CK5
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'91 K5 Four Wheel Camper

This is the build for my 1991 V1500 Blazer, AKA the K5.3. It started out life being sold to the U.S. Government with a 350 TBI/700r4/241 combo. 4 years with a 5.3/700r4 Combo and now moving to an 8.1L Vortec and NV4500 5-speed.
Got some stuff done. Metal tee installed, water pump resealed and the oil has been changed. I also bolted in factory skid plate for the 241 I picked up from another member @oatsk5 . Thanks again dude!

Once I fired it up I wanted to see if the oil pressure gauge would work with the new sender. It didn't immediately. But then after pulling out of the driveway and torquing the engine under acceleration, it started working normally. I have to believe that there is a break in the wire as it's going open and causing the gauge to peg out at max pressure. Going to have to get into a wiggle test mode to find it. But all the gauges work now. Even if one is coming and going.


Got a date in the Bigassgas Garage for the rear shock mount removal and installation next Sunday. In the meantime I've got a couple little electrical items to tweak and then start in on the organization of packing.
 
We had a very productive day over at the Bigassgas Garage. Our buddy Ian came over to help too. I was on demolition, as in cutting off the existing mounts and prepping the axle tubes for the new mounts. Larry prepped the brackets as they needed some minor adjustments prior to installation. Ian burned them in well. Larry gave the whole truck a bath and the axle so we could paint the new mounts. I fogged all the stuff back again.

I did test drive it to fetch some beer and tacos for crew. All I can say is wow. The Bilstiens out back with the front ones completely changed the attitude of the truck. It doesn't do a mule kick/hop over crappy roads any more. Ride is firm but not harsh. The shocks just soak up any imperfection in the road surface.

Pics are on my phone and it's dead so they will have to wait until tomorrow.
 
I can't stress how much of a pain in the ass it is to remove the shock brackets off the axle. But taking off bracket in one shot and whittling away at the remaining chunks, I switched to grinding and finished off with the flap wheel.

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So while I got to work on the other side Ian got to work mocking up the mount with the shock. Don't worry we didn't weld the bracket with the shock in place.
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Mounts in and prior to painting.
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Left side.
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Right side.
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It was productive in the shop. We kicked back and had a couple of beers and discussed the plans for the coming two weeks. Time is getting short now. Validation run is planned for Saturday. Larry needs to shakedown the new suspension and air locker in his and I've got to figure out how to load this pig and still be able to sleep inside if needed. An off road run up to Hermit Lake or Rainbow lake above Westcliffe.
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I can't wait to get bilsteins some day. Glad it all turned out good. Looking forward to pics.
I will say this, I was amazed at the change. This is with stiff as hell Rough Country springs up front too. Larry told Ian and I a different route to the taco shack and it's broken up rough as hell pavement. So we went after the food and hit the rough road. Holy cow. This setup just soaked it up. I followed that up with the ride home. Pueblo Blvd coming off Highway 50 is where Larry had seen the rear tires a couple inches of air under the rear tires as it hit a large expansion joint in the road every 20ft or so. To say it kicked like mule is pretty accurate. Going over the same section yesterday proved it for me. You know it hit the bumps but the mule kick was gone. The ride is firm, but not jarring. Highway manuvers are planted down. I'll know more about the off road quality next weekend.

It is money well spent. I'm pissed I didn't do it sooner. It's not cheap but it's totally worth it.
 
Any particular reason for mounting them tube down? I thought bilstein recommended tube up.
I could have swore that's the direction indicated in the instructions, but who reads those anyway? I think the kicker was the upper stud was pre-installed in the end on the rod side and not the tube side. That and the lables are right side up when they are installed this way.
 
Bilstein told me once that they install the labels and stamp the housings so the are legible when the shocks are properly installed, and that they do have both styles (some body up, some body down) so just install them so the sticker is right.
 
Bilstein told me once that they install the labels and stamp the housings so the are legible when the shocks are properly installed, and that they do have both styles (some body up, some body down) so just install them so the sticker is right.

That's probably why Larry's 7100's are the other way from mine. That and the reservoirs sit on the topside since there wouldn't be anyway to mount them on the axle.
 
Ahhh, now I see. Mine are mounted opposite and you can read the label, that's why I was slightly confused.
 
Validation time.

Nothing like a looming departure deadline to get your rig straight. Been dealing with a nagging issue with the fuel pump not holding pressure on the line. It was causing me to cycle the key 2-3 times to reprime the system before it would start. With a gauge on the rail you could watch the pressure drop to zero as soon as the engine was shut off. That's no bueno for a long trip where we will be stopping frequently to take photos and goof around.

So Larry volunteered to swap it while was at work this week. He did find a reason why my fuel gauge went nuts below a half tank too. He knocked that out pretty quickly while I got the oil changed on his daily at work. Fuel level sensor wires were loose and he tightened them up. Gauge is pretty darn accurate now.

Truck is loaded for a run up to Rainbow or hermit lake after work. Booyah!
 
I like those runs up above Westcliffe. Nice scenery up there.
Pretty good chance of some snow wheeling too
Yeah, we hit snow. Not alot but enough to block us from getting up to the lake. Got pretty hairy.

Where's the fuel pressure regulator on that truck?
It's stock for a 5.3 so it's on the fuel rail on the drivers side.

Uploading photos from the run now.
 
Since @Larry 's truck has seen some major changes over the winter and mine has only 3 off road runs under it's belt so far we needed one last quick overnighter to prove out everything is right. We also needed to make sure our gear was in order to camp as well as all the other intangibles you didn't realize you needed until after you left.

We met up at Larry's Mother in law's place after I got off work. Our buddy Bill was going to drive up with us, but wasn't camping overnight. The three trucks took off shortly after I got there. We took a different route off the beaten path to get up to highway 69 through a local mountain community. It gave us a few miles of dirt to see how the new shocks for both of us could handle the washboard roads. We both commented over the radio how different the trucks ride, or glide over the rough dirt road. Back onto the highway we are barreling down the Wet Mountain Valley for our target trail to Rainbow lake.
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While Larry and I started to air down, Bill pulled his t-case lever into 4hi and we all heard a loud clang ring out from under his Dodge. Larry investigated and found only 1 bolt holding the front driveshaft to the t-case flange. This is why we do a run like this. Find issues now, before we are 100 miles off pavement. So needless to say Bill doubled back home to address the problem and left Me, Larry and his Mother in law for the run to the lake.

This area has had a couple of fires in recent history, the start of the trail winds through the older of the two fires. Vegetation is starting to come back here.
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I got a lot of this view and will have more of the same next week. That damn ARB badge on the diff cover was reflecting light off it intermittently like Lightning McQueen's chrome bolt throughout the afternoon.
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More of the same. One thing I did notice from prior runs is that his truck wasn't rocking back and forth as it was before.
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We are starting to gain elevation here. @bent72 you are right, the area is very picturesque. That's the road into the trail from Highway 69.
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The snowmelt was running in full force. Creeks were roaring.

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I've been through here in the fall and this is normally a trickle compared to what you see here.
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Further up the trail is where things got interesting. Larry had pointed out a lady with a small daughter just sitting on the side of the trail. I saw her, no gear to speak of, not a hiker or anything like it. Odd. She wasn't in distress so we figured we would run into a camp nearby. So we plodded on. A couple switchbacks later Larry has a teenage boy approach his truck. He proceeded to tell Larry his Mom saw us and (she called both of our rigs Broncos BTW) and to warn us about the trucks above us that were stuck. The boy explained there were two Fords up above us that one got stuck in the snow and almost slid off. They were working to clear it, but told us to hold down here as there was no wide spot to pass. Pretty soon, both rigs come down. A mid 90's F150 and early 2000's F250. Both beat to hell with bald tires no less. On our way out we saw the F250 at the turn to get on the highway:

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Apparently, the F250 didn't quite make it home. But the guys did explain that the were a couple of snow drifts across the trail, forcing F150 to slide it's rear off the trail requiring the use of a come-a-long to bring it back up again. We decide to proceed with caution.

You can see the first drift here. The trail is narrow requiring careful placement of the truck through the snow.
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We scouted it and Larry gets through the first two without much drama. He gets to the largest snowbank and radios back to me to get up there to spot him. So I walk ahead and our plan was to get his left side up on the snow and let the wieght of the truck break through the crust and allow the width he needed to pass safely. He did that, but the snow didn't budge. It was solid. So Larry's sitting at what I would estimate a 30* angle to the downhill side. Neither of us liked how it sat so he backed down, scooted over a little and crept up again. The ARB was on and as he applied light throttle the tires broke traction and the whole damn rear of the truck shifted to the downhill side. Larry felt it, but I couldn't see him off from my point of view. He wisely stopped and got out to investigate. I walked up and saw it too. The trail was soft from the snowmelt and it allowed the truck to dig through the edge. In the process of trying again to drive it out the right front went off the edge. We regrouped and deployed Larry's rear winch. I ran the controls while Larry steered and gave light input in reverse. We make some decent progress, then the damn winch broke. Score another one for Shittybuilt Chinese winches. Every time Larry's tried to use it the stupid winch breaks. Motor runs but won't spool in or out. Freespool won't release. I got my winch going and hooked up to the rear of his truck. From that point, Larry figured going straight back he could get out and just needed the winch as a way to hold it. It popped right out. By now it was going on 6.30 so we wisely backed down to a flat spot and made camp. Between the ordeal and backing down the slope with snow on it, I was ready for a beer. I know Larry was. Lynn was a Godsend guiding me down backward.

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Sorry I didn't get any pics of the action. I was a little pre-occupied. Larry did, but the pics don't give the situation justice.

Anyway, We made camp and killed a few frosted barley pops to calm our nerves.
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I'm not sure but I might have got evidence of a bigfoot in the snowbank by Larry's truck. Looks pretty big by the impression..
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Poser shot..
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I slept inside the Blazer while Larry was roughing it in his camper. My Mr. Heater catalytic heater took the chill off before I went to bed and shut it off. My sleeping bags kept me warm the rest of the night. Outside temp dropped to the mid 30's by morning.
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As far as a validation run, we proved some things out. Bill needs to fix his driveshaft. Larry's rear winch is junk. Mine has a weird issue on a hot restart after it had heat soaked. A couple of times after stopping on the way up the trail, mine started but acted like it was out of fuel by stumbling and stalling. It was running just fine 5 minutes earlier. The second time it happened Larry hooked up a fuel pressure gauge and it was all over the place. The needle was bouncing 10 psi, when it was rock steady the day before when the pump went in. We let it set longer and once it cooled enough it restarted without a problem. Our theory is the right exhaust bank might be overheating the fuel with the engine off. If it was running, the high fuel pressure raises the boiling point but when it's off, the pressure reduces and was boiling the fuel in the line causing air bubbles that upon the restart causes erratic fuel pressure and stumbling. I'll be adding some heat control products to this area to prevent it.

I also generated a list of things I forgot and should have with me on the trip. One week to get it together!

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Not sure if the fuel pressure regulator is expensive but it may not be a bad thing to swap out.
I've got 3 spares in the console at this moment. Funny thing is as soon as it cooled off a few minutes the truck started fine and the fuel pressure stabilized. Pretty sure the heat soak from the exhaust when crawling. I've never had this happen in normal driving, probably because it's moving at a speed higher than 5mph. But crawling around slow in high ambient temps, like 80 and up could be a tipping point. Like I said, keep it running so it's under pressure and the problem will not happen either. It supports our theory that it's the heat soak while the engine off causing the fuel to boil in the line.

I'm going to get some header wrap and cover the affected area because the other option is re-running the pipe for the exhaust on that side. I'm out of time to re-do the exhaust so header wrap it is.
 

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