Dafey
1/2 ton status
I know what ya mean ...every project I do theres always some small thing I missed.Like Im going to post pone my lift till I get greasable bushings.
CK5
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Project: Dirty South (K5)
- Thread starter xanthias
- Start date
Ok, just asking because I did the same thing. You will need to modify the frame where the shackle hanger will be. Here's why:
That unpainted part is where the shackle flip bracket used to be. that lower part of the frame where it has the bump will need to be modified so that the shackle flip bracket can sit flat.
xanthias
1/2 ton status
I follow you. Thanks for the tip. If you have other pics of your setup, I'd like to see them.
Here's a good pic i took awhile ago. I flipped the ORD hangers around so they point back and I am using 7" long DIY4x shackles.
xanthias
1/2 ton status
After a hiatus related to job-change fun, I've gotten back to ordering parts.
1. Holley truck avenger 670 has been received.
2. Ordered 2 seats from Hunsaker sports:
These claim they will hold a 44" waist comfortably. I'll be putting that to the test I expect. $340 with $80 shipping for a pair. Sliders are build in and brackets are $40 extra.
3. I nickel and dimed myself to death at Summit Racing -
5-point harnesses:
#BOB-50502-18-234
Harness, Complete, Latch, Individual-Type, Bolt-In, Floor/Roll Bar Mount, Red, Each $59.95 (bought 2 - cheaper than Hunsaker at $80 ea.)
All needed fittings for properly rigging the throttle and TV cables on the Truck Avenger:
#HLY-20-121
Transmission Brackets and Levers, Steel, Gold Iridited, Buick/Chevy/Oldsmobile/Pontiac, 700R4/200-4R, Each $25.99
#HLY-20-38
Throttle Lever Stud, 1/4 in. Stud, Universal, Each $5.95
#HLY-20-40
Throttle Lever Stud, 5/16 in. Stud, Automatic Transmission Kickdown, Universal, Each $6.95
#HLY-20-95
Throttle Cable Bracket, Steel, Gold Iridited, Chevy, Big/Small Block, Holley, 4150/4160, Each $19.95
Pre-filter wrap for air filter:
#KNN-25-3770
Air Filter Wrap, PreCleaner, Foam, Red, Round, 14.00 in. Diameter x 6.00 in. Height, Each $25.99
4. From ORD, I ordered a complete set of greasable bushings and bolts for the entire suspension, grand total was right at $157. Your part numbers will vary by application (diameter of needed bushings and bolts).
1. Holley truck avenger 670 has been received.
2. Ordered 2 seats from Hunsaker sports:
These claim they will hold a 44" waist comfortably. I'll be putting that to the test I expect. $340 with $80 shipping for a pair. Sliders are build in and brackets are $40 extra.
3. I nickel and dimed myself to death at Summit Racing -
5-point harnesses:
#BOB-50502-18-234
Harness, Complete, Latch, Individual-Type, Bolt-In, Floor/Roll Bar Mount, Red, Each $59.95 (bought 2 - cheaper than Hunsaker at $80 ea.)
All needed fittings for properly rigging the throttle and TV cables on the Truck Avenger:
#HLY-20-121
Transmission Brackets and Levers, Steel, Gold Iridited, Buick/Chevy/Oldsmobile/Pontiac, 700R4/200-4R, Each $25.99
#HLY-20-38
Throttle Lever Stud, 1/4 in. Stud, Universal, Each $5.95
#HLY-20-40
Throttle Lever Stud, 5/16 in. Stud, Automatic Transmission Kickdown, Universal, Each $6.95
#HLY-20-95
Throttle Cable Bracket, Steel, Gold Iridited, Chevy, Big/Small Block, Holley, 4150/4160, Each $19.95
Pre-filter wrap for air filter:
#KNN-25-3770
Air Filter Wrap, PreCleaner, Foam, Red, Round, 14.00 in. Diameter x 6.00 in. Height, Each $25.99
4. From ORD, I ordered a complete set of greasable bushings and bolts for the entire suspension, grand total was right at $157. Your part numbers will vary by application (diameter of needed bushings and bolts).
Last edited:
xanthias
1/2 ton status
The Sealy Diet
How do you lose about 200 pounds in a single day?
How do you lose about 200 pounds in a single day?
bent and twisted
Newbie
hunterguy86
1/2 ton status
Lookin good. keep it up!.
xanthias
1/2 ton status
Parts Pics
Mediocre customer service, but the Hunsakers did arrive -
5-point harnesses, RJS brand from Summit, 3-inch, #BOB-50502-18-234
Harness, Complete, Latch, Individual-Type, Bolt-In, Floor/Roll Bar Mount, Red, Each $59.95 (bought 2 - cheaper than Hunsaker at $80 ea.). I'm wondering about the comfort on these a litte - the latch mechanism, with everything rigged up is surprisingly large and heavy. We'll see.
All needed fittings for properly rigging the throttle and TV cables on the Truck Avenger:
#HLY-20-121
Transmission Brackets and Levers, Steel, Gold Iridited, Buick/Chevy/Oldsmobile/Pontiac, 700R4/200-4R, Each $25.99
#HLY-20-38
Throttle Lever Stud, 1/4 in. Stud, Universal, Each $5.95
#HLY-20-40
Throttle Lever Stud, 5/16 in. Stud, Automatic Transmission Kickdown, Universal, Each $6.95
#HLY-20-95
Throttle Cable Bracket, Steel, Gold Iridited, Chevy, Big/Small Block, Holley, 4150/4160, Each $19.95.
From ORD, I ordered a complete set of greasable bushings and bolts for the entire suspension, grand total was right at $157. Your part numbers will vary by application (diameter of needed bushings and bolts). Basically, 12 of these showed up in various sizes -
Mediocre customer service, but the Hunsakers did arrive -
5-point harnesses, RJS brand from Summit, 3-inch, #BOB-50502-18-234
Harness, Complete, Latch, Individual-Type, Bolt-In, Floor/Roll Bar Mount, Red, Each $59.95 (bought 2 - cheaper than Hunsaker at $80 ea.). I'm wondering about the comfort on these a litte - the latch mechanism, with everything rigged up is surprisingly large and heavy. We'll see.
All needed fittings for properly rigging the throttle and TV cables on the Truck Avenger:
#HLY-20-121
Transmission Brackets and Levers, Steel, Gold Iridited, Buick/Chevy/Oldsmobile/Pontiac, 700R4/200-4R, Each $25.99
#HLY-20-38
Throttle Lever Stud, 1/4 in. Stud, Universal, Each $5.95
#HLY-20-40
Throttle Lever Stud, 5/16 in. Stud, Automatic Transmission Kickdown, Universal, Each $6.95
#HLY-20-95
Throttle Cable Bracket, Steel, Gold Iridited, Chevy, Big/Small Block, Holley, 4150/4160, Each $19.95.
From ORD, I ordered a complete set of greasable bushings and bolts for the entire suspension, grand total was right at $157. Your part numbers will vary by application (diameter of needed bushings and bolts). Basically, 12 of these showed up in various sizes -
offroadblazer764x4
1/2 ton status
this is gona be a good build alot like mine nice rig man
_______________________
76 k5
_______________________
76 k5
xanthias
1/2 ton status
If you can't show progress . . .
Show parts!
First up is the master cylinder upgrade I've picked up. The rear Dana 60 is set up with Caddy calipers and chevy discs. So, many folks like to swap out a 4-wheel disc master cylinder, though there is some debate over whether this helps much over a properly adjusted stock system. Be that as it may, this MC definitely has more fluid volume and a larger bore (40mm):
Essentially, you are converting from JB5 (1/2 ton) to a JB7 (1 ton non-hydroboost). This is NAPA part number UP 390278 and is intended for a 1999 K3500 1-ton. Details on NAPA Online: http://www.napaonline.com/NOLPPSE/(S(qoqedl45yr0ei1ebgslsibrt))/Detail.aspx?R=UBP390278_0161717504 This lists for $164, but your local counter guy should be able to cut you a break off that number. It bolts right up to the stock booster. Note that the fluid reservoir on this unit sits so tall, some people have reported hood clearance problems - easily remedied by loosening the top two bolts at the firewall of the booster and shimming them to lower the mount angle. The internal reservoirs are reversed from the old unit, however, and you will need two small fitting adapters for your brake line connections. NAPA pops you for $5.99 each on these:
Weatherhead 7912
(9/16 female inverted flare to 1/2" male inverted flare)
http://www.napaonline.com/NOLPPSE/(S(qoqedl45yr0ei1ebgslsibrt))/Detail.aspx?R=WH_7912_0000999999
Weatherhead 7913
(1/2 female inverted flare to 9/16" male inverted flare)
http://www.napaonline.com/NOLPPSE/(S(qoqedl45yr0ei1ebgslsibrt))/Detail.aspx?R=WH_7913_0000999999
Here are links to some good tech on this MC and proper adjustment of the Eldo calipers:
http://coloradok5.com/forums/showthread.php?t=174038
http://www.pirate4x4.com/forum/showthread.php?t=697483
And, another with good, basic information on the combination valve and its impact on a rear disc swap:
http://www.pirate4x4.com/forum/showthread.php?t=696663
Second, I'm very happy to have these on the way:
These are 42" IROK's on 15" DIY4X beadlock rims. Kert can do just about anything you want and they will set you back about $75 each.
http://www.diy4x.com/beadlocks.htm
Finally, if any of you are wanting to use a remote reservoir from a Chevrolet big block, diesel or Astro van setup with your typical P-style power steering pump and integrated reservoir, Chrysler actually has an adapter boot to let you plumb it:
This is a Chrysler factory part, number 4333475.
I know much of the parts tech in this post is well-known from the part number thread here, but I thought I would include the information anyway.
On the fab front, the DIY4X shackle flip and rear 63's are mocked up and it's almost ready to sit on its own weight in the back with the Dana 60 underneath. Pics in a couple of weeks of that stuff . . .
Show parts!
First up is the master cylinder upgrade I've picked up. The rear Dana 60 is set up with Caddy calipers and chevy discs. So, many folks like to swap out a 4-wheel disc master cylinder, though there is some debate over whether this helps much over a properly adjusted stock system. Be that as it may, this MC definitely has more fluid volume and a larger bore (40mm):
Essentially, you are converting from JB5 (1/2 ton) to a JB7 (1 ton non-hydroboost). This is NAPA part number UP 390278 and is intended for a 1999 K3500 1-ton. Details on NAPA Online: http://www.napaonline.com/NOLPPSE/(S(qoqedl45yr0ei1ebgslsibrt))/Detail.aspx?R=UBP390278_0161717504 This lists for $164, but your local counter guy should be able to cut you a break off that number. It bolts right up to the stock booster. Note that the fluid reservoir on this unit sits so tall, some people have reported hood clearance problems - easily remedied by loosening the top two bolts at the firewall of the booster and shimming them to lower the mount angle. The internal reservoirs are reversed from the old unit, however, and you will need two small fitting adapters for your brake line connections. NAPA pops you for $5.99 each on these:
Weatherhead 7912
(9/16 female inverted flare to 1/2" male inverted flare)
http://www.napaonline.com/NOLPPSE/(S(qoqedl45yr0ei1ebgslsibrt))/Detail.aspx?R=WH_7912_0000999999
Weatherhead 7913
(1/2 female inverted flare to 9/16" male inverted flare)
http://www.napaonline.com/NOLPPSE/(S(qoqedl45yr0ei1ebgslsibrt))/Detail.aspx?R=WH_7913_0000999999
Here are links to some good tech on this MC and proper adjustment of the Eldo calipers:
http://coloradok5.com/forums/showthread.php?t=174038
http://www.pirate4x4.com/forum/showthread.php?t=697483
And, another with good, basic information on the combination valve and its impact on a rear disc swap:
http://www.pirate4x4.com/forum/showthread.php?t=696663
Second, I'm very happy to have these on the way:
These are 42" IROK's on 15" DIY4X beadlock rims. Kert can do just about anything you want and they will set you back about $75 each.
http://www.diy4x.com/beadlocks.htm
Finally, if any of you are wanting to use a remote reservoir from a Chevrolet big block, diesel or Astro van setup with your typical P-style power steering pump and integrated reservoir, Chrysler actually has an adapter boot to let you plumb it:
This is a Chrysler factory part, number 4333475.
I know much of the parts tech in this post is well-known from the part number thread here, but I thought I would include the information anyway.
On the fab front, the DIY4X shackle flip and rear 63's are mocked up and it's almost ready to sit on its own weight in the back with the Dana 60 underneath. Pics in a couple of weeks of that stuff . . .
Last edited:
Great info, I'll be refering back to this thread for sure. 
blazin' j
1/2 ton status
subscribed x2...awsome info...keep it coming 
wasted wages
1 ton status
Subscribed,,,
bent and twisted
Newbie
Looks like she be setting, get to posting lol
xanthias
1/2 ton status
Thanks to B&T's hard work, what you're looking at, everyone, are the DIY flip-n-switch brackets reversed (a technique used to improve shackle angle with very long springs) and mounted near the end of the frame to accommodate the 63" springs. Brian reports a 10-degree shackle angle at ride height, which is pretty much perfect. The D60 rear is hung underneath but the perches, etc. are only tacked up for now until we are satisfied with everything. The 63's put the axle about 8" back from the stock location. The Ruff Stuff spring plates will need the center pin hole drilled out a bit more to fit the pin on the 63's. The axle looks narrow because Brian is using non-recentered H1's for mock-up.
Last edited:
Madmudder1234
Registered Member
Definatley subscribed!
xanthias
1/2 ton status
Now for some real pics
Here you see the rear 63's at droop with no weight, which were taken at the point when Brian was working on placement for the DIY flip-n-switch. The sides are reversed, the frame had to be cut to remove the 'hump' that is present at that location and the brackets are 2" from the end of the frame horns.
Rear 60. There is still some cleanup to be done of the remnants of a former truss.
Ruff Stuff perches, plates and u-bolts mocked up. The pinion will basically be pointed at the transfer case since we plan to use a double-cardan joint on the rear driveshaft.
That's what 8 inches looks like, regardless of what you tell your significant other. The masking tape denotes future body cut line. Note the angle finder on the shackle - 13 degrees resting on its own weight.
"Baby flexing" for fun. Brian confirmed his hand-forklift would not flex them out even though it will go about as high as your shoulders or so. He didn't want to do the full poser routine yet since nothing is fully welded. I see an anti-wrap bar in my future.
Here you see the rear 63's at droop with no weight, which were taken at the point when Brian was working on placement for the DIY flip-n-switch. The sides are reversed, the frame had to be cut to remove the 'hump' that is present at that location and the brackets are 2" from the end of the frame horns.
Rear 60. There is still some cleanup to be done of the remnants of a former truss.
Ruff Stuff perches, plates and u-bolts mocked up. The pinion will basically be pointed at the transfer case since we plan to use a double-cardan joint on the rear driveshaft.
That's what 8 inches looks like, regardless of what you tell your significant other. The masking tape denotes future body cut line. Note the angle finder on the shackle - 13 degrees resting on its own weight.
"Baby flexing" for fun. Brian confirmed his hand-forklift would not flex them out even though it will go about as high as your shoulders or so. He didn't want to do the full poser routine yet since nothing is fully welded. I see an anti-wrap bar in my future.
xanthias
1/2 ton status
Beginnings of a bumper
