SpeedyWS6

I talked to a few people about that... I have a guy checking on a converter out of a g van with a duramax as the g vans had 4l80's rather than an Allison.

6cylinders

I'm watching and asking questions because I am thinking of doing
the same swap, truck is exactly the same except it is an 06.
You are doing some nice work so far.
Thanks

SpeedyWS6

Well I got some duramax goodies today...

I found out that the only difference between my gas core support are a few holes and mine does not have the thread-certs in the correct location to bolt up the duramax intercooler.

The far outside holes are the new ones to locate the base of the cooler.



The intercooler mounts where the gas radiator would.



So obviously the radiator goes behind that, killing any chance I had to run a mechanical fan. I'm pretty bummed about that.

SpeedyWS6

I have been wanting to figure out my fuel pump situation for a while and I finally decided to tackle it today. I'm pretty pleased with how things are looking with it so far. I had an air dog laying around that I pulled of of my common rail 5.9 before I traded it in, so I decided to put it to use.

The late model gm vehicles use a return less fuel system. There is a regulator and a filter built in tank. I threw around a few ideas about how my setup was going to play out. I'll tell my reasoning as I go...

First I pulled the bed so I could pull the gas pump out.



Then I figured out how I was going to put the draw straw inside the stock fuel pump module.



Basically my draw straw is mounted to the side of the fuel module in place of where the in tank filter would have been.



I retained the original fuel pump, and it will be wired in to pump fuel, but it's job is to pump fuel into the module. My thinking behind this it that the fuel pump will do a much better job of keeping the module full of fuel at all times, especially when there is low amounts of fuel in the tank.

Air Dog has you drill large holes in the side of the module and disable the factory pump. The way they want it to work is so the holes allow the fuel into the module, but they also let fuel out, so you still suck air at times around turns or under acceleration. If everything works as planned mine will be full of fuel at all times just like originally designed.





The small line is an air bleed/return line off of the pump. It will be routed to my modified filler neck. The original pressure line will now be the return line off the engine.

teroma25

I'm curious how this project faired out?

SpeedyWS6

I lost interest in the build after buying a car to daily drive. I would probably take offers on the truck as is...

SpeedyWS6

Well I'm back on the build. Kind of. I started laying out the wiring. I'm going to run the stock GM PCM so I can have the A/C, and gauges work correctly. I actually think its going to be cheaper and easier.

I have a few problems though I need a little input on.

The biggest problem I see with this truck is the cooling system. I just know electric fans are not going to cool this engine under the hood. There is just too much heat through all these coolers for electric fans, and I just did not realize that the radiator was set so far back on the duramax. So I think my only option is to relocate the radiator to the bed, and run a mechanical fan to handle the other coolers up front. This way the radiator is not being heat soaked by the intercooler and two large electric fans should be able to cool the radiator just fine, especially considering the difference from under hood temp to ambient temp in the bed.

DragonSlayer

Can you put 2 fans in front of the coolers? Pusher style fans should cool it. The older 12v were not a "hot" running engine. Have you seen the coolers on a late model powerstroke??!!?? I read on the 4bt conversion forum that some guys swapping 6bt for the old 6.2l military trucks don't run fans at all.

SpeedyWS6

I have actually found a lot of cases were people are running the 6bt without a fan... I'm going to give it a shot.