"Bourbon and Water" build

[jetwrench]

I bought a wakeboard boat in Aug. Pannicked and bought a 03 Dodge Cummins 4x4. NOT what I wanted. Im die hard Chevy. So I sold it and bought a 1990 shortbed stepside for everyday, and now Im building a 1990 Suburban . Its a rust free 3/4 350 TBI SM465 with 4.10's. Engine was rebuilt , new exhaust, new steering and front end parts . Not a bad start...However, It had the worst paint job I have ever seen. Not a 4" area on the entire truck with out a run in the paint. All the window seals were painted! The electric fans(a po conversion) had all kinds of wire and resistors, plugs etc. It was screwed into the radiator frame with no spacers on the top and on the bottom he made a pvc pipe that went along the bottom and pushed it into the radiators as well.
To Do list
fix rad fan jerry rig
4 headlight front end conversion
dual batteries
upper rad hose support
bed line interior cargo area and door sills
killer stereo
overhead DVD
35" tires...NO LIFT
strip and paint
new carpet
bucket seats in front so I can put a tuffy console
new window seals
new upholstery
Well that what I need to accomplish before water skii season!

 

[jetwrench]

Heres the 1990 shortbed. It has a 95 frontend on it now

 

[jetwrench]

Heres the boat

 

[jetwrench]

So I bought the 35" tires and wheels and had them mounted so I could fit them in the fenders. Discount tire didnt like mounting them on the truck. Especially when I did a quick trim just to get it home. So after marking the fender and cutting I used 3/8 steel rod to fill the gap and welded the rod in after making a coat hanger template for the fender shape. then I hammered the sheet metal flush on the rod and finished the welding. Add filler sand and prime. Simple.. I havent seen it done this way on the board so I thought I d share and might as well make a build thread. Ive built a ton of vehicles but never documented anything.

 

[jetwrench]

Next is changing over the front end to the 4 headlight deal. I think it looks much newer and I like the style better. And of course more lights! I bought a complete frontend from a guy up in ft collins for $275. It came with wiring harness battery tray(more on that later)grille, lights, fenders, hood, inner fenders, radiator support etc. To convert you need the wiring harness and radiator support and of course all the lighting buckets etc so this was great. Then I can also take the old suburban frontend and update the 1975 shortbed I also have.Then Ill sell the 75 front end. Hopefully for $275!!

 

[jetwrench]

Might as well make a bumper template now. I will store it for a while . I need to get this ready for towing the boat!

 

[jetwrench]

I made a tow hitch on the front. I like to tow it into the shop front end first(truck) so I can see with out any help. It has to fit on the side of the lift and sinch everything was off the front what better time than now to make one. I also cut out the square for the hitch in the original front bumper.

 

[jetwrench]

No sense installing the grille and light bezels as I will be sanding the whole truck down soon. Next I want dual batteries for the audio/video so Im gonna convert the right hand battery tray to a left hand one. Pics to come soon.

 

[Keitha]

Looks like fun. Doesn't the 1990 Suburban have the quad headlight from the factory?

 

[jetwrench]

No. if you look in the first couple pics youll see what this front end was. Dont forget to comment on the mac truck hood ornament! My son wants it cause his football team is the Bulldogs.

 

[Keitha]

Quad headlights started in the 1989 body style. I guess they must have had both through 1990.
The hood ornament is a great toutch. Keep the pics comming!

No. if you look in the first couple pics youll see what this front end was. Dont forget to comment on the mac truck hood ornament! My son wants it cause his football team is the Bulldogs.

 

[ACannell]

Hey keep it going for sure! I'm gona start my 91' burb soon! Maybe I can steal some idea's - but don't tell anyone ok

 

[Drey]

Lower trim packages had single lights.

 

[jetwrench]

I have more pics coming soon. Dont have time to post on Mothers Day!! plus I work 10 1/2 hour midnightshift. Should have some up tommorrow.

 

[jetwrench]

Cheap battery tray

Well we all know the rh battery trays are a dime a dozen and left hand ones are close to $100 each. So I took the RH tray out of the donor front end and came up with this.
first original tray from donor

 

[jetwrench]

Then remove charcoal canister from truck its going into. next I cut the support portion off of the battery tray. Oh and I found a good picture of the shortbed with the boat. (emergency tow vehicle)

 

[jetwrench]

Shortbed and boat

 

[jetwrench]

Next I section the Battery tray support to reverse it.

 

[jetwrench]

After sections are welded reverse. I drilled into the "predimpled" spots on the inner fender and mount the support. Then I bolted the tray to the fender. I marked the under side of the tray so the holes would line up after the welding. I removed both sections, welded, painted and reinstalled.

 

[jetwrench]

and installed