the D44 and go with crossover steering, you'll be replacing the knuckles with flat tops anyway. You should definately look for 8 lug flat tops and have the passenger side machined for cross over.
 
Sounds like a great long-term plan. You know you can get 8 lug knuckles off of a 3/4 ton truck that will go right on the D44 front axle. They're probably about $20 a piece used. Check on the classified forum and if you don't see what you want, start a wanted to buy thread. I did that a few months ago and Kenny W responded with a used knuckle that was in great shape. You may want to PM Kenny W. He has lots of axle parts. Be sure to ask him to make sure the studs for the spindle and the steering arm are in good shape. If you need to replace them, I've found the entire stud, cone washer (adapter) and lock nut kit on amazon for about $20. Don't reuse the locknuts that attach the steering arm! They will come loose and cause the studs to break! Get new ones. It's no big job to change the knuckles out. I don't even fork around with a pickle fork, just a 4.5 lb. sledge hammer and about three blows on the axle yoke beside each ball joint is all you need. It would be a good idea to replace the ball joints before you put the "new" knuckles on too. That will cost $15-$50 per knuckle, according to how good of ball joints you want. I know this sounds like a lot of work, but it's worth it to have your wheels match.
It would be worth it if i was going to keep this longterm at all, But this beefed up 44 will be finding its way into my 73 k5 which is going to live out its life stock on half tons as a restoration project and a D60 8 lug will be finding its way into my 76 k5 shortly after im done with the 44. Until then i have more than enough room to carry 2 spares.
 
Since you're going to beef up the D44 and go with crossover steering, you'll be replacing the knuckles with flat tops anyway. You should definately look for 8 lug flat tops and have the passenger side machined for cross over.

My knuckles on the 73 came stock flat and im pretty sure the 76 did too at least thats what my dad said.
 
My knuckles on the 73 came stock flat and im pretty sure the 76 did too at least thats what my dad said.

I think he's right. I think just about all D44 fronts were flat tops. Sometimes, though, you'll find that they've been replaced with 10 bolt knuckles, which will work just fine, but they're not flat tops. The tie rod also goes on the bottom of the knuckle with on the 10 bolt and on the top for the 44. Those are about the only differences.
 
it doesnt matter what knuckles you have to go to 8-lug. you'll need the hubs, rotors, brake caliper brackets, and possibly the spindle to make a 1/2 ton front 8-lug.

76 should half flat tops I believe. I would go for the crossover too but make sure to brace up your frame at the steering gear as crossover puts more leverage on the frame there. Crossover definately made a huge improvement in wheeling capability for my truck especially after I swapped over to 52s.

Nice blazer and nice build just be careful with it. My 84 k10 started out as my first rig and dd. now it looks like this


 
I think he's right. I think just about all D44 fronts were flat tops. Sometimes, though, you'll find that they've been replaced with 10 bolt knuckles, which will work just fine, but they're not flat tops. The tie rod also goes on the bottom of the knuckle with on the 10 bolt and on the top for the 44. Those are about the only differences.
I definitley got the 44 so no machining :D

it doesnt matter what knuckles you have to go to 8-lug. you'll need the hubs, rotors, brake caliper brackets, and possibly the spindle to make a 1/2 ton front 8-lug.

76 should half flat tops I believe. I would go for the crossover too but make sure to brace up your frame at the steering gear as crossover puts more leverage on the frame there. Crossover definately made a huge improvement in wheeling capability for my truck especially after I swapped over to 52s.

Nice blazer and nice build just be careful with it. My 84 k10 started out as my first rig and dd. now it looks like this
Im definitley not going to do 8 lug since this axle will not be in this truck very long, Im basically building it for the 73 then giving it a few test run, but i will do the crossover on the 44.

No worries on going to far with the offroad truck build i intend to make my blazer greensticker :haha:.I try not to say this too much because it makes me sound like a douche but my eventual goal is to compete in offroad comps. Dont really have a preference. My truck should be capable for everything but high speed score desert racing by the time its done so ill run anything from mud drags to KOH to TTC to whatever else will let me in i just enjoy a little competition.

What im doing to make this dream come true is working a full time job living at home, Literally have no expenses except for gas since dad pays insurance/cell. I dont eat out, I dont go out and i dont date. I pinch pennies as much as possible alwalys looking for the best deals to make my hard earned dollars go as far as possible. In the end i have about 1000 dollars a month to spend to get a little closer to my dream. Oh and im 18 hence why this first job is paying so ****ty and why im living at home, Figure this is probably the best time to pursue my dream. So who knows it might even come true someday :dunno:. One things for sure i have a LOOOOOOOOOOOOOOT to learn every new thing i tackle is an uphill battle trying to be a professional engine builder/fabricator/driver/overall mechanic and everything else it takes is a lot to ask of myself as an inexperienced 18 year old guy.
 
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Ha. I know that sonic and that exit going to hollister. Right before that exit is a field I used to play in with my XJ. Lol.

Anyway sounds like fun man. Be careful with this build tho. Having a. dD makes it easy to get into a "it's ok if it sits for awhile" type of mood and that's a quick way to Ed up with an unmovable truck for a long long time
 
keep driveshaft length in the back of youre mind.
th400+203+205+14bolt+ lift= really short rear driveshaft with alot of angle.
a th350 is 2-3/4" shorter, will take alot of abuse, and takes 20 horsepower less to operate. plus you already have one.
just an fyi.

my truck has a longer than stock wheelbase, and still has to run a c.v. rear driveshaft. iirc it's only about 38" long. thats the only reason i dont have a th400 in my k5
 
Ha. I know that sonic and that exit going to hollister. Right before that exit is a field I used to play in with my XJ. Lol.

Anyway sounds like fun man. Be careful with this build tho. Having a. dD makes it easy to get into a "it's ok if it sits for awhile" type of mood and that's a quick way to Ed up with an unmovable truck for a long long time
Yeah its a bit of a tradition of mine to hit sonic on the way back, That and vanilla wafers every trip :thumb:. We need to get to wheelin ill hit you up next time i go with dean and his 74 k20.

keep driveshaft length in the back of youre mind.
th400+203+205+14bolt+ lift= really short rear driveshaft with alot of angle.
a th350 is 2-3/4" shorter, will take alot of abuse, and takes 20 horsepower less to operate. plus you already have one.
just an fyi.

my truck has a longer than stock wheelbase, and still has to run a c.v. rear driveshaft. iirc it's only about 38" long. thats the only reason i dont have a th400 in my k5

Good point, I have at least a year before i have to worry about that though forunately.

Having as many projects as i do with as little experience as i do can suck sometimes. Seems like i never make any real progress on any of em and everytime i try i spend all day trying to figure out what one vent hole is that or what bolt i need for that or which crossmember goes up front blah blah blah. Inexperience really slows you down i need to get me a pro over here on my build days so i can shoot through these builds.
 
Well, there's nothing wrong with aiming high. Just don't throw all your money into this thing. If you decide to try to sell it or you total it, you'll lose some money for sure. And go on some dates. You remind me of myself at your age - thinking about off road stuff instead of normal stuff all the time.:D Don't wait too long or the girls will all get married and have kids and you'll be stuck with your Blazer. Hmmm... maybe not such a bad deal.:haha:

What Big Dan said got me to thinking. To go to 8 lug, you would need not only the knuckles, but the calipers and backing plates off the 3/4 ton for the larger brakes. Not sure about the spindles. I was going to suggest buying new rotors at the parts store. You'd have to come up with the wheel studs too.

You could also look into a 6 lug 14 bolt for the rear to match your 6 lug front. I just don't want to see you riding around with a 6 lug front axle and an 8 lug rear axle. You'll look like a tool. Remember you're representing ck5.com here!:haha:
 
Well, there's nothing wrong with aiming high. Just don't throw all your money into this thing.
We'll obviously i wont i have a tow rig project to build too :whistle: duuuuh :haha:. Speaking of go look over on that build im trying to decide between a few motors.

If you decide to try to sell it or you total it, you'll lose some money for sure.
I'll live in it before i sell it. As for totaling it by the time im done this thing will be untotalable. :rolleyes:

And go on some dates. You remind me of myself at your age - thinking about off road stuff instead of normal stuff all the time.:D Don't wait too long or the girls will all get married and have kids and you'll be stuck with your Blazer. Hmmm... maybe not such a bad deal.:haha:
Thats the plan

What Big Dan said got me to thinking. To go to 8 lug, you would need not only the knuckles, but the calipers and backing plates off the 3/4 ton for the larger brakes. Not sure about the spindles. I was going to suggest buying new rotors at the parts store. You'd have to come up with the wheel studs too.

You could also look into a 6 lug 14 bolt for the rear to match your 6 lug front. I just don't want to see you riding around with a 6 lug front axle and an 8 lug rear axle. You'll look like a tool. Remember you're representing ck5.com here!:haha:

agaaiiin, This beefed up 44 is going to live a short life under my truck and live the rest of its life under my 73 which will be on half ton six lugs FOREVER. My dad is obsessed with keeping that thing all stock and the only way ill ever change it is when he dies and then i would feel bad changing it from what he wanted so its just gonna live on half tons until we both die and maybe my son will feel bad and he'll keep it on half tons too. Needless to say spending 100+ bucks an axle and a full day swapping to 8 lug just to swap back in a few months would be a less than smart use of my very limited time/money.
 
great story, you have a really cool dad:waytogo: my oldest is going to be 12 in march and has told me she wants a Blazer when she turns 16:woot: so I've told the wife it's getting close to time to find one to build up...hers will be a Mall crawler
 
Since ive decided to cut my losses on the 84 burb this is my only real project except for the 73 so i figure ill start my 44 build up as the first stage of the project. I Figure the first part of the build is inventory of needed parts. This should be a good guide to follow for basic info.
http://www.off-road.com/trucks-4x4/tech/solid-axle-7879-dana-44-rebuild-18371.html

1.for the basic rebuild im thinking
http://www.4wheelerssupply.com/catalog/product_info.php/products_id/70677
Then change out my wheel bearings with some from the local hardware store since im pretty sure those are long overdue :whistle:. To anyone who read my grinding thread. That should take care of freshening up the axle assuming all the gears are good.

2. For the front locker im thinking a 30spline lock right. If i understand this correctly since i have manual hubs, When the hubs are unlocked i will have a normal open differential but when i turn the hubs it will work act as a lockright. I'll be running this on a truck with a fulltime 203 if that matters.
http://www.desertrat.com/cart/Default.asp

3.Then chromoly shafts/u joints
https://www.4wdfactory.com/store/products.php?product=73%252d78-GM-Dana-44-Chromoly-axle-kit

4.Im thinking of running stock steering on the 44 with a ORD 1.5'' D44 Tie rod
http://offroaddesign.com/catalog/HDsteeringlinkage.htm
and then pick up some tie rod ends out of kragen or somethin since im only running 33's on this axle i dont think i need the heavy duty tie rod ends.

Total bill (not including shipping)
Dana 44 overhaul kit 147.11 w/ free shipping
dana 44 30 spline lock right 323.00
73-78 gm dana 44 chromoly axle kit 560.00
1.5'' ORD tie rod 115
wheel bearings i'll guess 40 bucks at the auto store
=
$1185.11 :eek: for a dana 44
 
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