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

[pma4x4]

As of right now, the plan of attack is after the California run the Mule gets a paint job. The body is not bad it just needs some good 180 grit sanding. We are about 90% sure of going with a Arctic white with black accents. It has a blue interior so we are kind of limited to exterior colors.

 

[pma4x4]

Truck and tranny survived the 1400 miles from Phoenix, az to Gorman, CA to Death Valley to Las Vegas, NV and back. stop and go, cold and warm weather and 8% up hill and down hills. low gear and cruising. This is going to be a great rig to build for expedition, nice and comfortable and it doesn't wear you out after being on the road all day.

I start on body work this week.

 

[Greg Ducato]

Very cool, I love my Burb for the same reasons

 

[y5mgisi]

Good deal!

 

[natemc]

sweet

 

[pma4x4]

Still here the Mule aint going anywhere. just busy for the holidays. I am hoping to start sanding in early January for the paint.

Have a happy holidays and Merry Christmas y'all

 

[pma4x4]

Its been cold enough in these parts to turn me off from prepping the body for paint. My shop is warm but I don't think warm enough for painting. So I am moving forward on the front bumper. I still need to finalize the drawings but I should have them off Monday to the cutting shops for quotes.

Plans for the roof rack are coming to fruition and once the files are off for the front bumper I hope to start mocking up the rear bumper. The rear bumper maybe seeing a spot for a winch. I dont know right now. I may crate the bumper for a M8000 winch and then just leave it for now.

Aside from the TBI tune-up and the 33 BFG ATs the truck is still pretty much stock and we have been using it as such and its been a blast. I cant wait to actually start building it!

 

[Greg Ducato]

Looking forward to continued installments

 

[pma4x4]

Looking forward to continued installments

hehe, me too!

 

[cuervo]

I just need to finish wiring the hot side of everything but its pretty much good to go. The front end still retains a factory clean look with the grill on.

What is that yellow wire for and it sure looks like it's getting crushed by the hood.

 

[pma4x4]

the yellow wire is sheathing for the wires for the headlight upgrade i did. Its temporarily routed it that way (until i do the full wiring job under the hood) and its really just the wire loom getting crushed in the image. I thought about that when i routed it that way and it is fine.

 

[pma4x4]

Finalized the drawings for the bumper pieces. Files go off for estimates Monday.

 

[pma4x4]

I should have my front bumper next week hopefully.

Anyways. I have started on the rear winch bumper and have come to a complete halt trying to figure out the assembly of this while only being able to use a 4'x4' Plasma cutting table.

7" face with a 4" flat top and will be tapered at ends to 4" tall with two welded though D rings for Clevis'


(Pics not found at this time)

 

[elyon]

I will keep watch for your progress on the rear bumper. I haven't found one that I like outside of designing one myself. I am hoping to find one that will look like it belongs to the front one I have now.

 

[DarkandShiny]

I'm also excited to see how the rear bumper looks. I've been unable to find an aftermarket one that I like.

Thanks for sharing with us.

 

[pma4x4]

Ok here is the core of the rear bumper. You have to use some imagination to fill in the cracks.

All 3/16" the frame mounting plates are 1/4" with 4 bolts on each side

76" wide
4" deep top
7" tall face
(2) 1"wx2"2 Welded D-rings that go thru directly to eh frame plates

there will be 4 holes center on the face to mount a winch and an offset Hawse fairlead.

Yes it appears to sit a bit low but that's because the plastic skirt is removed right now plus I want to make sure it sits under the plastic trim on the outer corners. It will look better with the skirt back on.


Opinions, ideas, like, dont like.

The underneath will be finished off with 3" plate coming in.

 

[y5mgisi]

I dont think your going to do much better than that. Any plans to incorperate a tire carrier?

 

[elyon]

I think it looks great! what about radius around the corner a few inches?? I know that is a lot more effort, but it would tie into the lines of the truck just a little more. Nice work!

 

[pma4x4]

I think it looks great! what about radius around the corner a few inches?? I know that is a lot more effort, but it would tie into the lines of the truck just a little more. Nice work!

I was thinking of something like this below to help blend the ends in

 

[elyon]

I think that is perfect.