Project MULE - Expedition build on a 1991 1500 4x4 Suburban

[pma4x4]

Thats a clean sub

Thanks this one really just fell out fo the sky and we were the first to call. I gave him his full asking price just because he was asking so little on it.

 

[y5mgisi]

Looks like it will be a fun truck!

 

[pma4x4]

Yeah I got smog here.... stupid smog...

Anyways heres how it works

Step1) Sawsall in front of cat but after the alignment tang it need to be part of the 3"OD

Step 2) Sawsall right after the muffler as close to muffler as possible.

Step 3) suspend muffler and cat and figure out how much pipe you need inbetween.

Step 4) Weld middle pipe to cat

Step 5) resuspend everything. tack all together

Step 6) weld all connections which will be in front of cat, in front of the muffler and after muffler.

If you are clamping then you need 4 clamps and a 5th to replace the OEM muffler hanger in front of muffler (see pic).

Note: I live in Arizona, the sub was bought and driven on Arizona so I just scotch-brited the welding surfaces and it was good to go.

The existing muffler clamp bracket on top will accept a 3" muffler clamp so you can still suspend the exhaust at the factory location still using a rubber.

 

[pma4x4]

So with the heater/vent problem I have been having being that it blows thru both the vents and the floor I assumed it was that vacuum manifold behind the HVAC controller. So what do I do. I rush into it and pull the dash apart!

Then find out it was the little plastic Actuator arm price that's a common brake and not 5 minutes to get to

 

[pma4x4]

The barn doors had some rattle and found the pass side barn door lower latch bar had a notch worn into it over the years so it wouldn't secure tight any longer. I ordered a couple of new latches from LMC, swapped them out and adjusted them inboard a bit more to offer a more tight seal against the springs. It did the trick the doors don't rattle and they have a nice positive seal when closed.

 

[pma4x4]

Within the next month or so I will be repainting the hood if not the entire sub. But when the hood gets doen I am installing a set of RunCool Hood Louvers from Hoodlouvers.com Thet are bit spendy but they are well proven to be one of the best ones for helping hot air escape the engine compartment. The picture shows to sets but I am only using one. They measure 22 by 11 and are powder coated white.

 

[pma4x4]

The TBI upgrade package is just about complete.

All I am waiting on is a new Injector pod and the Hypertech Powercharger aka "the Salad Bowl".

 

[Greg Ducato]

Beautiful Burb and nice group of mods

 

[Big Ray]

Within the next month or so I will be repainting the hood if not the entire sub. But when the hood gets doen I am installing a set of RunCool Hood Louvers from Hoodlouvers.com Thet are bit spendy but they are well proven to be one of the best ones for helping hot air escape the engine compartment. The picture shows to sets but I am only using one. They measure 22 by 11 and are powder coated white.

I keep thinking about using late 70's Z-28 fender scoops on my 86 hood..

these

or these

 

[Deuling]

So clean

 

[pma4x4]

So clean

Dueling, I am from northern Minnesota. I know what you go thru for vehicle rust. You have my sympathy.

 

[pma4x4]

I am thinking of maybe doing a write-up for the TBI upgrades but don't know yet.

 

[munepit]

I am thinking of maybe doing a write-up for the TBI upgrades but don't know yet.

Do it. A lot of people here could benefit from it.



Nice Burb!!!!

 

[muddysub]

i love it man, that's what mine should look like. maybe one day it'll be that nice again...

 

[pma4x4]

I really appreciate all the compliments. We thought we got a really goods score on this one.

 

[pma4x4]

TBI upgrades from RV Morse start tonite plus a write-up for it.

Parts are as follows:
Bored Throttle body
Powerplate (Bored to match)
Adjustable fuel pressure regulator
Injector Pod spacer
remanned Injector pod
Fuel pressure gauge
Matched fuel injectors
Hypertech Powercharger (aka Salad Bowl)
Amsoil AE performance air cleaner.

 

[pma4x4]

Will have to finish it tomorrow. It runs, Its just the stupid throttle cable is a hair to short and high idles. I am using the supplied spacers but its turning out to be the biggest PITA in this whole project.

Sore, sweaty and I am pretty sure I bled into the TB. I know my DNA will forever be cooked onto that intake!

Had to modify how the coil sits so that adds to it when its on the same bolt as the spacer.

 

[pma4x4]

Ok Good news. The TBI project is done!

I just need to modify the air cleaner for the salad bowl tomorrow morning and that's it.

 

[y5mgisi]

Nice!

 

[pma4x4]

TBI upgrade and write-up complete.
See the write-up here
https://ck5.com/forums/threads/1991-5-7l-bored-tbi-upgrade-write-up-warning-lots-of-pics.301416/