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Lowbuck 87 Burb, Cut Front, planned 700r4>SM465 1/2>1 Ton axles

rgilmartin

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Location
aurora, co
I'll try to tell the story mostly in pictures.


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Here she is, just got back into the garage. I ran it in a tough truck back in December. It's been in front of my father's house since. The steering arm was ripped off of the box, and it took a bit of the splines with it. More on that later.

The city sent out a letter that my father was going to miss having his new sidewalk put in if I didn't move the burban, so TODAY it goes back in my garage.

I think it is fitting it is march first, and I want to have it on the road for memorial day, so just about three months to the day... MAN have I got my work cut out for me.

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Funding the project is going to be as much of a challenge as the time. Much of my plan is together, at least in my head. Here I'll try to document as much of the process as possible.

My goal is to build a vehicle capable of extended off-road travel in Colorado. Mechanically I'd like to keep it as simple and reliable as possible.
Body wise.. the rear cargo area of the burb is handy, but the length is a hindrance, over rocks and around trees. The front is also hard to see around, especially when going over an incline, it can be hard to spot obstacles in front of you.

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In the front I plan on taking out the section covered in white tape.

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Along with the grill, and the inner fender.

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Then bend the hood along the dotted line down to become the 'fender'

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The hood will probably need some additional support, after some surgery removing what's already there.

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Then on to the rear.. section the wheel well, move it forward and up inside and out.

Move the rear axle forward as much as possible, even moving the wheel well into the door if possible..
there are power windows inside those doors somewhere I remember HOWDIY talking about it when he shortened his. Maybe I can take out some of it, and just lose some window travel?

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a dana 60 front, supposed to be from an 81 one ton chevy, this is DRW, right?

I've got a lot to learn about these, rebuilding kingpins..replace u-joints..hub service/replacement.

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And a 14 bolt full floater rear, supposed to be from an 85 blazer CUCV w/ a detroit. It has no axles, hubs, need rotors, calipers, lines,

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My 'should a known better' frame crack

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And an even better view from the bottom.

I'll try to get some more info about the build plan in the next few days.

I'd really appreciate any input about the body mods..
 
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The Plan

From Front to Rear, hope I don't leave anything out:

Build Front Bumper
-Stinger, Tow points, Future Winch Mount

Front Clip Repair
-Chop Driver Side, if chop works, same on PS, if not, need to rebuild to 'stock'

Headlights
-get round buckets from 70's truck

Grill
-Perforated Steel

Radiator?
Oil Cooler?

Upper Radiator Hose

Windstar Fan
-Mount
-Wiring, Relays, Switches

Frame
-Cracks at Steering Box
-Square?
-Reinforcement / boxing?

Steering Box
-Output shaft stripped
-Get 2wd box for crossover.

Front Spring Hangers
-homebrew 52's
-get 52 springs

Front Axle
-Research Rebuilding D60
-U-joints
-Kingpins ?
-Hub service / upgrade?
-Ubolts

Front Shocks
-Towers
-Get Shocks

Engine
-Regasket
-Oil Filter Mount / Hose routing
-AIR system
-Eval current: Oil Cooler / Adapter ; alternator; P/S pump

Transmission
-No Reverse
-Rebuild or Swap 700R4 to SM465

Transfer Case
-Keep same (NP208) or Swap to NP205, add twin stick
-Clock

Exhaust - Need to Route

Rear Axle
-Get Axles, Hubs, Rotors, Calipers, Mounts
-relocate spring perches

Driveshafts...
-Depends...on tranny swap / shorten wheelbase.

Parking Brake
-not sure yet

Rear Springs
-Get
-Shackle Flip / Mount

Rear Shocks
-Mounts / Towers
-Get

Fuel Tank / Cell
-Will need to address if I do the rear chop
-Fuel Pump
-Fuel Lines

Rear Bumper
-Tow points
-Future winch mount

Hitch

Wheels and Tires
Considering H1' s w/ military surplus 37's but am iffy about the 16.5 rim size. But love the price. I believe I have a DRW 60, and could use the rims w/o recentering.

That leaves the Interior!
Heater
-Mount, Plumb and Wire

Build Console
-Radio
-Shifter?

Dash
-Gauges
-GPS mount
-Trim

Mount Seats

Rear sleeping Area
Rear Storage Area
 
I've got a lot going on here.

My next step will be to try to put it all into a spreadsheet, and estimate $ and hrs. Then determine how much of this I should bite off right now, and If some of it needs to be put off for the future.

I know what I want the truck to be, but don't want to put myself in a position where I won't be able to use it this summer!
 
Here's my drivers side front fender, trimmed.

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And here's the part that's removed.

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I am so PISSED, My digital camera was giving me read errors, I figured it was the memory card, and replaced it. Yesterday was the first day for the new card, I took 73 pictures, and copied them to my hard drive.

These are the only ones I have, from my phone...

Today, I took a bunch of pictures, and when connected to the laptop it only has 26 of the pictures from yesterday. When I try to view the pictures through the camera it just says file error.

I wonder if there is something wrong with the camera, or maybe its Vista screwing it up?
 
Nice project. I will be following it. I can't wait to see how your front end design turns out. I would like to do something similar on my 1987 Jimmy.
 
Got the Pictures!

After running a check disk, windows 'found' 96 files. It stored them all to a found folder, and named them FILE000##.chk I renamed them to jpg's and now have all the pictures from last night!!

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This piece of tube steel held the fender up while I cut it off.

I was worried it might need more triangulation.

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This saw worked pretty well, I could make plunge cuts, and it made straighter lines than the angle grinder. I had never used it on metal before, just wood, but saw the blades at home depot and couldn't resist trying.

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I used a sawzall too, it worked well in the corners, following the lines from the circ saw.

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This is about how she sits now....For now I have only really only cut out dented metal...

next up is cutting the passenger side, then I've got to get ready to do hood surgery. Even thought I've never done anything like this before, that part is the one I am least comfortable with.
 
i would get another set of fenders and run it that way with it narrowed. Its gonna be hard to get that hood to fold down and not look ehhhh
 
i would get another set of fenders and run it that way with it narrowed. Its gonna be hard to get that hood to fold down and not look ehhhh

Thanks Chris, I'm hoping it wont turn out too UGGHH, but am pretty committed to what I'm doing, so far at least...

I am thinking about using a piece of tube or flat stock to beat the metal against.

Worst case, I can cut above / inside where I tried to bend it. Then go more of the route you're talking about... I guess we'll see.
 
Nice project. I will be following it. I can't wait to see how your front end design turns out. I would like to do something similar on my 1987 Jimmy.

thanks for the encouragement, just so you know, I like what you've done so far as well!
 
Finished cutting the fangs and rad support

Got a few more things done yesterday

Here's the right side fang removed :laugh:

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Don't know what's gonna happen here yet, I'm thinking of just trying to pound it back in a little bit, or maybe just leave it the way it is.

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And, as she sits

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Just a blank canvas
 
OH YEAH,,,I had forgotten about that thread, but definitely remember the truck now! It is probably one of the ones motivating and inspiring me to cut mine up mostly to learn how to fabricate, its what I should have done 15 years ago, in high school with access to tools, shop, a job, and no bills!

I also had been thinking about a later model truck, chopped, with a hot rod look, and I walked across this...

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I dont know what the h3ll it is, But I'd drive it. That'd be my mall cruiser.
 
That truck is cool. A similar design has crossed my mind periodically. I have been looking at semi trucks and thinking about fabbing a front end along their lines.
 
Yeah, I think a tilt nose front would be cool. I don't really want to mess around with trying to design the hinge though.

The cut fenders leave just enough to cover the original hinges.

The inner fenders have been removed.

Along with this:

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Also removed the exhaust, and rolled the 60 under it.

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Got the rear axle, and springs out.

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The 52's, from the rear, need to have the bushings replaced.

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The rear driveshaft, It is 52 1/2 inches ear to ear and 60 inches from rear u to the end of the front yoke.

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Mounting the 52's

Next I'll get the 52's mounted. Need to get some stuff...shackles, bushings, ez-inch

Design/build/buy a front spring hanger.

Another member is selling a SM 465 / NP 205 combo, that I am trying to get...depending on how that works out, or if I can find another for the right price I'll do that swap instead of rebuilding the 700R4 and keeping the NP 208.
 
Thanks Magik! I'm trying to hit it when I can!

Some parts / plans need to be put together for the next couple of steps.

I am trying not to bite off too much and then letting this thing get away from me time and $ wise..

It didn't work out for the 465/205 combo, but something better might have come along...supposed to meet a guy on saturday who is parting out the same year 3/4 ton 87 burb w/ a 350/465/208, I'm planning on getting everything to convert mine from 700r4 to sm465.

Here's the thread on that:

http://coloradok5.com/forums/showthread.php?p=2877490#post2877490

My current plan is as follows, please let me know what you think!

Grind off the front shackle hangers.

Remove my tranny / xfer case.

Get the parts for the swap.

put in the tranny /xfer case

get 52's ready

put in front d/s

roll 60 into place

measure and build homebrew spring hangers

hopefully work out wheels / tires by then.

Then design / fab new front clip.

Then more decisions:

head gasket / pull motor / motor upgrades?

What to do, if anything in the rear (shorten drive line / a*s hangover)

My goal is to use as many used and home made parts as possible.
 
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