chaotick5's cummins crew cab rebuild

[chaoticK5]

So I finnished the build on this truck 6 or 7 years ago and its time for some chanages , I can't leave a good thing alone ! I am finally geting around to installing my magnum box after it sitting on my bench for almost two years . The best part is I eliminated my adapter and coupler so the magnum will only make the assembly about 3" longer than factory . The last time I wheeled the truck I junked out the front 1350 double cardon so I figured it was a good time to do the swap with the drive lines needing mods and all . There are lots of pics of the original build in my profile . I removed the case and completely disassembled it , had the input baring bored out then sand blasted it . I panted the case and started asembling it with new seals and ord shift rails , this is how far I got today.

 

[kgblazerfive]

blingy ......

 

[Hogback Fabrication]

You're going to be super happy with the gearing, night and day compared to what you had

Beat on that Magnum extra hard and keep us posted, 0 failures so far and we've done a lot of high horsepower Cummins setups.

 

[nvrenuf]

Damn that input shaft is big.

 

[Deuling]

Subd. Love this rig

 

[82355]

Is there a build thread for the original work?

Martin

 

[Z71paramedic]

Damn that input shaft is big.

That's what she said

Sub'd to watch the progress.

 

[chaoticK5]

Thread

Nope , I never did a build thread on this truck , but I do have some pics in my profile and ill bet you can find lots in the blazer bash pic thread .

 

[82355]

Nope , I never did a build thread on this truck , but I do have some pics in my profile and ill bet you can find lots in the blazer bash pic thread .

If you find the time/ambition, you should post some history/pictures.

Martin

 

[ryoken]

always loved this rig...

 

[jekquistk5]

Awesome Rig!

 

[chaoticK5]

installed

well I got the t-case bolted up to the trans and the floor and the exhaust clears just fine ! I didn't have the room to clock the case up as the 4" exhaust is in the way but it only sticks down a couple of inches , I think the front drive line is a little close to the trans crossmember so I will look in to that after I get them back from tom woods (need length mods). I have plenty to do tell I get the drive lines back with the shifters needing to be fabricated , I am starting with a ord twin stick and will mod to fit but the magnum will need to be shifted from the opposite side of the trans with a separate shifter . I want the shifters to be mounted to the trans so I don't have body movement popping the t- case out . I just noticed after I got the case up and bolted up that I forgot to put the magnet in the bottom of the 205 , guess I don't need to worry about it getting into the gears one day

 

[kgblazerfive]

Needs a skid plate

 

[chaoticK5]

history

so I will give some of the mods of my truck but don't have the time for a complete build thread
first gen 5.9 ctd ,p pump , mod hx 35 turbo , marine injectors
sun coast built 518 trans w/od ,manual valve body
np 205 , ord magnum box , twin stick
Chevy Dana 60 , 35 spline crome shafts in and out ,4.56 , ox locker ,
14 bolt ,4.56 ,Detroit locker , Boyce disk brakes
8in sky jacker front springs , ord fush kit
56in rear springs 4" inbord , traction bar ,ord shackles
p.s.c hydro assist with custom pump , ord crossover
warn m12 front , m15 rear
viair dual pump oba ,optima dual batteries , 39.5 16.50 rockers on 17x12 marsh bead locks

 

[chaoticK5]

pics

pics

 

[kgblazerfive]

I am shocked that you cut a hole in the floor

Looks good man

 

[chaoticK5]

shifters and boots

I got the shifters done after a couple of days , both shifters are mounted to the trans like I wanted . lots of mods to the ord shifters but faster than finding the correct size dom and such to do it my self . The drive lines will be done soon and I will start on the extra t-case mount and skid plate .

 

[chaoticK5]

floor

got the hole fixed in the floor , I started with a 6" exhaust pipe and molded to fit .Ill Finnish it up tomorrow and start on the breathers and fill with gear oil . Thanks KGB , so 3 of us utah boys junked out drive lines at the blazer bash this year . My front c.v. gave out the next wheeling trip after moab , maybe tom woods will start giving a local wheelers discount . repairs/mods will cost 300$ but I had both of them built in 2008 so I'd say thats good life for extreme use .

 

[chaoticK5]

magnum done

I got the install finnished up today , had to replace the front output bearing retainer and another new seal . The retainer cracked and started leeking oil , I got a thicker gasket and a retainer at boyce equipment . I got tcase mount done and I think it will work good as I only lengthened the case about 3in , drivelines are rebuilt but cost 415$ but its good money spent for the beating they will get . The test drive went well , the brakes will barely hold it back in low low at idle ! I am a little disappointed , the gasket between the magnum and the transmission has a minor leek . I smeared some sealant over it , figured Ill give it a shake down for a while sense I had it all buttoned up when I noticed the leek . Ill probably replace the gasket Im just frustrated . I also had to remove a busted spring mount bolt in my d60 housing ( happened last wheeling trip too ) took a couple hours but got it out without damaging the threads . I replaced the grade 8 bolt with a cat grade 8 bolt , caterpillar bolts are the best bolts on the market imo .

 

[kgblazerfive]

Ah they just charge you more for the Cat name

Did you get the shafts from Wood yet ?