SAS'ing my 02 Duramax - Garage Build

[grizzlyoffroad]

I think the half tons lack the crossmember between the frame rails that the 3/4 ton trucks have. Thats why they tie the mounts together on the half ton kits. You can see his round crossmember behind the winch.

You're right, there is a x-member right above the brackets....but I'm still going to throw one in there, right down on the brackets. The brackets seem well built, but are pretty thin material. I want it as tough as I can get while I'm still fabbing and powder coating Like I said before, this truck weighs about 9900 lbs and the 60 is going to add to that! Can't hurt!

 

[grizzlyoffroad]

Well guys...don't hold your breath for any killer progress over the next couple weeks. My real job is as an engineer for the oil companies, and I work 2 weeks on and 2 weeks off. I am back to work now, so will only be updating you on purchases and parts findings. Please keep the comments and suggestions coming though, as the planning (and credit card) for a project like this is darn near as important as the welding wire, grinding wheels and wrenching! I need all the help I can get from guys that have been through it already and those that KNOW the parts!

Don't worry though, we'll hit it hard when I get back to the shop and should be close to getting it busted out by the end of my next hitch home! It's all the little things like ABS tone rings, custom cross members, drive line angles, etc...that will eat me up on time and patience.

Pretty soon this....

Will have a front end more like this!.....

 

[y5mgisi]

Hey man! I saw you over on pirate talking about your stuff. Safe to say that over here is alot more friendly then over there where everyone seems to have a grade school mentality of what makes you cool... Good work so far!

 

[grizzlyoffroad]

Hey man! I saw you over on pirate talking about your stuff. Safe to say that over here is alot more friendly then over there where everyone seems to have a grade school mentality of what makes you cool... Good work so far!

LOL...ya, I took a beating before they finally started to let me in the "club", but now that I'm doing this build they are being a bit more friendly. Let's hope it stays constructive like it is over here and on GMfullsize! Thanks for the note!

 

[grizzlyoffroad]

I know you guys are sick of of seeing pics of my fender wells...but can I just say how liberating is it to go from this...

To this...

This this!

Can't wait to get-r-done!!

 

[TheBeast_88K5]

omfg....




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I need to SAS this thing, one day....

 

[Chevy305]

I want your truck

Suscribed

 

[desertrat67]

Your truck looks great! Glad I popped back in to see what I have been missing.

My Uncle lived in Kenai and worked up on the north slope, too. You don't happen to know Jim Mullins, do you?

 

[y5mgisi]

Thats a nice lookin Toyota also!

 

[grizzlyoffroad]

Your truck looks great! Glad I popped back in to see what I have been missing.

My Uncle lived in Kenai and worked up on the north slope, too. You don't happen to know Jim Mullins, do you?

Thanks! Sorry, can't say I know your Uncle. People don't realize that about 10k people work in our little oil field...so even though it seems like a small world, it's not very often you "run" into someone

 

[TheBeast_88K5]

Thats a nice lookin Toyota also!

Well, thank ya... It's the wife's.

 

[jekquistk5]

Damn now I want to do this to my dmax. I think its because both your truck, and my truck are the same color.

 

[grizzlyoffroad]

Damn now I want to do this to my dmax. I think its because both your truck, and my truck are the same color.

If you're going to go with a big lift anyway, this SAS'ing is the way to go. It's very time consuming and not cheap, but when you're done, you're done...not constantly trying to upgrade it to keep it from breaking. It's not over complicated for a Garage builder either...just need big jack stands, a torch, lots of cutting wheels, and welder, normal hand/air tools....and some buddies to lift when you need it! I just sure hope it drives OK when I'm done, cause this is my daily driver!...think it will after a track bar, hydro assist, and maybe a sway bar.

 

[grizzlyoffroad]

Short update....I contacted ORD about getting two of the same rear hangers and not including the left side. They got right back to me and said they would be glad to replace it and to not worry about sending the other one back to them...and sincerely apologized for the inconvenience. That was pretty cool to not have to fight over getting my part and it to happen in such a timely manner. Thanks Offroad Direct!

While I am getting the correct bracket sent from them, I figured I might as well get the Track Bar and Brake lines sent too....and just pay the extra shipping! Problem is, I never got a chance to mount the springs and measure for the brake lines. Does anyone like happen to have a suggestion for front brake line length with the 8" Alcan springs and 3-5" ORD hanger lift?...maybe 11-13" of total height??....think the 24's will work fine? Any advice appreciated.

 

[Cruz89K5]

Short update....I contacted ORD about getting two of the same rear hangers and not including the left side. They got right back to me and said they would be glad to replace it and to not worry about sending the other one back to them...and sincerely apologized for the inconvenience. That was pretty cool to not have to fight over getting my part and it to happen in such a timely manner. Thanks Offroad Direct!

While I am getting the correct bracket sent from them, I figured I might as well get the Track Bar and Brake lines sent too....and just pay the extra shipping! Problem is, I never got a chance to mount the springs and measure for the brake lines. Does anyone like happen to have a suggestion for front brake line length with the 8" Alcan springs and 3-5" ORD hanger lift?...maybe 11-13" of total height??....think the 24's will work fine? Any advice appreciated.

Mine is quite a bit smaller than that, but with 52's in the front with zero rates and brackets sitting directly on the frame I'm barely able to max out the stock brake lines. How long are the stock lines? I recall them being pretty long. I can go get a few measurements for you tomorrow if you'd like.

 

[grizzlyoffroad]

Mine is quite a bit smaller than that, but with 52's in the front with zero rates and brackets sitting directly on the frame I'm barely able to max out the stock brake lines. How long are the stock lines? I recall them being pretty long. I can go get a few measurements for you tomorrow if you'd like.

I didn't put a tape on them, but you're right...the stock lines are around 16-18" if I had to guess. Even with a 10" lift, all I had to do was move the hard line half way down the frame and the rubber lines were long enough. Of course, there's not a whole lot of flex with IFS! That's way I'm thinking the 24" ones would probably be plenty. Don't go out of your way, but if you got a chance to measure up, I'd appreciate it! Thanks Cruz!

 

[Cruz89K5]

So here's a few quick measurements. If you need anything more specific let me know.

Brake lines are hard to measure. Damn flexible hose. From top mount to around the banjo bolt hole is roughly 29". My axle to frame distance is around 13 1/2", and at all the droop I could manage makes that distance just over 22". I'm not sure how much lift I have, but that's stock 52" springs and a zero rate. I did my own front bracket right off the frame to avoid adding as much lift as possible. With stock lines in the stock location I can usually pull them tight, I went as far up the dirt as I could but I couldnt get them completely straight, but 29" is a pretty good estimate.

I always enjoy a good excuse to go play on my makeshift RTI ramp. Here's a shameless picture of my beater I took while measuring.

 

[grizzlyoffroad]

So here's a few quick measurements. If you need anything more specific let me know.

Brake lines are hard to measure. Damn flexible hose. From top mount to around the banjo bolt hole is roughly 29". My axle to frame distance is around 13 1/2", and at all the droop I could manage makes that distance just over 22". I'm not sure how much lift I have, but that's stock 52" springs and a zero rate. I did my own front bracket right off the frame to avoid adding as much lift as possible. With stock lines in the stock location I can usually pull them tight, I went as far up the dirt as I could but I couldnt get them completely straight, but 29" is a pretty good estimate.

I always enjoy a good excuse to go play on my makeshift RTI ramp. Here's a shameless picture of my beater I took while measuring.

AWESOME! Thanks Cruz!....this is exactly why I love these forums! I'll get some longer ones to be safe!

Nice flex BTW!

 

[grizzlyoffroad]

OK, nothing is easy. I'm just trying to order the brake lines for my Dmax, but Offroad Design is unsure of the ones I need. I assumed that if they had a metric 10mm bango bolt at the caliper, that they would also have some metric thread for the hard line connection at the frame....BUT, Chris says they may be 3/16IF and 1/4"IF like the old ones. So, since I am not near the truck, can someone tell me what connection the brake lines (front and rear) are at the frame and what Bango bolt is really needed for the late model trucks? I've Googled it, but I trust you guys more....people that have recently swapped them out with SS lines like I am trying to do now!

PS. Think I'm going with a 33" ORD line to be safe....remember, 1979 Dana 60 in front and AAM 11.5 in the rear.

 

[Cruz89K5]

OK, nothing is easy. I'm just trying to order the brake lines for my Dmax, but Offroad Design is unsure of the ones I need. I assumed that if they had a metric 10mm bango bolt at the caliper, that they would also have some metric thread for the hard line connection at the frame....BUT, Chris says they may be 3/16IF and 1/4"IF like the old ones. So, since I am not near the truck, can someone tell me what connection the brake lines (front and rear) are at the frame and what Bango bolt is really needed for the late model trucks? I've Googled it, but I trust you guys more....people that have recently swapped them out with SS lines like I am trying to do now!

PS. Think I'm going with a 33" ORD line to be safe....remember, 1979 Dana 60 in front and AAM 11.5 in the rear.

Going from memory here, so bear with me. My axles are from an 85 1 ton, so I'm assuming they are metric. I've got the stock lines in front bolted to the 85 caliper. I believe it's a 10mm banjo bolt. I've got the stock rear line off of the truck ran down to the axles stock hard line on the long side, and I've got a parts store short piece or hard line ran into ord stainless lines for a disc brake 14 bolt conversion on the short side.

I recall the new truck axle having a 15mm flange, but the threads were identified to the old stuff with the 3/8 flange.

Sorry if none of this makes sense, it's been a long day, and typing on my phone gets annoying.