Extra free time in the last few weeks has allowed several projects to get done on the suburban. So this thread is being transformed into an official build thread.
The Great Smaug was purchased to fulfill several roles:
1.) Move people (our pair of trucks has been decidedly lacking in this area)
2.) Accommodate longish road trips (Mileage being a large factor)
3.) Provide a shelter for primitive camping
4.) Provide moderate off-road capabilities to accommodate primitive camping in fun locations.
At the end of the day, we'd like to have something we can cheaply drive to the Rockies, pull off the road, and camp out in the middle of the high desert. Or some other fun place. Campgrounds just aren't fun when they get full. But much more emphasis will be placed on daily drive-ability than the few off-road miles it's ever going to see. Also, being an expedition rig, I want all parts to be both rugged and cheaply available at any Autozone in the remotest parts of the country, as far as possible. So crucial hardware (drivetrain, suspension, engine, etc) will mostly be creative arrangements of stock parts. Non-essential parts have no such restraints.
With these goals in mind, I have been collecting parts and ideas to get the truck better equipped (Props to CK5 for providing many of the ideas). The truck came with a good set of traits for an expedition rig. It already seats 9 between the 3 bench seats. My other 6.2 averages about 24MPG on the road when lightly loaded (hoping to get something similar here). The original 31" tires are a nice step up from the 29" tires that Blue has. And, with two cross-state trips under its belt, I'm getting to know the truck's issues (no huge ones yet).
Modifications I'm considering include (in no particular order):
1.) Manual transmission with at least 5 speeds. I'm not a fan of automatics. NV3500 is a possibility, but I'm leaning toward the NV4500.
2.) Increasing tire size to 33" (depending on how much suspension work is required).
3.) 2nd generation 14bff in the rear. Mostly because I think it's easier to service (and I've seen 2 10-bolt gov-lock axles fail).
4.) Adding matching 8-lug hubs to front 10-bolt (since Chevy doesn't offer a 6-lug ff axle).
5.) Swing-out spare tire & cargo rack behind the barn doors.
6.) Auxiliary heater to provide warm camping in cool weather.
7.) Adding 6.5TD turbo to the 6.2 engine
Additionally, if any of my diesels experience engine failure, I'd consider a 4BT swap for fun and mileage purposes. But I'm not particularly interested in ripping out a nicely running 6.2 at this time.
It's worth noting, for those just tuning in, that this is a vehicle I'm building with and for my wife. So some requirements, like "it must have running boards," are not originating from me. But it also means that she often helps out with the projects. So I'm teaching mechanical theory as much as I'm building. This is truly a team project.
So...Daily Driver/Expedition Rig or bust!
). They stripped out before I even got them tight. 
It started fine while jumping, so I ended up replacing the alternator on the truck. In the campground. Fairly late in the evening (by flashlight). The truck fired up again and all was well. One of the neighbors even came over after I fired it up and said it sounded like a 6.2 engine. 
What was the big fire ball from?
