Can't be worse than the Fugly Duckling was.
CK5
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Is the rear crossmember/ tailpan solid? That's the only bad rust on my sub, Im not looking forward to that weekend.
I replaced the tail pan support a couple years ago so yeah, it’s good to go.
Grab a cup of coffee and take a seat, this is a lengthy writeup ....
I may have started my mid-life crisis early.
Or maybe I am self-imploding.
Frankly, I've been hesitant to post what's going on because I question my own sanity ... but here it goes: I'll start with a riddle ...
How does a turbo install turn into a frame-off restoration and a body swap ???
Everyone okay?
Simple answer: I knew, ever since I bought this truck, that some day I was going to have to deal with the rot and decay. My truck came from Kansas, so there was quite a bit. More than others? No. More than I cared for? Yes. Could you see it from 30 feet away? No, I got good at hiding it.
But when I pulled my fuel tank and surveyed the extent of the damage, I decided now was the time to do something about it, because I was tired of building around a rusty truck and couldn't bring myself to put a brand new fuel tank and fuel system back into a crusty frame and body.
The question then became whether to repair or replace the body. The determining factor became the condition of the window frames around the rear quarter windows. The paint was bubbling, so I knew something was up. I pulled both windows and it was as I feared. Both frames were rotting out significantly. That sealed the deal for me: body swap it would be, and I began stripping it down.
I've pulled off all 6 doors (which Ive replaced before so they are good). I pulled off my tailpan which was also new-ish. and stripped the body shell down to just the sheet metal. All other associated parts have been pulled, stored, and saved. The most logistically feasible way to remove the body then was to cut it up and haul it off to the scrap yard, so a buddy and me broke out our sawzalls and got to work. Turns out, a 1988 Chevy Suburban can fit just fine in an 8x10 trailer.
It was unfortunate to scrap the roof, because it was mostly in good shape. But sacrifices must be made. It is less work, in my mind, to swap on a rust free donor body than it would be to replace all of the rusted out panels (which by my calculations, would be 60% of the body shell).
The frame is salvageable with exception for a pair of body mounts which can be rebuilt.
I am also taking this time to refresh the suspension as well. The ORD 47s and 52s have worked really well, but I cannot escape the "Might As Well" mindset when it comes to certain things. So I have sold off the suspension to a really cool guy in North Carolina who also has an 88 burb and will put these to good use. I also gave him my factory tank skid.
SO ... here are the summer plans for the Rusty Cedar Suburban:
- Quasi-frame off restoration. I say quasi, because really only the back half of the frame needs restoration. The front is still in decent shape. Though when I pull the rest of the body for the new donor, Im sure it will get a paint refresh. I am also contemplating the Dueling Design weld on windowed frame reinforcement plates.
- I left the front cab section of the body shell on so that, once the frame is done, I can still focus on installing the new fuel and turbo.
- For the fuel, I have a FASS system on the shelf waiting, along with the new tank, new straps, new 4911 pump, and new Bosch injectors.
- Suspension: I have ORD's "Xtreme Travel" shackles and HD tension shackle hangers on the shelf waiting. They, along with the main eye hangers, will be repositioned to fit a new set of ORD 64s in the rear, much like David did, that I'll have ORD build me later this summer. For the front, I'll ask ORD to build me a set of 52s at the same time, which will be an easy bolt in affair, thanks to the DIY4x B52s I already have installed. For shocks, I sold off my rear Bilstein 5100s but kept my 5125s since they are already 14" long travels, and will likely get another pair for the rear and develop a unique mounting system to keep them out of the new body. The front shocks will be repositioned using a shock hoop system that I'll build to allow for more up travel (my previous Ford towers only allowed about 2" of up travel). I also have an airbag kit for the rear, waiting on the shelf, to help with overloads whenever towing.
- Axles: Axles are in good shape, but upgrades are great. I have a PowerStop Big Brake upgrade kit sitting on the shelf for the front Dana 60. The rear axle will get an axle truss for strength, new perches set to correct pinion angle (no more shimming), contemplating 4340 shafts, and new shock mounts of course.
- Donor: Clearly the truck is getting a "new" body. I'm on the hunt for the most rust free shell I can find for a reasonable price. They're out there, just requires patience, and I have enough to keep me busy to allow the search to consume the full summer months. If I find a ridiculously clean 4x4 donor, there's a strong chance I may dump this frame and do a full frame off on the donor and swap all my good parts over. Either way, I'll be proceeding with the resto of this frame with the expectation that I'll be using it. If I end up not using it, I can always sell it off for some lunch money.
Once the donor body is installed, it'll get professionally repainted. I'll be snagging some junkyard springs so I can keep the truck attached to the axles for any potential test drives post-turbo install. I anticipate waiting to order the ORD long boy springs until the truck is totally rebuilt so I can weigh it and give Stephen an accurate weight. Though I already weighed the truck prior to tearing it apart and it came in at a hefty #7,760 on a very empty tank, which makes the truck well over 4 tons with a full 40 gallon tank of diesel. So I could go ahead and order the springs as I doubt there will be much difference in weight by the time it is done.
I'll be pulling the front clip probably in the next week or so to give myself more room to install this turbo.
Additionally, my 6.5 is telling me she wants some more attention. I hear there are these fancy new valve cover clamps/girdles/whathaveyou out there that help spread the load and keep these valve covers from leaking.
I get there will be people who don't understand, agree with, or support why or how I am dealing with the rust on this truck and will likely express those thoughts. That's totally okay. I made a decision, pursued it, and will see it through to the end. I hope you will join me for the adventure and enjoy the ride along the way. Just remember, a body shell - heck, even a frame - is just another replaceable part.
And hey, if you happen to have a rust free donor sitting in your barn, give me a shout. I'm in the market.
Naturally, this keeps me away from BlazerBash this year. Like I said, sometimes sacrifices have to be made. This just means the near $3,000 investment in the trip can be used elsewhere. Primarily, getting my wife a reliable vehicle, though she prefers we just fix her suburban, which we are also pursuing.
It's a busy summer coming up. Enjoy.
Andy
I may have started my mid-life crisis early.
Or maybe I am self-imploding.
Frankly, I've been hesitant to post what's going on because I question my own sanity ... but here it goes: I'll start with a riddle ...
How does a turbo install turn into a frame-off restoration and a body swap ???
Everyone okay?
Simple answer: I knew, ever since I bought this truck, that some day I was going to have to deal with the rot and decay. My truck came from Kansas, so there was quite a bit. More than others? No. More than I cared for? Yes. Could you see it from 30 feet away? No, I got good at hiding it.
But when I pulled my fuel tank and surveyed the extent of the damage, I decided now was the time to do something about it, because I was tired of building around a rusty truck and couldn't bring myself to put a brand new fuel tank and fuel system back into a crusty frame and body.
The question then became whether to repair or replace the body. The determining factor became the condition of the window frames around the rear quarter windows. The paint was bubbling, so I knew something was up. I pulled both windows and it was as I feared. Both frames were rotting out significantly. That sealed the deal for me: body swap it would be, and I began stripping it down.
I've pulled off all 6 doors (which Ive replaced before so they are good). I pulled off my tailpan which was also new-ish. and stripped the body shell down to just the sheet metal. All other associated parts have been pulled, stored, and saved. The most logistically feasible way to remove the body then was to cut it up and haul it off to the scrap yard, so a buddy and me broke out our sawzalls and got to work. Turns out, a 1988 Chevy Suburban can fit just fine in an 8x10 trailer.
It was unfortunate to scrap the roof, because it was mostly in good shape. But sacrifices must be made. It is less work, in my mind, to swap on a rust free donor body than it would be to replace all of the rusted out panels (which by my calculations, would be 60% of the body shell).
The frame is salvageable with exception for a pair of body mounts which can be rebuilt.
I am also taking this time to refresh the suspension as well. The ORD 47s and 52s have worked really well, but I cannot escape the "Might As Well" mindset when it comes to certain things. So I have sold off the suspension to a really cool guy in North Carolina who also has an 88 burb and will put these to good use. I also gave him my factory tank skid.
SO ... here are the summer plans for the Rusty Cedar Suburban:
- Quasi-frame off restoration. I say quasi, because really only the back half of the frame needs restoration. The front is still in decent shape. Though when I pull the rest of the body for the new donor, Im sure it will get a paint refresh. I am also contemplating the Dueling Design weld on windowed frame reinforcement plates.
- I left the front cab section of the body shell on so that, once the frame is done, I can still focus on installing the new fuel and turbo.
- For the fuel, I have a FASS system on the shelf waiting, along with the new tank, new straps, new 4911 pump, and new Bosch injectors.
- Suspension: I have ORD's "Xtreme Travel" shackles and HD tension shackle hangers on the shelf waiting. They, along with the main eye hangers, will be repositioned to fit a new set of ORD 64s in the rear, much like David did, that I'll have ORD build me later this summer. For the front, I'll ask ORD to build me a set of 52s at the same time, which will be an easy bolt in affair, thanks to the DIY4x B52s I already have installed. For shocks, I sold off my rear Bilstein 5100s but kept my 5125s since they are already 14" long travels, and will likely get another pair for the rear and develop a unique mounting system to keep them out of the new body. The front shocks will be repositioned using a shock hoop system that I'll build to allow for more up travel (my previous Ford towers only allowed about 2" of up travel). I also have an airbag kit for the rear, waiting on the shelf, to help with overloads whenever towing.
- Axles: Axles are in good shape, but upgrades are great. I have a PowerStop Big Brake upgrade kit sitting on the shelf for the front Dana 60. The rear axle will get an axle truss for strength, new perches set to correct pinion angle (no more shimming), contemplating 4340 shafts, and new shock mounts of course.
- Donor: Clearly the truck is getting a "new" body. I'm on the hunt for the most rust free shell I can find for a reasonable price. They're out there, just requires patience, and I have enough to keep me busy to allow the search to consume the full summer months. If I find a ridiculously clean 4x4 donor, there's a strong chance I may dump this frame and do a full frame off on the donor and swap all my good parts over. Either way, I'll be proceeding with the resto of this frame with the expectation that I'll be using it. If I end up not using it, I can always sell it off for some lunch money.
Once the donor body is installed, it'll get professionally repainted. I'll be snagging some junkyard springs so I can keep the truck attached to the axles for any potential test drives post-turbo install. I anticipate waiting to order the ORD long boy springs until the truck is totally rebuilt so I can weigh it and give Stephen an accurate weight. Though I already weighed the truck prior to tearing it apart and it came in at a hefty #7,760 on a very empty tank, which makes the truck well over 4 tons with a full 40 gallon tank of diesel. So I could go ahead and order the springs as I doubt there will be much difference in weight by the time it is done.
I'll be pulling the front clip probably in the next week or so to give myself more room to install this turbo.
Additionally, my 6.5 is telling me she wants some more attention. I hear there are these fancy new valve cover clamps/girdles/whathaveyou out there that help spread the load and keep these valve covers from leaking.
I get there will be people who don't understand, agree with, or support why or how I am dealing with the rust on this truck and will likely express those thoughts. That's totally okay. I made a decision, pursued it, and will see it through to the end. I hope you will join me for the adventure and enjoy the ride along the way. Just remember, a body shell - heck, even a frame - is just another replaceable part.
And hey, if you happen to have a rust free donor sitting in your barn, give me a shout. I'm in the market.
Naturally, this keeps me away from BlazerBash this year. Like I said, sometimes sacrifices have to be made. This just means the near $3,000 investment in the trip can be used elsewhere. Primarily, getting my wife a reliable vehicle, though she prefers we just fix her suburban, which we are also pursuing.
It's a busy summer coming up. Enjoy.
Andy
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Might as well.
Wow! The first couple of pictures make it seem like the options are limitless....
Rock on! 
Sub body wise fourwheelerjeff had good looking option in the classifieds.
Edit: https://ck5.com/forums/threads/2wd-suburban-body.345161/
Sub body wise fourwheelerjeff had good looking option in the classifieds.
Edit: https://ck5.com/forums/threads/2wd-suburban-body.345161/
Sone times you just gotta rip the bandaid off and get it done.
The end goal will make this all worthwhile.
The end goal will make this all worthwhile.
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Chris did all that design work. I only cut and made a prototype from his drawings, and abused them thoroughly.
The truck looks like it’s burnout ready.
David
Does this mean you have to change the title?
It gets us into a lot of trouble, doesn’t it?
I thought heavily about a single or crewcab swap with a tub bed, but settled on sticking with the suburban. It’s the most versatile vehicle I have ever driven.
Rock on!
Sub body wise fourwheelerjeff had good looking option in the classifieds.
Edit: https://ck5.com/forums/threads/2wd-suburban-body.345161/
I’ve reached out to him.
Agreed. The rip still hurts, but the end goal is worth it.
My misunderstanding, oops. I bet I can chirp those 40s even without a turbo now.
Maybe not. I’m also contemplating building a tube dash, in which case the VIN plate would be transferred over. No change in title necessary.
I just did the same thing for the same reason. Got tired of putting shiny new parts in a rusted out body.
Boy, there's an example of might as well if I ever saw one. It's your ride. No need to justify your actions. Have fun with the project.
That's pretty much where I was at. And there were other parts of the build that I have been holding back because of the rusty body. Now it's full steam ahead.
There is a lot of fighting the M.A.W. here just the same. There are many things I am tempted to do while I have it torn down this far (coilovers) that I am resisting simply because I know that if I go too far down the rabbit hole, it'll be YEARS before I get it finished, if I get it finished at all. As it stands, I'm already expecting this to take me up to a year to be fully ready to hit the road. Blazerbash is more of a 2023 or 2024 expectation now. SO I am trying to keep it as simple as possible. Resto the frame. Find a donor body that requires nothing other than a repaint. Longboy leaf springs front and rear. Turbo and fuel. Get on down the road.
There is one particular rabbit hole I'll be chasing for my own personal preference that I'll share when I have something to share.
Mostly the justification was speaking to myself. This is a HUGE step. There are not many people in my part of the world that think the way that I do, that I know of anyways. The average Joe doesn't do this sort of thing, so there's a little voice in my head saying "You're crazy". LOL.
I know where there is a rust free 52 suburban body. Not mine, as it is a 48 and rusty.
Totally get it.
I did a similar crazy move yanking out a perfectly running 5.3 (only underpowered for my needs) a week after getting home from a trip with it. It was peak wheeling season too.
But you know, had I not ripped the band aid off quickly I would have procrastinated. I know I would have justified to myself that the 5.3 was running good, I’ll get one more trip out of it. Years would go by.
It sucked not having my truck to go play on the weekends but looking back I’m glad I did.
Keep your nose to the grindstone and get it done.
I dig it, rust sucks! We were in the same place with our k5, it was dialed in for us, but the body was beat down in most places you can't see or fix easily, it donated the drivetrain for the new truck.
I'll keep an eye out in Mississippi for a clean body.
I'll keep an eye out in Mississippi for a clean body.
Maybe on a different build for one of my sons.
Missing out on the use of it will definitely be the hardest part. But I’ll keep at it. A little progress each day gets the old truck back on its way.
I appreciate the lookout. It’s great having a community like this to work together on sourcing the donor. Definitely a crowd project.
I’ll admit, there’s something exciting about seeing it broken down this far.
Andy
So long as plans stay in place, I, along with another local CK5er, will be heading to Texas Square Bodies next Friday 5/13. He’s got the perfect specimen for a body swap on the Rusty Cedar Suburban.
