'89 R3500 Crew Cab 2wd to 4wd conversion & beyond

[mrk5]

Took a couple days off work to get some work done on the truck. We're planning to make a trail run Sunday so I wanted to have a few things done. Not to mention Blazer Bash is drawing nearer, much nearer.

First thing I did was to get the power steering cooler installed. It's a heat sink cooler made by Howe.

This is the perfect spot. The top lined up directly with the reservoir and the bottom lined up with the outlet on the steering gear. I used 2 strips of aluminum to make straps to fasten it down. I also cut a hose apart and sandwiched it behind the cooler to keep it from wearing against the core support.

I did have to move the horn. I loosened the bolt and rotated it around 180°.

I chose that cooler because it uses larger -8AN lines. I plumbed the steering return with -8 to accommodate a little more flow on the steering side.

 

[mrk5]

Another thing I finished was the rear shock installation. I kept it simple. Welded a pair of tabs to a plate and bolted that to the bed floor. I figured since the bed is bolted straight to the frame, it would be simpler.

I made the bracket wide enough to span 3 ribs to spread the load. It also worked well so that the bolt heads are in the "valleys" on the top side.

The lower tabs are from Ruffstuff.

I tried to put the bottom of the tabs even with the bottom of the axle tube.

Here you can see the angle they ended up at.

From the rear.

With the tire on.

The mag-chloride sure does a number on the chrome finish of the shocks. Unfortunately I hadn't been keeping up with cleaning them.

This is the best I could do with them using a chrome cleaner/polish.

 

[blazinzuk]

I know you probably realize this but watch that floor close.

It is pretty thin metal.

I think if your shock is not limiting you you might be alright. Actually I think over time it will tear the floor out. I think you will be alright for now.

If your shock is limiting you it will tear the floor out in short order.

 

[82355]

Yeah, I've ripped shock mounts off the frame, I am not so sure of the floor mounting.

Martin

 

[blazinzuk]

Got some old floor kicking around anywhere Scott, cut out a big piece and back up the other side.

I do think you need to rethink those mounts though

 

[Smokinthehippies]

I was gonna ask if samwhichin from the other side would help buy him some time

 

[sweetk30]

just got done moding and fixing dents in my floor of the 2wd build and you NEED TO MOVE those mounts from the bed floor.

unless you tie them in to some sort of frame structure .

 

[mtnman]

I think you will be good for BB... When I sectioned out 13" of the bed of my truck, I discovered that the bed floor was half the thickness of the inner bed sides. Not as strong as you would think it should be.

 

[mrk5]

Well damn. So much for my bright ideas. All I did for now was 1.5" fender washers up top. I could make a plate for the top side. I'm hoping being near the wheel-well will help lend some support. I guess it's worth a shot. No matter what this bed is scrap (I'll explain at the end of this post).

I did at least round off the top edges of the plate so as not to create a point that could tear the floor as easily.

I think like mtnman said I can make it thru the Bash. If I get time in the next couple of weeks I'll see about doing something different. I have an idea how I can bracket to the frame. At the very least I know where everything needs to land. I'm not going to bombing down Gemini Bridges Road yet this year. I need bump stops in for that and I don't see that happening before Sept 26th.

Here's why the bed is scrap. The previous owner spilled something in the bed, roofing tar or something that stays gooey.

The entire bed is covered in it. Thick in some places.

 

[blazinzuk]

Yah I don't think that BB is gonna kill em. Or you will kill them just driving down the road.

It looks like the freaking tar or whatever the heck that is might hold the bed together even after they rip through.

The caveat is of course your shocks can't be bottoming out or be limiting you on down travel.

That happens and they are gonna tear out quick fast and in a hurry.

Sucks when a brilliant idea doesn't always work out when other people look at it.

I have had many many many of those ideas

 

[mrk5]

No worries about shock travel. There's 6" up and 9" down. I know the rear suspension isn't traveling that far. Matter of fact I can already tell that drilling out some rivets for shackle flip and new hangers will be happening not long after Blazer Bash.

 

[miniwally]

Is the power steering res mounted to the chassis or engine?

If it's on the chassis you need to change that, the engine rocks and moves around and will take things apart and make some leaks.

 

[Hogback Fabrication]

I'd weld something to the top of the bed to reinforce the shock mount, easy, done and doesn't even need to be pretty if you're ditching the bed anyway.

I haven't been around the nasty you have in the bed, is it really that impossible to deal with between an air chisel and fire? I don't envy that situation

 

[mrk5]

Is the power steering res mounted to the chassis or engine?

If it's on the chassis you need to change that, the engine rocks and moves around and will take things apart and make some leaks.

Shhhh, only one design flaw per week and the new week hasn't started yet.

I'd weld something to the top of the bed to reinforce the shock mount, easy, done and doesn't even need to be pretty if you're ditching the bed anyway.

I haven't been around the nasty you have in the bed, is it really that impossible to deal with between an air chisel and fire? I don't envy that situation

You have pull it away about 8 to 10 inches before a piece will break off. Some of it is kinda setup and some of it is complete goo. Based on the time and effort it took to clear the areas for the shock mount bolts I'd probably need 40hrs to clean the bed. It's not worth that effort.

 

[mrk5]

My solution for now is to throw a bed mat over it.

 

[blazinzuk]

Your going to a shortbed anyway right?

 

[mrk5]

Your going to a shortbed anyway right?

Sometimes I think the longbed is cool. Well it is around town. Just hauled new recliners out to my parents last weekend. Which was great I love having a pickup again. But I can't help but think once we run a couple of forest service roads it's going to be an issue.

 

[blazinzuk]

Sometimes I think the longbed is cool. Well it is around town. Just hauled new recliners out to my parents last weekend. Which was great I love having a pickup again. But I can't help but think once we run a couple of forest service roads it's going to be an issue.

Shortbed it is LOL, just build a bed extender and make sure the tailgate is in good shape, shortbed to long bed in nothing flat

 

[mrk5]

I finished up the steering and got the ram installed.

I am concerned about fitting on the left hitting the engine crossmember. There's only about 2" of clearance.

I also need to come up with an idea on how to hold the feed line up off the spring. It needs slack to be able to move with the axle. Maybe I just cover it with some protective covering and let it hang.

 

[AJMBLAZER]

Wrap it with hose and then hose clamp that?