Glorified Grocery Getter Build- WARN Premiums and Dual Battery Mock Up and Boxes

[mini_mull]

Good news/Bad news

Well, today was bitter sweet. I got my new shoes.

Here's mock up, not bad.

A few inches higher and those will fit just right.

Now for the bad news. I picked up my burb this morning with brand new converted A/C installed, and was enjoying my cold air. Then as I was waiting in line at my kid's elementary school to pick up kindergarten carpool I heard a funny noise like the belt was slipping. I rolled down the window to hear it better and heard some more weird noises. I looked down at my gauges to see the voltmeter dropping the temp rising and oil pressure dropping slightly. OH CRAP!! I pull out of line and head for the parking lot. I've lost power steering and something is starting to smell like burning plastic. As I round the corner into the parking spot I hear an awful noise. I throw it in park, and pop the hood to find my belt mangle and twisted, and it's actually eaten though the connector on the air compressor.

I caught a ride home with the kids and came back later to cut off the belt and check the pulleys. None of the pulleys were seized, so I threw my old belt on and drove home, no problems, but no a/c. Good news is an a/c coil only costs $6, but I still have no idea why it happened unless my perfect looking 6 month old gator back belt just decided to take a dump for no reason. Oh well, could have been worse.

 

[badger red]

That sucks about the A/C, but it could have been worse, I suppose. I run the Pro-Comp MT on my K5--33 x 12.50/15 and really like them--pretty quiet for a mud tire too. Like what you've done to your dash bezel--the flat black looks awesome!!

Jeff

 

[mini_mull]

Well, got the front done today and the back is in pieces with eight out of twelve rivets out, one bracket almost off and the gas tank in the front yard. Would have finished today if we wouldn't have taken a three hour break to go pick up the shocks and eat lunch. Anyways, we'll be finishing up in the morning. I should have the pics and details up by Sunday night. I am very happy with how it's going together so far.

 

[desertrat67]

Those black wheels look good on the dark blue paint.

 

[mini_mull]

Thanks.

 

[mini_mull]

Update on the AC debocle (sp?) the part actually costs $80, not horrible, but not as good as $6. I'm taking it in tomorrow to be replaced, and then I'll have AC again, YEAH! As for the lift.....

 

[mini_mull]

New suspension PART I

Thursday night I did a little prep work. I gave every bolt I’d need to remove a generous helping of PB blaster for a second time (did the day before also). Then I needed to take the bottom leaf out of my new spring pack, since I ordered the HD springs, but only need the EZ ride version until I get my winch and winch bumper. So I cut the center pin off with the grinder and chiseled the glued on bottom leaf off, then tried to reuse the center pins, but since they didn’t work I used the new ones I got with my zero rates instead.

Next, I drilled holes in the bushing sleeves for the rear front spring eyes. The TC front lift springs have grooved poly bushings in the rear eyes so if you just drill the sleeve and get some greasable bolts, wahlah, you have greasable bushing for the rear eye.

Friday morning bright and early we got down to business. My husband’s cousin came over to lend a hand. We got the truck jacked up and the old wheels off. Bye-bye stock suspension.

Next came the old springs, shackles, and shocks which weren’t to much trouble. Now the steering arm was a little more difficult, the bolts came off OK, but the cone thingys were a little stubborn, but a chisel and hammer offered a little persuasion and they eventually gave up. Then Dennis (my husband’s cousin) took one look at where we’d have to get to get the old front shackle frame eye hanger off and put the new DIY4X version on and in not so many words said, “No thank you.” I was a little disappointed, but happy to have his help with the rest of everything, so I shrugged it off. FYI, it looks like it would be a lot simplerif you had a body lift, or if you didn't have really poorly placed exhaust. It will be installed later, or I’ll save it for another project truck. Now all the old was off and it was time to start installing the new.

First the super beefy DIY4X shackles, then the Tuff Country EZ ride springs stuffed with ORD greasable bushings, and the ORD steering arm.

After that we needed to make a trip to pick up shocks (not bilsteins anymore due to cash crunch, but 4 Pro Comp ES9000s and a ES2000 stabilizer for $149, not a bad deal from 4wheelparts) and took a lunch break. When we got back we installed the shocks and put the new shoes on (not 5 315/75s and series 7089, but also due to cash crunch 4 pro comp muds in 285/75/R16s on Rockcrawler series 51 steels.)

Fronts done!!

 

[mini_mull]

New Suspension- PART II

Next came the rear. First it got jacked up. Then off with the old, springs and shocks that is.

That left these behind in the front

And these mean vile things in the rear.

There was no way to get to the back of the frame to install the new brackets or to the rivets on the bottom without removing the freakin huge tank so off it came. The HF tranny jack really came in handy here as well as the fact there was only a gallon or two of gas left in the tank. First we removed the skidplate, then the straps. Once the jack was under it I started by disconnecting the filler and vent hoses. Next the hubby helped me disconnect the supply and return lines by using a wrench from one side to loosen while I held the other fitting still. Here’s the big bad boy.

Rust had been attacking the top edged thanks to the crappy sound deadening material trapping mud next to the steel, so it would get a good cleaning with a wire wheel and a coat of rust bullet before going back up. I capped off then taped the lines, since we still haven’t paid our Rural metro fire bill, I don’t really like to stop, drop, and roll.

Here’s the first two victims

And here’s me gettin’ after ‘em.

I did the relief cuts with a cutting wheel first

Then ground them flat with the grinding wheel.
Next came the outsides. (for some reason this pic makes me look like a midget, I mean little person)

BTW, if you have a burb the drivers side outer rivets are an especially big PIA because of the spare tire well, just to warn you, a 4.5” grinder barely fits. Once the rivets were ground flat I took a chisel and hammer and excepted them to pop right off. Hmm, that wasn't working so I broke out with the air hammer and a chisel bit. WOW, they popped right off, but since it was 10:45 PM, the hubby explained how I may want to finish that tomorrow if we didn't want to see flashing lights and pay a HO fine. So I was done for the day, which stunk since I had to leave the garage open all night (which can also lead to a home owners fine). I did hook a baby monitor up though, so I could at least hear it if someone robbed me blind and attempt to scare them off with assorted firearms. I also had to leave the garage open while we got lunch, but I left the rottie tied to the burb and a neighbor watching from across the street so that seemed like less of a risk than leaving it unattended all night long.

 

[mini_mull]

New suspension- Part II cont.

The next morning we made short work of the last hanger

Installed the drivers side super beefy DIY4X shackle flip with my custom bowties and super beefy cross tied stock length shackles. Don’t they look sweet. You rock, Kert.

The other side took a bit longer since we cross threaded a bolt and had to send a gopher on a run to the hardware store for a new bolt and nut (thanks, honey). But here’s the finished passenger side.

Once that was done we got the springs on with the 4 degree shims (seemed to work for most so it seemed like a good starting point, we’ll see after a hi speed test drive.)
Then the new shoes went on and the jack stands came off. Here’s some poser pics before the gas tank got back up. Not bad if I do say so myself.

 

[mini_mull]

Once the gas tank was clean with a coat of rust bullet in the problem areas, it went back up without too much trouble thanks again to the HF tranny jack. Then I took a ride around the block which was good except that everytime I braked it didn't go down smooth, but kind of boucy back or felt bumpy as I pushed down, so I didn't go over 25mph. Tomorrow I'll take it to get the AC coil replaced and maybe I'll get him to check the brakes if I don't have time to do it my self before I take it. I also still need to install my BWP brake lines, ORD swaybar correct/disconnect, ORD steering brace, and ORD poly body bushings, so I'm far from done.

 

[burban89]

Nice looking Burb, Great Job.

 

[Jason4x4]

lokking good, keep up the good work.

 

[desertrat67]

Very Nice work. I see you have auto hubs. I have a set of manual hubs I am selling if you want them. Warn premiums, used but good shape. pm if interested.

 

[mini_mull]

Tried to install the brake lines yesterday and ran into a speedbump. As you can see in the pics of the lines they have square heads on the end that goes to the calpier, but my calipers take rounded ones. I emailed Shawn, and he said it would take 2-3 weeks to ship the ones I need, but if I wanted to grind 'em off round myself they would still warranty them. I'm going to pick up a new line to use as a pattern tomorrow, along with a bench grinder. Wish me luck.

 

[mini_mull]

Poser Pics

Wish I had my brake lines done, and I'd post some flex shots, too. Poser pics will have to do for now.

 

[y5mgisi]

Sweet dude, looks good!

 

[burban89]

Sweet dude, looks good!

Yea SHE did a great job.

 

[desertrat67]

You are missing your hood ornament!

 

[mini_mull]

You are missing your hood ornament!

I am?

 

[y5mgisi]

excuse me "dude'et(sp)?"

Of coarse i did read this earlyer which should have givin me a bit of a clue!

My husband’s cousin came over to lend a hand.