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Project Penny - All good things must come to an end

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Time for an update!

So, the parts that have arrived thus far include:

- ORD crossover steering
- ORD solid front axle swap brackets
- ORD rear shackle flip kit
- ORD Zero Rates
- ORD u-bolts
- ORD extended brake lines
- Rough Stuff spring perches and spring plates
- DIY4x HD rear shackles
- Black Bird Customs rear disc brake kit
- Warn M12000
- 17" Trail Ready HD17 aluminum bead lock wheels
- 37" Kevlar MTRs

I had got the rear axle re-geared and had an ARB locker installed a few months ago. Today I installed the ORD shackle flip, HD shackles, zero rates and the u-bolt flip kit. Everything looks good, the shackle angle is excellent. The axle looks like it is offset to the rear in the picture, but that is just the mud flap hanging down into the wheel well. With the flap removed, the axle is centered at ride height. I got my diff breather line lengthened, and the ARB air hose run up to the solenoid valve on the OBA setup up front on the engine.

I wanted to switch to disc brakes to reduce the frequency I had to change my brakes all the time before with drums due to all the mud up here and also would like to have my wheel stay on should I ever break an axle shaft (14 bolt semi floater). Unfortunately, my axle is apparently a bit of an oddball version and the disc brake kit does not fit at all... I was told to try installing a different set of rotors and to install some spacers to see if I can get it all lined up properly. I'll find out tomorrow if it'll work or not. If it doesn't, I'll just rebuild the drums yet again and run them instead.

I forgot to order shock tabs, so I'll put an order in for them tomorrow. The shocks I've got look like they should fit quite well, which is a nice change from the norm with ordering shocks :waytogo: I'll also be dropping the tires off at the tire shop to get them dismounted and mounted on the rear bead of the bead locks. I'll install the rings at home and inflate them myself.

Once the rear is set back down, I'll jack up the front and put my brand new Miller Spectrum 375-Extreme plasma cutter to work removing all that IFS junk. I also bought a bunch of grinder wheels to smooth everything out afterwards. I've got ford shock towers on order from the Ford dealership, which should be in tomorrow. Once the IFS is out, I'll install the ORD SFA brackets and then I'll be stuck until I can find some 52" leaf springs. I'm amazed at how tough they are to find around here! Once I find a set and get them installed, I'll set the D60 in place temporarily to get the shock towers placed, and take some measurements for the front drive shaft which I'll be ordering from Jessie at HAD. I have to wait for my SYE to arrive from ORD, as well as the rear flange / driveline brake setup from Jessie for the NP241 to take measurements for the rear drive shaft.

I am still gunning to have this thing done in time for Blazer Bash, but it's gonna be close. Installing the parts is no trouble, its getting them here on time that is the tough part... I am still waiting on my D60 ARB, gear set, ARB front bumper and front plate diff cover. Hopefully they don't take too long to arrive... I am also dropping the K5 off to get some bumpers and sliders installed, then will be replacing the drive shafts to eliminate some highway vibes. If the Tahoe ain't ready to go in September, the K5 will be ;)

Anyways, on to some pictures I snapped with my phone for you guys!

Mods, can I get this topic moved to the driveway build thread area?

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Well, today I continued with my rear axle. I stopped by the local napa armed with a measuring tape and discovered that 2500HD rear disc rotors fit perfectly with the brackets I bought earlier. I traded in the old new rotors as cores. I also ordered new studs for the axleshafts, which will arrive tomorrow. I got my brakes tubed in, and tomorrow all I'll need to do is install the new studs, install the axleshafts, fill the diff up and bleed the brakes out.

While I was under there, I finished tubing in my OBA tank, and ran my ARB air locker hose up to the air solenoid in the engine compartment. Finally, I installed a conversion u-joint and re-installed the stock driveshaft. Just so happens that with the pinion pointed at the t-case where the SYE is going to put the flange, the u-joint angles are within a few degrees of each other, sweet!

Since I was then out of things to do on the rear axle, and a buddy of mine showed up, we set to work burning the IFS out. Needless to say, there were a few hose casualties, including the ARB line I just ran :doah:, but the IFS is now out and sitting on the ground outside :pimp: Tomorrow I have another parts run to go get my studs, ford shock towers, and then lunch with a young lady (:waytogo:) before I take the ford wrench back to her to burn off the rest of the brackets, and start cleaning the frame up a bit. I will also be taking the tires in tomorrow to have them dismounted off the 5 luggers, and get the rear bead installed on the bead locks.

My goal is to have the frame cleaned up, SFA brackets and pitman arm installed, and the tires totally mounted on the bead locks by Saturday night. Sunday I commute back home, and continue my regular work schedule. Hopefully I'll be able to get the thing done in time for Blazer Bash, assuming all my parts arrive on time.

Again, pics for those who are interested!

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Lookin good Russel!
Post as many pic as you can we will be watching.:thumb:
Did you get that 6.5 running any better?
 
The wheels that were on the tires still belonged to the previous owner. He sold them to the guy manning the tire machine when we got them swapped over to my wheels today :haha:

Anyways, as you might have guessed, I got the tires mounted to the rear beads today and got two rings installed in the front. They take a bloody long time to torque down in 3 steps! They look good but I think I am going to replace the rings with their slim version in the future. They will collect mud and water big time the way they are right now.

I also got all of the wheel studs today, finally, and got the axle shafts re-installed. I also installed the brakes and got the rear two wheels on and the truck set down on them. I still need to order a set of lug nuts for the wheels and also stop by the junk yard to find a little bracket for the rear brake hose on the diff. Once I get that installed I can trim the two new lines to fit and bleed out the rear brakes. The diff is now full of oil and only requires some tabs for the rear shocks otherwise.

Tonight my buddy and myself finished cutting out the rest of the IFS brackets and cross members. I'll be taking the grinder to the frame rails tomorrow to clean everything up and give it a shot of paint. All that I'll have left to do after that is install the SFA brackets and the steering pitman arm then I'll be out of things to do until my D60 is finished up. I still need to get all the parts ordered up for it anyways.

Only one picture for you guys tonight with the truck sitting on the rear axle. I am really liking the stance so far! I hope the front plays nice...

Also, I found the charger for my camera tonight, so tomorrow I'll start posting some higher res photos :waytogo:

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Well, today wasn't much for progress... Spent the whole afternoon grinding on the driver's side frame rail but I did get it finished up! I also got word that all my parts, less the ARB bumper and my synthetic winch line, are in. So, my D60 should be finished up next week :woot:

Anyways, as promised, slightly better quality pictures for tonight! I took some pictures of my rear axle, my OBA tank etc as well. I will be re-adding the pieces I cut out of the disc brakes by bolting the cut out chunk on to the backing plate then drilling / tapping the main bracket and installing another chunk of steel across the back of the bunch to tie them all together.

For the rear bumper, I'll be installing an air connection just beside the 7 pin electrical connector, I also have one under the hood up front. I'll have the rear output at the full 130 PSI the system runs and the front output will be regulated down to 90ish PSI that the ARB lockers run at.

Up front, you can see how open the engine is now... I am going to be building a crossmember to tie the two engine mounts together to add some support and will be depending on the ARB bumper to provide some support up front with the stress of the leaf springs. I will have to re-route the passenger side brake line though as it was tied to the previous IFS crossmember that no longer exists.

Tomorrow I'll grind the passenger's side frame rail smooth and give it a shot of paint like the driver's side then will burn the rest of the torsion bars out. If I still have time / motivation I'll get the new pitman arm installed as well as the front two SFA brackets. I need to go buy myself an angle drill to install the rear two brackets. I am hoping that I can get the rear two brackets installed before I leave for work. Also just so happens to be everything that I can do on the truck this week.

So, I'll get a few more updates in this weekend then this thread is gonna die for a week while I am at work and ordering parts.

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Well, I finally finished all the grinding, and got my SFA brackets installed. I had to chop my down pipe to fit the passenger's side rear bracket on :doah:I guess exhaust is on the list now too... Oh well!

I also finished up the OBA port on the rear bumper. I think it works well, out of the way and easy to access.

These will be the last rounds of pictures until next weekend, just made the 300 mile trip home for another work week. All good though, last week was rather expensive, and I got everything I can do for the time being done.

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Hunter loves my trucks! He can lay under them without banging his head on something when he gets up, haha!
 
Lots of good progress, the wheels and brackets look real good on there. It's a lot closer!

What's the deal with your rear disk brackets? They usually bolt on from the outside of the flange, with all 4 bolts, but you had to notch yours and only use 3 bolts from the inside?
 
Yeah, there are a number of different spacings of the drum backing plate mount throughout the years. I just happened to get one of the rare oddball sizes. The rotor that came with the kit didn't fit, but it winds up that Duramax slip on rotors were perfect!

Alaska 2012 is a go at this point!
 
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