84 Optimized M1009

[2INSANE]

This thread is for the general discussion of the Item 84 Optimized M1009. Please add to the discussion here.

 

[2INSANE]

Overview:

I purchased this Fine M1009 back in 2009. It is a 1984 Chevy K5 Blazer CUCV M1009.
It was completely stock with only 23,000 original miles. The only thing that was upgraded at the time was leather bucket seats.

I started the build in 2011 and have not stopped building it to this date.

My goal with this build is to keep it street legal, body mostly intact and extremely capable of going just about anywhere, in any terrain, confidently and alone if needed.

When it is running, I drive it daily.

It now has about 55,000 original hard miles. It is on its 3rd motor, 2nd transmission, 2nd transfer case, 2nd set of rock sliders, 2nd set of front spring plates, 3rd set of front springs, 3rd paint job, 4th soft top, 12th set of U-Joints, 3rd set of driveshafts, 2nd set of bushwhacker fender flares and 3rd set of interior seats.

In 2005, one of my horses bucked me off into a thorn bush and fractured my lower spine. (An injury almost equivalent to Christopher Reeve’s) Since that day I have been extremely limited to doing the hard and heavy modifications to this fine M1009 and hire shops to help with those projects that I can not do. For the most part, I do a lot of the work myself. I can not lift over 40 pounds without the risk of bursting a disk and I wear a back brace whenever I drive (Micro vibrations) and at work. I work up to 70 hours a week as the Yellowstone National Park Recycle Manager and an additional 5-10 on my days off helping customers with their 6.2 and 6.5 motors. My time is extremely limited. Hiring shops to help has worked well for me so I can mostly plug and play on my well deserved paid vacations. Sooner or later, there will come a time for me where I will no longer be able to ride trails and will need to sell or convert this fine M1009 into a grocery getter. That time is not now, so let’s ride! Don’t feel sorry for me! Feel sorry for that horse that went to the glue factory! Lol!

This first post will be a living document that will be updated often. I will add costs for all parts and try to remember the labor costs.

As of this moment, I have at least $60,000 invested. From parts to labor. If you calculate how long I have owned this M1009 and compare the cost to a new Rubicon, $60,000 over the time span of 13 years is not a lot…

Initial Purchase Cost $1,500

Under the hood:

1. Bostic Motors Reman Long Block 6.5 Diesel Optimizer GEP Navstar.
2. Refurbished Junkyard 6.5 GM1 Turbo.
3. Refurbished Junkyard 6.5 Oil Feed/Fittings.
4. Refurbished Junkyard 6.5 Lower Intake Plenum.
5. Refurbished Junkyard 6.5 Turbo Exhaust Manifolds.
6. Refurbished Junkyard 6.5 CDR Valve.
7. Refurbished Junkyard 6.5 CDR Tube.
8. Refurbished Junkyard 6.5 Turbo Intake Elbow.
9. Refurbished Junkyard 7 Blade Fan Upgrade. (Rare)
10. Refurbished Junkyard 6.5 Passenger Valve Cover.
11. Refurbished Junkyard 6.5 Injection Pump Lines.
12. Refurbished Junkyard 6.5 Oil Dipstick.
13. Refurbished Junkyard 6.5 Timing Cover.
14. Refurbished Junkyard 6.5 Water Pump Plate.
15. Junkyard 4911 6.5 Injection Pump (Stock Tune).
16. ORD Motor Mounts.
17. ORD Motor Support Brace.
18. Quadstar Turbo Oil Drain Tube.
19. Quadstar Passenger Glow Plug Shields.
20. Quadstar Boost Master.
21. Quadstar Upper Intake Plenum.
22. New Made In Germany Bosch Injectors.
23. CUCV V-Belt Dual Alternators.
24. CUCV Coolant Crossover.
25. CUVC Crank pulley.
26. CUCV Rebuilt 4 Core Radiator.
27. New Radiator Bushings.
28. PSC V-Belt Power Steering Pump.
29. ESS Oil Pump Drive (Tach Signal).
30. Fluidamper.
31. New 6.2 Flowkooler Water Pump.
32. Oil Pan Temperature Sensor.
33. Clear Fuel Line from Ip Nipple to Return Nipple Mod.
34. Fuel Manager FM100 With Water In Fuel/Fuel Heater.
35. Mechanical Pre And Post Fuel Filter Fuel Pressure Gages.
36. Hydraulic Fuel Filter Fittings.
37. New LMC Truck Corner Battery Trays.
38. New G60 Glow Plugs.
39. New Modified Diamond Eye Exhaust Crossover (Full Heat Wrap).
40. New Exhaust Manifold Flange Gaskets.
41. New Modified 3” Diamond Eye Downpipe (In-Frame w/Heat Wrap).
42. New Aluminized Custom 4” Straight Exhaust.
43. New 300W Freezep lug Block Heater.
44. New 2X Electric Battery Warmers.
45. New Edlebrock 3-8 Psi Electric Lift Pump.
46. New Passenger 2 Center Glow Plug Wiring Extensions With Heat Wrap.
47. Huge Junkyard Transmission Cooler.
48. 1400 Stall Torque Converter.
49. Custom Built Pre 1986 Hydraulic Controlled 700R4 With 3-4 Clutch Pack Upgrade, Corvette Servos, Etc. 500HP rated.
50. Upgraded Aluminum 700R4 Pan W/Temperature Sensor.
51. Rebuilt NP208.
52. Glow Plug Manual Push Button Override Mod.
53. Glow Plug Resister Ballast Delete Override Mod.
54. Custom Front and Rear Driveshafts.
55. 1” Transmission Crossmember Drop.
56. Derale Remote Electric Oil Cooler w/Custom Lines.
57. ARB Air Compressor.
58. Dog head Starter Relay Mod.
59. Spectre SPE-9831 Enclosed Airbox/Filter Successfully Mated To ARB Snorkel.

Body:

1. Bushwhacker Fender Flares.
2. Soft Topper. (My 4th)
3. Ord Low Pro Front Bumper.
4. LMC Scowl Hood.
5. LMC Front Fender Marker Lights.
6. Warn M12,000 24v Winch.
7. Rigid D2 Front Bumper Lights.
8. Rigid Dually Front Bumper Lights.
9. Rigid 50” Light bar w/Custom Mount.
10. 1978 Truck Tailgate.
11. Blazingoffroad Rear Bumper/Tire Carrier.
12. 5 gallon Fuel tank w/Mount.
13. Hi Lift Jack.
14. 8’ CB radio Whip.
15. 8’ Stereo Whip.
16. ARB Snorkel w/Pre Filter.

Interior:

1. LMC Door Panels.
2. LMC Door Billet Door Trim.
3. LMC Lower Door Pad.
4. LMC Billet Steering Wheel w/suscide Knob.
5. LMC Billet Rear View Mirror.
6. LMC Headliner with Cobra 29 Nightwatch CB w/1969 40w Final, Led Lights.
7. Isspro Boost/Pyrometer Gauges.
8. Junkyard K5 Seats/Console.
9. DIY4X Aluminum Dash Black Powder Coat.
10. Under Dash Leds.
11. Phantom 2 Gauges.
12. 2xRear 6x9’s in custom box.
13. 500 watt amp.
14. 4x 5 1/2” Clarion Dash Speakers

Tires/Rims:

1. 37/12.5/R16.5 Goodyear MTR on 16.5 8x6.5 lug Comet Raceline Aluminum Rims.
2. 42” 16.5’s on Backorder. I will mount these to my set of Trailworthyfab 16.5 Beadlocks with inserts when they arrive…

Rear Suspension:

1. Boyce Equipment Reman Corp 14 Bolt Full Float/4.56/Arb Locker.
2. Ord Disk Brake Conversion.
3. DIY4X Shock Absorber Inboarding Kit.
4. DIY4X Lower Shock Absorber Mounts.
5. DIY4X Razor Back Differential Cover.
6. DIY4X Shackle Flip N Switch.
7. DIY4X 6” Cross Tied Shackles.
8. DIY4X Spring Plates.
9. DIY4X U-Bolts.DIY4X Pinion Guard.
10.DIY4X Spring Perches.
11. DIY4X Bump Stops.
12. Bilstine Shocks.
13. ORD Steel Braided Brake Lines.
14. Junkyard 64” Rear Springs From 2wd Chevy Truck.
15. DIY4X Wishbone Truss/Anti Wrap Wrapitor $916.86


Front Suspension/Steering:

1. Boyce Equipment Crate Dana 60/4.56/Arb Locker/Chromoly 35 Spline Inner And Outer Shafts.
2. Premium Warn Hubs.
3. DIY4X Razorback Differential Cover.
4. ORD Crossover Steering.
5. ORD Heavy Duty Tie Rod And Ends.
6. ORD PSC Power Steering Pump.
7. ORD PSC Power Steering Reserve.
8. ORD PSC Hydraulic Ram Assist.
9. DIY4X Spring Plates.
10. DIY4X B52 And Beyond Hangers.
11. DIY4X 6” Crosstied Shackles.
12. DIY4X U-Bolts.
13. Junkyard 52” K5 Rear Leaf Springs.
14. Bilstine Shocks.

Audio:

1. Alpine ILX-F511 Floating Din $1400
2. 12” JL Audio Subwoofers and Box $300
3. Kenwood 1000 Watt Amp $250
4. Samson Marine 8” Speaker Subs $300
5. 4x Dash Speakers
6. 500 Watt Amp



Recognition:

1. August 2013 Off-Road Magazine (Full-Size Invasion).
2. January 2014 Fourwheeler Magazine (Full-Size Invasion).
3. July 2014 Fourwheeler Magazine (Off-Road Camping)
4. May 2016 Fourwheeler Magazine (Best of the Best)
5. Motor Trend Article April 10, 2016
www.motortrend.com/features/1604-christopher-hufstetlers-reborn-ex-military-1984-k5-blazer/amp/
6. 2020 K5 Of The Year Chevyk5blazer.com Self-Appointed.

Conquered Trails/Famous Roads/Over-landing/National Parks/Mountain Ranges:

Utah:

1. Steel Bender (1x)
2. Find N Things (5x)
3. Hells Revenge (5x)
4. Moab Rim (1x)
5. Top Of The World (1x)
6. Poison Spider (3x)
7. Gold Bar Rim (1x)
8. Golden Spike (1x)
9. Behind The Rocks (1x)
10. Porcupine Rim (2x)
11. Strike Ravine (2x)
12. Mineral Basin (1x)
13. Inspiration Point (10x)
14. Spiral Jetty (3x)
15. Farmington Peak (10x)
16. Left Hand Fork Trail (2x)
17. Old Ephram’s Grave (2x)
18. Logan Peak (2x)
19. Monty Christo (5x)
20. Escalante (2x)
21. Hole n the Rock Trail (West 1x)
22. Zion National Park (1x)
23. Arches National Park (2x)
24. North Meadow (5x)
25. Prospector Trails (3x)
26. Tooele Rattlesnake Trail (3x)
27. Tooele Constrictor Trail (3x)

Montana:

1. Over The Sun Hwy (1x)
2. Bear Tooth Hwy (3x)
3. Crazy Mountain Range (All Trails) (2x)
4. Tobacco Root Mountain Range (This is my favorite mountain range, as it is where my late father got me hooked on off-road and it has the most technical/beautiful trail in the State of Montana. All Trails 8x)
5. Glacier National Park (1x)
6. Bridger Mountain Range (All Trails) (3x)
7. The Gravely Mountain Range (All Trails) (2x)
8. Yellowstone National Park (100x)
9. Pipestone OHV Park (All Trails)

Future Upgrades/Maintenance/Modification:

1. Another paint job.
2. Minimal boat siding.
3. Front/Rear Traction Bars.
4. Exo roll cage.
5. Considering Nv4500 Swap
6. Fix small leaks
7. Rear flood lights
8. Convert swing out tire carrier to spring loaded swing down tire carrier.
9. 42” tires on back order.
10. Install more vents in hood.
11. Install DIY4x rear frame support.
12. Sell Snorkel.
13. Hx35w turbo swap.
14. Serpentine belt upgrade with dual alternator bracket, HO water pump/9 blade fan.
15. Build a pickup truck conversion kit just for winters.
16. Shave 14 bolt.
17. Truss 14 bolt.
18. Reid knuckles.
19. Line lock.
20. Convert to synthetic winch line.
21. Buy more recovery gear.
22. Install wheel well tool boxes.
23. Install front upper shock tower mounts.

Planned Future Events/Trails/Volunteering:

1. Blazer Bash 2022
2. Full-size Invasion 2022
3. McKelvey Trail Bridge Restoration Project 2022.
4. Boulder Creek Trail 2022
5. Montana Square Body meet and greet event. 2022
6. Random Bozeman Mountaineers Trail Rides.
7. Rubicon Trail 2023.
8. Sand Hollow.

 

[2INSANE]

Here’s a few more older pictures…

A 6.2 Banks Sidewinder Turbo I built and sold to a customer for a lot of cash. I used that money to buy a 6.5 Optimizer long block, mostly self refurbished 6.5 parts and currently have it in my M1009.

 

[2INSANE]

A few more photos for your viewing pleasure.

Very rare to see an in frame 6.5 exhaust photos. This custom exhaust took 14 hours+parts. $2800…

If you want to see much older photos and info on this build:

84 m1009 cucv chevy blazer build-up

Purchased stock m1009 chevy blazer 1984 6.2L diesel v8 3.08 axle ratios 1/2 tons New Boyce Equipment Dana 60 front with 4.56 gears ARB air locker installed. Rebuilt Boyce Equipment Custom Corp 14 bolt full floater rear with 4.56 gears ARB air locker installed

www.steelsoldiers.com

 

[2INSANE]

Few more… I got 8+ years to get you guys caught up :-)

 

[2INSANE]

Last night I installed the famous Doghead starter Relay mod… Here is the pictures from last nights work… The plug was partly toasted but the Oem relay was still good. Better to be safe then sorry. Removing the passenger DIY4X dash only took 30 minutes.

 

[2INSANE]

Hx35w swap coming soon! Stay tuned!

 

[GWeakland620]

I like it!

 

[2INSANE]

I like it!

Thank you!

 

[max 02]

Again in to watch.
Nice man!

 

[joshuak]

In for the story, that's quite a relationship you've developed there with the '09.

Nice!

 

[2INSANE]

In for the story, that's quite a relationship you've developed there with the '09.

Nice!

Thank you!

Again in to watch.
Nice man!

X2!



Nothing exciting done today… Just finished reinstalling the DIY4X dash, speakers and radio.

Got the battery terminals cleaned, connectors cleaned, took out the recently toasted 12v starter, refurbished one of my spare 24v starters and installed it.

Back to daily driving it again.

It does get a lot better MPG then the Duramax LBZ I noticed and is a lot more fun to drive.

If anyone wants more pictures of anything specific or has questions about the 6.2/6.5 motors, please feel free to ask! I am here to help!

 

[Cucv_M1008]

Sweet Cucv

 

[swettysblazer]

I thought your name looked familiar. I remember the first build thread

 

[Truckman4life]

Love the blazer! You have accomplished quite a bit mod wise and wheeling wise with this thing. I will definitely be referencing this build if I get around to 6.5L swapping my blazer. The 6.2L is gutless but does good and gets 17 mpg.

 

[2INSANE]

Sweet Cucv

Thank you!

I thought your name looked familiar. I remember the first build thread

Yeah there was a lot of good info in there but the pics were gone… I do not have the old pictures to revive it.

Love the blazer! You have accomplished quite a bit mod wise and wheeling wise with this thing. I will definitely be referencing this build if I get around to 6.5L swapping my blazer. The 6.2L is gutless but does good and gets 17 mpg.

Thank you! You could always put a turbo on your 6.2 and throw low boost levels at it for reliability, more hp/torque and maybe even get better mpg!

 

[Truckman4life]

Thank you!



Yeah there was a lot of good info in there but the pics were gone… I do not have the old pictures to revive it.



Thank you! You could always put a turbo on your 6.2 and throw low boost levels at it for reliability, more hp/torque and maybe even get better mpg!

I've actually got a 6.5L out of a '92 or '93 Chevy. Turbocharged with a mechanical injection pump. I bought it like 15 yrs ago and been dragging it around with me everywhere I moved. It probably needs a rebuild. Also I think I have a better injection pump in a box somewhere but I'm nor sure what it was any more. I'll have to dig it out and see. Been too broke to do any thing with it and it just keeps going with the 6.2L so I haven't worried about upgrading.

 

[Big Ray]

Wow!

Color me impressed! How's that Bostic motor holding up? I've heard a lot of scary stories, but not from anyone that actually owns one.

Thats a bad ass rig.

 

[2INSANE]

Wow!

Color me impressed! How's that Bostic motor holding up? I've heard a lot of scary stories, but not from anyone that actually owns one.

Thats a bad ass rig.

The Optimizer is running very well! Got about 3000+ miles on it now. Compression is at 415! Zero blowby cold or hot. Conservatively pushing 6-7 psi in town and about 9-12 psi on the interstate. I’ve peaked it shortly to 14 psi only 2 times to test ability.

Since I disconnected the snorkel and added a bigger air filter, my Egts stay at 700 degrees or less.

The increased coolant pressure from the upgraded water pump causes small seepage around the timing cover/thermostat housing/water pump plate. Nothing too serious to cause me to want to replace it.

The higher pressure Oil Pump caused the rear main seal to leak a little. Might change that out if I do an NV4500 swap.

I’ve had to make multiple timing adjustments on the ip because of timing chain break-in stretching. I have it timed perfectly right now.

Bostic Motors does not have a lot of reviews. Their reviews are better then any company I’ve seen out there as far as Optimizer Remans and other Diesel motors.

So far I am loving it! Not liking the Corvette mechanical 700r4 though… the rpm shifting points don’t seem to be to my liking. Shifts way to early when I need the higher rpm. Edit: To compensate this issue, I keep it in Drive at all times and manually switch it to Overdrive when the rpm gets to 2000.

In town, my blazer gets better mpg then the Duramax. On interstate, the Duramax gets the better mpg.

 

[2INSANE]

My Warn M12,000 24v motor went out this last winter. I did a lot of research and watched a lot of rebuild videos and decided not to drop another $2,500 on a new winch but to simply just replace the motor. $350

This new motor is an upgrade for the M12,000. Even though it is a 12volt, the additional HP of this new motor will now turn this M12,000 into a M15,000 and will spool much faster.

The old motor had no seals or gaskets. No wonder why water and moisture went inside. This new motor is completely sealed with gaskets on each side and even rubber O-Rings on the bolt ends. I am hoping this one will last a long time.

It only took an Hour to replace the motor and put new grease on the spindle bearings. Everything bolted right up!

I will bolt it back up to the ORD bumper and wire it up to the 12v side terminal on the battery when the rain stops.

Edit:

I called Warn up and learned the 24v contactor #83085 will need to be replaced with a 12v contactor #81400 to make the transition from 24v to 12v on a M12,000/M15,000.

Cheapest one I could find was at Montanajacks.com. $128 Shipped.