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The Great Smaug
- Thread starter campfire
- Start date
Came across this quote today and chuckled. Yes, that is just about what was going on. 
Richard, the lack of fan caused no problems while putzing around town or cruising down the road. Before towing the CUCV 400 miles, I installed my backup fan (redrilled the hub because it was too small), but I had forgotten to bring the shroud with me, so I wound up doing the towing without it. The trip is memorable for the transmission failure, but the truck was blowing steam regularly during the run. The temperature started climbing about a mile from my house, and the water level was close to the bottom of the radiator when I shut it down. So the system clearly is not ready for real life yet. The lack of shroud certainly isn't helping, but I can't help but think that this fan, of a slightly smaller diameter than the original fan, is not up to the task. It should be able to handle towing through the hot desert with A/C on, it shouldn't be blowing off steam in Wisconsin.
Maybe.
This is another concern that I have, the drilling may or may not be centered perfectly. I may be overthinking this, but the having the original fan fly into the radiator caused an unhappy day.
So you're wagering 3 stoplights against 4 bolts.....
Richard, the lack of fan caused no problems while putzing around town or cruising down the road. Before towing the CUCV 400 miles, I installed my backup fan (redrilled the hub because it was too small), but I had forgotten to bring the shroud with me, so I wound up doing the towing without it. The trip is memorable for the transmission failure, but the truck was blowing steam regularly during the run. The temperature started climbing about a mile from my house, and the water level was close to the bottom of the radiator when I shut it down. So the system clearly is not ready for real life yet. The lack of shroud certainly isn't helping, but I can't help but think that this fan, of a slightly smaller diameter than the original fan, is not up to the task. It should be able to handle towing through the hot desert with A/C on, it shouldn't be blowing off steam in Wisconsin.
Maybe.
This is another concern that I have, the drilling may or may not be centered perfectly. I may be overthinking this, but the having the original fan fly into the radiator caused an unhappy day.
Looking underneath the rig today I spotted my zero-rate rusting. This surprised me, as this zero rate has seen just a few thousand miles since I installed it, and zero of those were salt miles. 
It's aging while sitting in a shed? I know other parts of the rig are aging during this hibernation, but I didn't expect rust.
It's aging while sitting in a shed? I know other parts of the rig are aging during this hibernation, but I didn't expect rust.
Came across this quote today and chuckled. Yes, that is just about what was going on.
Richard, the lack of fan caused no problems while putzing around town or cruising down the road. Before towing the CUCV 400 miles, I installed my backup fan (redrilled the hub because it was too small), but I had forgotten to bring the shroud with me, so I wound up doing the towing without it. The trip is memorable for the transmission failure, but the truck was blowing steam regularly during the run. The temperature started climbing about a mile from my house, and the water level was close to the bottom of the radiator when I shut it down. So the system clearly is not ready for real life yet. The lack of shroud certainly isn't helping, but I can't help but think that this fan, of a slightly smaller diameter than the original fan, is not up to the task. It should be able to handle towing through the hot desert with A/C on, it shouldn't be blowing off steam in Wisconsin.
Maybe.
This is another concern that I have, the drilling may or may not be centered perfectly. I may be overthinking this, but the having the original fan fly into the radiator caused an unhappy day.
Hmm--I have taken some fan clutches that had a smaller 4 bolt pattern (but the center pilot was the same size),and just used a hacksaw to "slot" the holes and bolted them up,and never had one fly off--I think some OEM or aftermarket ones were also slotted so "one size fits all" too..I used original bolts and lock washers too..
This one has a slipping transmission correct?
Yep.
Condensation. Humidity. Bare metal.Looking underneath the rig today I spotted my zero-rate rusting. This surprised me, as this zero rate has seen just a few thousand miles since I installed it, and zero of those were salt miles.
View attachment 213279
It's aging while sitting in a shed? I know other parts of the rig are aging during this hibernation, but I didn't expect rust.
I have neither time nor money for this truck right now. But I think that will change as summer turns into winter, so I'm gonna start collecting ideas now. Last month's overlanding trip has given us motivation to put time & money into this thing over the winter season. I have 11 months to get it road worthy so it can do camper duty next year. Actually, it's more like 8 or 9 months until camping season starts, but having it ready for next year's overlanding trip is the real goal.
Things to be done:
Engine:
Reseal rocker arm cover(s).
Diagnose & repair P/S leak.
Serpentine conversion.
Find a fan that actually works (Windstar?).
Tranny:
Replace with NV3500 or NV4500. I can get this cheaply if I'm patient. Or I can get into a time crunch and spend way too many dollars here (
). Having worked through many (most?) of the bugs on the Blazer, I'm much more confident that I can get the Suburban converted without breaking stuff. Confidence is worth its weight in gold. I already have all the pieces required for the conversion except the gearbox and a 32-spline input shaft for the NP208.
Interior:
Lots of ideas that will be implemented one by one, starting with a basic platform bed. This phase comes last, after the truck is running well.
Suspension:
This is the only part of the plan that has changed. Riding around in Luke's K5 has sold both of us on putting some dollars into softer springs. Neither of us wants crazy amounts of body roll, so I may try to keep some sort of sway bar for on-road use (does anyone make disconnect kits for these trucks?). I would also like a few inches of extra clearance (though I need to keep it down to a kid-friendly height). The back springs are pretty tired (one of them is resting on the overleaf when unloaded, the other is not much better), so I want to fix that while I'm at it. While I'm redoing front springs I will probably install my extra front axle (has been rebuilt and also has an Eaton posi).
Body:
Not much planned at this point, but I do have a couple of brush guards to choose from. I'd like some deer protection. I also have no skid plate covering the gas tank. Wifey really wants a swing-out tire carrier, but that's a later phase of the plan.
Things to be done:
Engine:
Reseal rocker arm cover(s).
Diagnose & repair P/S leak.
Serpentine conversion.
Find a fan that actually works (Windstar?).
Tranny:
Replace with NV3500 or NV4500. I can get this cheaply if I'm patient. Or I can get into a time crunch and spend way too many dollars here (
). Having worked through many (most?) of the bugs on the Blazer, I'm much more confident that I can get the Suburban converted without breaking stuff. Confidence is worth its weight in gold. I already have all the pieces required for the conversion except the gearbox and a 32-spline input shaft for the NP208.Interior:
Lots of ideas that will be implemented one by one, starting with a basic platform bed. This phase comes last, after the truck is running well.
Suspension:
This is the only part of the plan that has changed. Riding around in Luke's K5 has sold both of us on putting some dollars into softer springs. Neither of us wants crazy amounts of body roll, so I may try to keep some sort of sway bar for on-road use (does anyone make disconnect kits for these trucks?). I would also like a few inches of extra clearance (though I need to keep it down to a kid-friendly height). The back springs are pretty tired (one of them is resting on the overleaf when unloaded, the other is not much better), so I want to fix that while I'm at it. While I'm redoing front springs I will probably install my extra front axle (has been rebuilt and also has an Eaton posi).
Body:
Not much planned at this point, but I do have a couple of brush guards to choose from. I'd like some deer protection. I also have no skid plate covering the gas tank. Wifey really wants a swing-out tire carrier, but that's a later phase of the plan.
The original set of build guidelines (from 2 years ago). I've checked a few items off the list, but not much has changed, goal-wise.
Build Has Begun
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!
So...what tips or ideas do you guys have for turning this steel box into an overlanding home-on-wheels? Look through the pictures of the Yooper trip if you haven't already. I'm looking for basic trail riding and camping in the rain. Lots of rain. This year's trip was really good experience for us, but I know there are lots of things I have yet to figure out. Starting with waterproofing. 
ORD has swaybar disco's.
Thanks. I had missed that when I read through their catalog.
One of their oldest products I think.
I don't have much input. But if anything comes up in the process of getting a truck bed camper in mine, I will share all I know.
go to expedition portal. Lots of vehicles from around the world and all the ideas you can dream of....
Been there. I hafta stay away from there, or it will start sucking time like this place does. And this place already sucks a lot of time.
I'll probably spend more time there when the truck is roadworthy. Getting over just that one hurdle will take a bunch of time.
You were talking about fans, I've ALWAYS preferred engine driven fans over electric. I did an electric fan swap on a V8 S-10 I did in high school and immediately started having overheating issues. I run an engine driven fan (thermal clutch from A/C vehicles) in my Camaro that sees 7000 between the shifts and we use one in my buddy's F150 truggy. My K5 currently has the centrifugal type clutch that disengages when engine speed is up and I have some heating issues on the trail when I'm running in low gears because of rough trails. A quick shift to 2nd gear to drop the revs and it cools right back off. I'll be putting a thermal clutch (which it should already have because of the A/C system) back in it once it's running again. I don't like relying on the electric fans off-road either. A little bit of wire or even a hole drilled through the thermal clutch and a bolt and you've got it locked solid and cooling really well till you can replace it. If you loose an electric unit, you're destined to drive short stints till you heat up too much to drive then have to cool it down before progressing.
I might add an auxiliary electric fan for the A/C or transmission cooler for a heavy towing vehicle where you were approaching it's load ratings or were in extremely hot climates but so far I've never had an issue.
This is just my $0.02 on the subject.
I might add an auxiliary electric fan for the A/C or transmission cooler for a heavy towing vehicle where you were approaching it's load ratings or were in extremely hot climates but so far I've never had an issue.
This is just my $0.02 on the subject.
Thanks for the input. My thoughts about my particular application:
I'm not in a hot climate. Most of our "hot" days in summer have a high temp of 80-85*F. Last summer I daily drove the suburban with no fan at all. The only issue I ran into was when I did a 400 mile towing trip with my new replacement fan. 400 miles (empty) with no fan was fine, 400 miles towing with crummy fan setup (no shroud) was not fine. So for normal use I'm already fine, but I want to be able to cruise through the desert without having issues. Being an efficiency nut, having an electric fan means that I don't hafta be wasting that power during the >95% of the time that I don't need any fan at all.
