Cummins Crew Cab Resto Mod Build
 

First let me start out by saying that I bought this truck with the Cummins already swapped in it. Therefore that is why I'm not putting this in the conversion forum since it was already done. This thread is to show what I'm doing to the truck since I bought it from a guy in MO in Dec. of 2010.

This is what it looked like when I had my good friend go pick it up for me since I was at work.
http://www.texas4x4.org/gallery/albu...1070.sized.jpg

It's a 1985 W350 Crew Cab that was an ex Air Force truck. The guy that I bought it from bought it from the guy that swapped in the 1992 Cummins, A518 and NP205. They also put a 92 core support and grill along with power doors and mirrors. Overall whoever did the conversion did a good job, it looked factory when I got it home.

http://www.texas4x4.org/gallery/albu...1075.sized.jpg
Shot of the engine bay.

http://www.texas4x4.org/gallery/albu...1065.sized.jpg
Interior.

Now, my plans when I bought it was to do a full frame off restoration on the truck and make it completely my own. I'm about a 1/2 way into it and hope to be done with it in about another year. I did from the frame down the 1st year I had it and now I'm in the process of getting the full frame off restoration done.

A short list of what all the mods that will be done to it when finished.

7" lift ( 4" Deaver leafs, 2" Jungle drop hangers, 1" Zero Rates frt/rear, Jungle shackle flip rear with his hangers using GM 63" springs)
Tires 38x15.50r20 Toyo MTs
Wheels 20x12 Fuel Octanes
Ranch Hand bumpers front and rear.
50 gallon SS fuel cell mounted in bed.
Rebuild engine (Hamilton 188/210 cam, port/polished head, 60lb springs, O'ring the head, twin turbos, SDX sticks, 14mm IP or Hot rod 12mm IP, Air Dog 150, cooler tubes, aluminum radiator, Hellman Intercooler and CIA along with Steed Speed manifold and full 4" exhaust)
Trans is a Garmons Stage II 47rh with triple disc billet converter.
Interiror will be completely custom will only be reusing the gas and brake pedal.
Mineral Gray paint wiht Line-X rockers and bed.

Currently the truck is in the body shop getting painted and next week I will be taking the frame to get powder coated and start putting the suspension back underneath it to make it a roller again.

What are those 1 inch zero rates?

Pics of the 1st year mods
 

http://www.texas4x4.org/gallery/albu...ount.sized.jpg
All the good stuff from Jungle.

http://www.texas4x4.org/gallery/albu...Axle.sized.jpg
Rear end replace with a AAM 11.5 from a 2008 Dodge Cummins 4x4.

http://www.texas4x4.org/gallery/albu...sted.sized.jpg
Front Dana 60 totally disassmebled and rebuilt with all new parts.

http://www.texas4x4.org/gallery/albu...on_1.sized.jpg
Deaver 4" springs with Jungle mounts front and rear.

http://www.texas4x4.org/gallery/albu...60_2.sized.jpg
New Dana 60 installed.

http://www.texas4x4.org/gallery/albu...ge_5.sized.jpg
Pic right before the tear down to do the rear suspension.

If you want to sell that bench seat let me know.

http://www.texas4x4.org/gallery/albu...rs_2.sized.jpg
Jungle's front rear spring hangers and shackle flip, again AWESOME stuff.

http://www.texas4x4.org/gallery/albu...sp_2.sized.jpg
Rear suspension done. Fun drilling 24 1/2" holes.

http://www.texas4x4.org/gallery/albu...lled.sized.jpg
Rear AAM 11.5 axle in place.

http://www.texas4x4.org/gallery/albu...341a.sized.jpg
NP205 before full rebuild.

http://www.texas4x4.org/gallery/albu...605b.sized.jpg
Bare case during rebuild.

http://www.texas4x4.org/gallery/albu...P205.sized.jpg
Finished NP205.

http://www.texas4x4.org/gallery/albu...nk_1.sized.jpg
50 gallon SS fuel tank mounted in bed.

http://www.texas4x4.org/gallery/albu...ft_2.sized.jpg
Tow Woods 1pc rear drive shaft.

http://www.texas4x4.org/gallery/albu...Home.sized.jpg
Drove it home to it's new home for the tear down.

http://www.texas4x4.org/gallery/albu...ab_2.sized.jpg
New/used cab I bought for the project getting ready to be blasted and sent to body shop.

http://www.texas4x4.org/gallery/albu...sy_1.sized.jpg
Getting ready to pull old cab off so I could stip the frame down.

http://www.texas4x4.org/gallery/albu...sy_1.sized.jpg
This is pretty much how the truck looks right now other than the front and rear axles are already been pulled. Only have 1/2 dozen more parts to pull off the frame and it will be ready to go to the powder coater.

I will update this thread as I make progress, but it's kinda slow going right now and the next big thing is going to be getting the engine rebuilt.

Stay tuned though for updates and feel free to comment, critize or ask questions!!!!

Eric

Sorta like an add-a-leaf.
http://offroaddesign.com/catalog/Zero%20Rates.htm

The front one I sold last week, but I still have the rear one. It doesn't split in the middle though like the front one did.

Great looking project. Another style of 1st gen on my wish list right there. Did you build that tank ?

Lookin nice! Its came along way since you started!

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WOW...That is looking great!! Another long box crew made into a 4x4...making me re-consider turning mine into a 4x4......curse you guys!!![laugh]

I think its a short bed...

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Looking good!

Thanks!

No I had a company over in Tyler, Texas build it for me.

Thanks man, meads a lot!

Appreciate the kind words and bryson is right it's a short bed.

Thanks gyman, I wish I was far as long on mine as you are on yours.

I don't want to sound like an old grumpy guy but PLEASE find some way to put a roll bar in your truck. Putting a Cummins engine in raises the center of gravity + a spring lift adds more to that + you are compounding the center of gravity issue even further with the huge tires and wheels. I'm concerned about this with the one I am building which only sets about 2 inches higher than my 91 standard cab 4WD. These crew cab trucks are easy to flip and I feel that I'm about at the borderline with mine as it sets now. I actually have parts on my truck that came from the crew cab that member 93flatbed had accidentally flipped!

Appreciate the concern, but I think I will be fine. I've built and owned several big trucks before and never hand an issue with them wanting to flip over. The truck will have front and rear sway bars when completed and for 38s 7 inches of lift is not that tall. To keep it that low I'm having to move the front axle forward and the body shop is doing some fender trimming to help clear the tires/wheels when turned at full lock.

Trebor Are you thinking this more for off road or on the road getting into some kind of wow maneuver.

On the road. IIRC I believe 93flatbed crashed his in the flat lands of Arizona. Maybe he will chime in and give the particulars. When you install a 1000 pound engine that is 30-40% heavier than the old 318 gasser and elevate it almost 50% higher it changes the handling and tipping characteristics from a factory built 4x4 V8 crew cab setting at stock height. I think this may be more prevalent with the crew cabs with the shorter wheelbase with the 6 foot bed. (I just wanted to pass this along & not clutter up this build thread)

simplysmn Knows something about that kind of experience.
He has had more then one Crew Cab.

CE TX
Nice truck.

What is your color scheme for the truck and btw awesome rig as it sits now can't wait for the finished product!

Thanks Buddy!

Here is a photo rendering another member on RCC did for me. It will have no chrome anywhere, black fender flares and windows will be tinted Limo.

http://www.texas4x4.org/gallery/albu...yBlk.sized.jpg

Won't be long now, its really coming together! You might even beat me!

Well after I get it out of the paint and body shop and sitting back on the frame it will be a while because all the interior and engine work is going to take some money which I will have to save up for. I'm shooting for this time next year to have it completely done, but might have it running and driving by the end of the year. I only want to do this once and hopefully never again. lol.

Man that should look pretty sharp are u gonna put a big bumper on the front?

Yes sir, it's getting the bumper off of this truck.
http://www.texas4x4.org/gallery/albu...ge_1.sized.jpg

The rear will get a matching Ranch Hand as well.

Nice!

Taking the frame to the powder coater tomorrow so got the frame stripped down of all the brackets and any bolts and nuts.

Also got the frame plate reinforcements welded in from Jungle.
http://www.texas4x4.org/gallery/albu...me_4.sized.jpg

Blurry pic, but also welded the mount for my Air Dog to the frame instead of clamping it with another plate to the outside of the frame.
http://www.texas4x4.org/gallery/albu...me_3.sized.jpg

On the trailer ready to go.
http://www.texas4x4.org/gallery/albu...me_2.sized.jpg

http://www.texas4x4.org/gallery/albu...me_1.sized.jpg

Next pics should be after shots of the frame, Yeah!!!!!!

Can't do it any better then that!

Amazing to know what it will look like and what it is right now a bunch of steel hope its all done in a flash!

That is going to look AWESOME with the powder coating!!
Jim

Only want to do this once, so I'm doing it the best way I can/know how. Thanks!

Don't hold your breath brotha, I still got a long road ahead!

Thanks Jim, I aboustly love your parts I got from you. IMO they are the best out there!!

CE TX
I see you boxed the frame up front what will you do for the rest of the frame.

Nothing else, just the area up front. I will probably add an extra cross member though.

Thanks for the kind words!
Are you going to powder coat all the hangers also?
Jim

Yes sir, also all my factory cross members will be getting powder coated as well. When I get the frame back I will be taking all the small pcs. to get coated next.

Custom Dash
 

Well here is a rough draft of how I will be doing my custom dash. It will be made out of 1.25" tubing and SS/Aluminum sheet then some of it wrapped in black leather. I have never like the dashes in these 1st gen trucks and the ones that I've had the gauges always failed. So I figured why not start from scratch. The dotted lines represent where it will be bent at either a 45 or 90 degree angle depending where they are at.

http://www.texas4x4.org/gallery/albu...gn_1.sized.jpg

Tell me what you think, good or bad. I know some may think it's a wast of time and money, but I think it will be well worth the effort in the long run.

Eric

Eric,
I think it could be sweet. This pic is one idea that I am working into my 440 RC thats not done yet.
Another idea is a 2nd gen dash & I know a couple guys over on RCC have done this conversion. Joecool was one of them & just do a search on RCC & it should come up.
Jim

I've seen the one that Joe Cool did over on RCC with the 2nd gen conversion, looked very nice. Trying to stay away from plastic and use mostly metal and some fabric to give it that racing/baja truck look on the inside, but still very fuctional.

I like the pics you posted above, be sure to post some pics of your setup when your done. Are you going to replace the factory gauges in the existing dash?

CE_TX,

Where are you getting the powder coating done?

Longview, White Oak, Tyler, Dallas?

Just curious.