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Blazer chalet off road rig build advice

rom67

rom67

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Hello ck5ers. The name is mike.
I just recently purchased a 76 blazer chalet, was in great shape, interior was surprisingly all intact, thus i couldn't pass up on the buy. I bought this rig to take my 8 and 5 year old sons out camping and exploring, never did it as a child and now that im a father, i wanna give my kids that opportunity. So now that i have it, ideas are growing everyday. I'm also realizing how much dead speace their is in the factory set up, I feel i should re do all the cabinetry and bunk bed set up, more of a face lift, new wiring and new upholstery. Oh fyi, ive never built an offraod rig before. So i have alot of questions in regards to drive train and design. Should i keep the sbc400 with the th400 or upgrade to maybe a iron LS motor with a 4L65e and should i keep the dana 44 and upgrade to some RCV axles or go dana 60 and upgrade the rear to a 14bolt ff, what lif at tire size would any of you recommend and why. Let me know what you guys think. Im also planing on redoing the color scheme, but still keeping the factory desing, just different color combo.

IMG_20161104_081450.jpg
 
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What types of wheeling are you planning on doing with this rig?

From what I understand these Chalets are kind of top heavy, so going crazy with flexy suspensions and huge tires might make it less capable for the uses you stated above.
 
it really depends on your budget with some of those questions. You could easily spend $10K swapping to an LS/4L65E with upgraded suspension, tons and wheels/tires.

I would be tempted to do maintenance work, remodel the inside as you feel necessary and use it for awhile with the family. This will give you a better idea if suspension and drivetrain work is necessary for your intended purpose.
 
Justin V said:
What types of wheeling are you planning on doing with this rig?

From what I understand these Chalets are kind of top heavy, so going crazy with flexy suspensions and huge tires might make it less capable for the uses you stated above.
Click to expand...
Justin V said:
What types of wheeling are you planning on doing with this rig?

From what I understand these Chalets are kind of top heavy, so going crazy with flexy suspensions and huge tires might make it less capable for the uses you stated above.
Click to expand...

More of
Justin V said:
What types of wheeling are you planning on doing with this rig?

From what I understand these Chalets are kind of top heavy, so going crazy with flexy suspensions and huge tires might make it less capable for the uses you stated above.
Click to expand...

Factory suspension is very week, does
Justin V said:
What types of wheeling are you planning on doing with this rig?

From what I understand these Chalets are kind of top heavy, so going crazy with flexy suspensions and huge tires might make it less capable for the uses you stated above.
Click to expand...

Trails. Not any kind of rock crawling, as i also understan how top heavy it is. But im sure theirs some mods i can do to add some stability?
 
skunked said:
it really depends on your budget with some of those questions. You could easily spend $10K swapping to an LS/4L65E with upgraded suspension, tons and wheels/tires.

I would be tempted to do maintenance work, remodel the inside as you feel necessary and use it for awhile with the family. This will give you a better idea if suspension and drivetrain work is necessary for your intended purpose.
Click to expand...

So you're advising to stick with the SBC 400 and stock drive train for now, take her out and try it for now?
 
If it was me:

(Assuming the truck has a functional drivetrain currently)

I would spend my money on good maintenance first, getting everything up to par so I could spend some time driving it. Wheel time is the only way to know what really need more attention and what works as is.

I don't think too much would need to be done revamping suspension design, but I would likely get a nice set of 2 inch springs in the front (eliminates the factory flat / negative arch front spring) and probably a 3 or 4 inch rear spring, depending on how much heavier the camper really is.

I think that I would look for a 9.5" semi-floating 14 bolt rear axle as there are 6 lug versions out there, and several members will attest to the strength over a 10 or 12 bolt. I would grab some helper air bags for the rear and probably an air locker or two. 33's would fit except for (maybe) some minor trimming up front. Might not have to trim at all.

GOOD shocks.

Standard preventative stuff, like a steering gear box frame brace.
 
Justin V said:
If it was me:

(Assuming the truck has a functional drivetrain currently)

I would spend my money on good maintenance first, getting everything up to par so I could spend some time driving it. Wheel time is the only way to know what really need more attention and what works as is.

I don't think too much would need to be done revamping suspension design, but I would likely get a nice set of 2 inch springs in the front (eliminates the factory flat / negative arch front spring) and probably a 3 or 4 inch rear spring, depending on how much heavier the camper really is.

I think that I would look for a 9.5" semi-floating 14 bolt rear axle as there are 6 lug versions out there, and several members will attest to the strength over a 10 or 12 bolt. I would grab some helper air bags for the rear and probably an air locker or two. 33's would fit except for (maybe) some minor trimming up front. Might not have to trim at all.

GOOD shocks.

Standard preventative stuff, like a steering gear box frame brace.
Click to expand...

I bought it from the original owners. They had the rig sitting for 25+ years. They put 117k miles on it. She said, her and her husban enjoyed the hell out of it. So once i took over, the engine had plenty of rat poop, especially in the carb. Lol. Not to worried though. Its been raining hard here in SO-CAL so as soon as i get a good weekend of sun, I'll clear her out and squirt some lube, prime it and turn it over. I was thinking of acquiring factory rally wheels and jeep it 6 lug. But wasnt sure if upgrading to dana 60 would have been better. But you're right. Maybe i should clean her up and give her a run. For sure the suspension needs an upgrade. So i may do that now.
 
rom67 said:
So you're advising to stick with the SBC 400 and stock drive train for now, take her out and try it for now?
Click to expand...

I would.

However now that I know it's been sitting 25 years you're probably looking at fair amount of maintenance and repair work.
 
Again, if it was me...

A good heavy front bumper and winch could put some balance back into the Chalet, while providing protection and allowing you to get yourself out of a tricky situation. I wouldn't want to be stuck on a muddy trail somewhere with two younger children and no way to go for help. A winch is a nice little insurance policy.

They make some really economical fuel injection conversion kits now. If that 400 SBC turns out to be a runner, you'll spend a bunch less time and money on the efi than you would swapping in a LS truck motor.

If you do end up going LS, and your chalet is definitely the TH400 trans, try to get a 4l80e instead of the 65e.

TH350, 700R4, 4L60E/65E all are 27 spline output shaft, where as the TH400, 4L80E, 4L85E, 6L80E are all 32 spline, and would make fitting the stock T-case less of a hassle.
 
As for the one ton axles, neither is going to hurt except in the pocket book, and ground clearance. A 60/14FF require new wheels, and usually a 16 or larger wheel diameter, so tire are a few bucks more atleast.

The 9.5" 14b semi floater comes as a 6 lug in some 88 and up trucks, and I think they even had a 6 lug disc brake version in mid 2000's. They allow for much more clearance under the differential than a 14bolt full floater. You'll have to swap spring perches but if you can keep your tires and wheels and your front axle, it ends up being pretty darn cheap respectively.

And a stock front axle should hold up quite well under 33's and a sensible right foot.

The only difference between your axle and a 3/4ton front is the lug pattern...

I put 38's on my 3/4ton 10 bolt front, and while I don't expect it to last, it hasn't broken yet.
 
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Justin V said:
As for the one ton axles, neither is going to hurt except in the pocket book, and ground clearance. A 60/14FF require new wheels, and usually a 16 or larger wheel diameter, so tire are a few bucks more atleast.

The 9.5" 14b semi floater comes as a 6 lug in some 88 and up trucks, and I think they even had a 6 lug disc brake version in mid 2000's. They allow for much more clearance under the differential than a 14bolt full floater. You'll have to swap spring perches but if you can keep your tires and wheels and your front axle, it ends up being pretty darn cheap respectively.

And a stock front axle should hold up quite well under 33's and a sensible right foot.

The only difference between your axle and a 3/4ton front is the lug pattern...
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Thank you for the reply, i have 5.3 waiting for something to be put on. I was thinking of 4l65e just because of mpg . But a 4l80e is stronger and i was planning of swapping out the transfer case for a np241c passenger drop. As far as the dana 44 goes. The hd version is just a hub swap. Which, again, i wouldnt mind keeping the rallys. Looks cleaner. I'll look for 14bolt semi float. That sound plenty good for what im going to be doing with it.
 
A NP241C can be had in both spline counts, look for a 90 or 91 blazer or suburban unit for built in VSS, or an 89 for a cable driven speedo. Fairly easy to swap input shafts in the 241 also.
 
Justin V said:
A NP241C can be had in both spline counts, look for a 90 or 91 blazer or suburban unit for built in VSS, or an 89 for a cable driven speedo. Fairly easy to swap input shafts in the 241 also.
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Here in so cal, those parts have been really hard to find. Ive been searching ever since i bought my chalet. Been looking for a dana 60,no luck! Np241 pass side, no luck! So keeping the dana 44 with some RCV axles sounds good. Their website states they can handle up to 40inch rubber. All i want is 35.
 
Don't forget to start a build thread in the driveway sub forum here. Lots of guys will follow and be interested in what you do to revive this old girl.
 
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Justin V said:
Don't forget to start a build thread in the driveway sub forum here. Lots of guys work follow and be interested in what you do to revive this old girl.
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Will do Justin V. Thanks for the tips. I'll probably DM for more tips
 
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