Project Penny - All good things must come to an end

[Russell]

Russell submitted a new Build:

Project Penny - Going wheeling

Took my K5 wheeling today -- got myself totally stuck 4 times, ripped off both front tow hooks, destroyed my winch solenoid pack, bunch of new dents / scrapes, and popped a bogger off the bead. Had a blast, but at the same time, it was a sad day because that was the last time I am ever gonna take my K5 out

I've decided that my K5 is just finished. The body doesn't look too bad from the outside, but the thing is held together with hopes and dreams these days... Back window is all that holds the tailgate up, can't take the top off or my box sides sag so much that I can't get it back on again, neither door opens or closes properly anymore, and it has so many shakes and rattles, any time you take it over 10 mph you're afraid it'll blow up at any moment. Not to mention how friggin huge of a cop magnet the thing is

Either way, I am planning to go wheeling in Moab for BB `11, and I need a rig that I can take across the border without any trouble (diesel VIN etc) so I've decided that I am going to switch to a GMT400 platform.

I bought myself a 95 2 door Tahoe to build up instead. The truck is in great shape, has a 6.5L TD, 4L80e automatic, NP241 floor shift transfer case. 3" exhaust from the turbo back, barks when you get on it, but isn't so bloody loud as my K5 was with a 4 foot straight pipe off the turbo dumping just infront of the rear wheel. At idle, you can hear the engine, but it doesn't make young children cry, or attract the fuzz like a fly to poop.

I have made arrangements with a fella to trade my Chevy D60 + some labour to install an NV4500 into his K5 for a cherry Ford Kingpin / High Pinion D60 from a late 70s F350. All it needs is an arb, 5.13 gears and crossover / highsteer / hydraulic assist installed. For the rear, I have built a 14BSF with an ARB, gears and a disk brake conversion. I plan to update the NP241 with an SYE + driveline brake, and install high angle / high slip CV driveshafts front and rear.

For my suspension, I am going to run the stock Tahoe springs out back with a shackle flip and a shock inboarding kit, 52" springs up front with a SAS and shock hooks. Tires will be a set of 37" Kevlar MTRs on 17" bead locks. Of course, I'll be swapping the York OBA setup over from the K5 to the Tahoe.

I think that it'll be a much more solid platform to work with, tons more parts available around here for the GMT400s vs the old square bodies. The DS4 injection will be nice for major elevation changes too, won't be smoking...

Read more about this build here...

View attachment 230459

 

[dfl701]

This is going to be a sweet looking truck! When's the plan to have it finished?

 

[Russell]

Funds pending, I am hoping to have it finished up by July. I want to do a few small local wheeling runs with it to work out all the bugs etc. In August I have a wheeling run in the mountains which will be the real test of it's capabilities. Then in September I am headed off to Moab.

Should be a nice looking rig! It is summit white, and is a pretty highly optioned rig, it was someone's baby for a lot of years. Well taken care of. I plan to be a lot nicer to this one than I was with my K5. I used to take my old K1500 wheeling in all the same places I take my K5 now, but never even so much as scratched it. I think I can do the same with the Tahoe, haha

This one isn't mine, but is very but looks very similar:

 

[kgblazerfive]

Put in a drivers drop 205 Im guessing it has a stand alone 4l80 so you should be able to any tcase in it.

 

[BoondocK5]

Would you be interested in a kit to turn that NP241 into a gear doubler, then bolt the 205 up to that?

 

[super k]

Sounds like a great plan. I always liked those 2dr Tahoes. Can't wait to see her on all fours.

Put in a drivers drop 205 Im guessing it has a stand alone 4l80 so you should be able to any tcase in it.

The '95 won't have a stand-alone ECU since it has electronic injection and waste gate control.

 

[lectric80]

Put in a drivers drop 205 Im guessing it has a stand alone 4l80 so you should be able to any tcase in it.

No, 95 will have a tone ring on the 241 for the VSS.

 

[Russell]

Yup, it's an EFI diesel, so no stand alone controller... The PCM takes a speed signal off both the transmission and the transfer case. I don't understand the love for the poorly geared and overly heavy 205 though. The 241 has a much better low range and is rated for more torque than the old cast iron dinosaur is. I worry about that much weight hanging off the end of an aluminum transmission tail housing too. The trans and tcase are both tucked up into the frame rails and will have large skid plates under them to protect from rocks and stumps.

A doubler doesn't really help out much with the kind of terrian that we run up here, so thanks, but it isn't in the plan at the moment! We have a lot of muck and muskeg up here, not to mention snow, wheel speed is important, hense the decision to run the auto.

I made some big progress this last weekend though, got my ARB switches fitted into the dash, lol!

 

[scottsdale86]

I'm with you on the 208/241. Everybody loves the 205 but its low range really sucks. I hated riding the brakes every steep decline i would go down. Now i have a NP208 (older slightly less durable sibling to the 241) and i love it. In 1st and 4hi i can get down any incline easily. It climbs like a SOB as well. I really have no complaints on at all about it.

 

[Russell]

Well, I got the new 4l80e installed, shifts beautifully! I got it all cleaned up and parked it outside to take a picture for you guys! I absolutely love the clatter of these engines! And as much as I hate to admit it, I am really liking the quiet exhaust on this truck. I can drive it at 70 mph and hold a normal conversation with the person beside me. No wind noise, no shakes / rattles or droning exhaust. I think I am gonna leave it as is... 3" exhaust from the turbo back, will need to get a new crossover pipe made to make more front drive shaft clearance and tuck it a bit closer to the engine than the factory did.

I'm gonna get it registered and insured then commute back and forth to work with it for the next couple of months while I get all my goodies pulled together for it . Shouldn't take long to do my build at that point!

 

[super k]

Nice! I love the chatterboxes,too. You're going to have one hella nice on/off road vehicle when done. But I imagine in stock form that thing is one sweet highway machine. And,not too shabby off road...within it's obvious limits. IFS is actually a great asset to a point. I have the 6.2/4L80E combo in my '91 Suburban and love rolling that thing @ 75 mph all day long. They're actually a very smooth running engine,they just like to let you know what's under the hood when idling. My Suburban is at the point your K/5 got to and it's good parts will live on in the '85 6.2 Jimmy I picked up. I can't wait to get it all swapped over.

 

[DEMON44]

Well, I got the new 4l80e installed, shifts beautifully! I got it all cleaned up and parked it outside to take a picture for you guys! I absolutely love the clatter of these engines! And as much as I hate to admit it, I am really liking the quiet exhaust on this truck. I can drive it at 70 mph and hold a normal conversation with the person beside me. No wind noise, no shakes / rattles or droning exhaust. I think I am gonna leave it as is... 3" exhaust from the turbo back, will need to get a new crossover pipe made to make more front drive shaft clearance and tuck it a bit closer to the engine than the factory did.

I'm gonna get it registered and insured then commute back and forth to work with it for the next couple of months while I get all my goodies pulled together for it . Shouldn't take long to do my build at that point!

thats pretty sweet nice one.

 

[Russell]

Well, it was a bright and sunny day today, so I wandered on over to the local junkyard to find a new e-brake release handle for the Tahoe. While I was there, I spotted an 88/89 C1500 and remembered how much I like the look of these trucks with quad beams instead of the newer composite stuff. So, I figured what the heck, and pulled the quad beams off the other truck, since I was pretty sure I'd read somewhere that they were almost a direct swap.

Got home, and while they were not quite a perfect bolt on, they were pretty close! I had to trim the grille a bit, as well as the mounting brackets for the headlamps to make everything fit, as well as move the power steering cooler and a sensor for the AC stuff (just gave it a bit of a twist out of the way). For the wiring, all I had to do was un-pin the 9005/6 connectors and plug the wires directly into the older style headlamp connectors (they use the same pins). While I was there, I also installed a relay that turns my low beams on with my high beams to help with the light output at night, these trucks kinda suck that way. I am hoping to find a set of e-code H4 conversion headlights for the truck with a set of PIAA drivers and better wiring to make the lighting as good as it can be.

While I was at it, I removed the front license plate holder, since we don't run front plates up here, and also removed the front air dam. Looks much better than before! I also got the busted e-brake release handle replaced, but broke the hood latch handle in the process, doh! I'll get that replaced next time I'm down south...

I also plan to get the truck registered and insured pretty quick. I'd like to put a few miles on it while I collect the SAS parts. I've got a couple local guys who are trying to convince me to run a set of coils and a radius arm setup. I may wind up going for it, probably be cheaper than running leaf springs at this point...

BTW, I have 5 37x13.5x17" Kevlar MTRs sitting in my parts pile

Here is a new pic for your enjoyment!

 

[AJMBLAZER]

Good luck finding those Hella E-codes. Rare bird these days. Not a lot of options for the little square lights like that. I'm not too impressed with the bulb/housing setup I have.

 

[chulisohombre]

I just bought a 94 blazer sport with the 5.7l.nice lil trucks.i like what u are doin with yours.ill be watchin 2 see how it turns out.im only lookin 2 do 2 inch lift and 33s on mine.

 

[super k]

I was thinking the same thing about the headlights on my '92. I've been driving an '89 K1500 SLE I picked up cheap while I went over some things on my '92. If I part it I think I'll swap the lights. I like the look (just headlights) and don't like the plastic that fogs up.

 

[dfl701]

Good luck finding those Hella E-codes. Rare bird these days. Not a lot of options for the little square lights like that. I'm not too impressed with the bulb/housing setup I have.

i would just swap over to the newer setup

 

[AJMBLAZER]

Can't see, whatcha got?

 

[79rustyk10]

I LOVE that 94-99 grille, definitly one of the best looking trucks ever.

Maybe I should do a 6.0 swap in one...

 

[folkenheath]

Sounds like a real nice plan, I look forward to it coming together.