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1966BT Dodge Camper Special Resto/Mod
My name is Andy and live outside of Baltimore, MD. I have built a few rock crawlers over the last ten years including a few Toyotas and Jeeps. I completed my last project major project in July 2010; a Jeep based racer I built for the Raush Creek off road series. Check out Crawl Magazine, issue no. 26 for an article the owner wrote about the race series and the build.
Other than fabricating, I have a great family including my wife and our two boys. I found the blue '68 W200 Crew, a former Air Force truck, on a farm in Luray, Va in October 2010. At the time, my wife and I had been contemplating buying an older 3/4 or 1 ton truck to do work around the house and eventually pull a single car hauler for my personal off road project (Toyota 4Runner). Having a small family, the four door cab immediately stood out to me. The truck was (is) ugly and rough as hell so I wanted it bad. My wife was on board with the project so I got the ball rolling. The timing worked out and I brought the '68 home with the help of my two good friends, Austin and Rob. http://inlinethumb16.webshots.com/46...600x600Q85.jpg It was worse than it looked. The a-pillar floors and body mounts were gone. The bottoms off all four doors were completely rusted out and there was very little left of the rockers and door sills. The front of the cab was sitting on the frame. The doors were so out of whack that the driver's front was really hard to open and was lucky if it would close. The fender/cowl seams were gone and the inside of the cowl was really bad. At some point, a 383 was swapped in along with a radiator out of something like a '55 Chevy. Whatever butcher did the swap, cut the core support and put a hole in the hood to clear the radiator neck. All four leaf packs were shot; the fronts were negatively arched and the rear main leafs were cracked. The plan WAS to bring the '68 back to life but rust really compromised the structural integrity of the cab. I hated to let it go but it was the best thing to do. Fast foward to May 2011; I came across a Craigslist add for 4 Sweptlines including a complete '66 D200 (318/727) Camper Special which I brought home 5/5/2011. Thanks to Shane for hauling and Rob for making the ride to help load the truck. http://inlinethumb30.webshots.com/47...600x600Q85.jpg Fast forward to November 2011; I found a '91 12v 6BT donor truck in PA so I'm going NV4500/diesel instead of with the BB. I'm still linking the front suspension, new rear leafs, a GM D60 front axle, Dodge D70 rear axle, hydro boost brakes with discs on 4 corners, and power steering along with a hydro assist ram. The body will remain stock for the most part. I'll admit, I'm cross posting whore and have this build on two other sites but this was before I realized I'm going diesel. I've got it on Sweptline.org since this truck is a Swepty and on an East Coast wheeling board named rightcoast4x4.com. My original inspiration came from a thread on Pirate4x4.com; on which "Chopperman" with a set of coil overs, sold axle swapped is 2003 Duramax CC 2500HD truck: Link removed site violation due to profanity) I like everything about this truck and feel that the 4WD conversion with coil overs will be worth the time and money since the ride will hopefully be that much better compared to leafs. I'm also digging the rear 4 link work that Phil @ Sillyneck Fab did on this '08 F450: Link removed site violation due to profanity) More than likely I won't 4 link the rear due to simplicity and function. When I'm done with my '66, at the most it'll see a 20' or so gooseneck trailer so I don't really the bags considering most people get away with the equivelent of one ton rear leaf springs.. This time last year, I took advantage of some end of the year sales and bought most of the parts to link the front. I also got a new Vanco hydroboost unit, and a passengetr side high steer arm and studs from Off Road Design. http://inlinethumb50.webshots.com/17...600x600Q85.jpg http://inlinethumb34.webshots.com/47...600x600Q85.jpg http://inlinethumb15.webshots.com/34...600x600Q85.jpg |
Having written it off due to body rot, I spent a good part of the spring tearing the '68 down:
http://inlinethumb47.webshots.com/47...600x600Q85.jpg http://inlinethumb52.webshots.com/22...600x600Q85.jpg http://inlinethumb26.webshots.com/37...600x600Q85.jpg http://inlinethumb58.webshots.com/47...600x600Q85.jpg http://inlinethumb63.webshots.com/47...600x600Q85.jpg http://inlinethumb36.webshots.com/47...600x600Q85.jpg http://inlinethumb48.webshots.com/48...600x600Q85.jpg I shevled the reamining sheet metal I kept off the '68 then jumped on the '66: http://inlinethumb64.webshots.com/49...600x600Q85.jpg http://inlinethumb62.webshots.com/46...600x600Q85.jpg http://inlinethumb28.webshots.com/49...600x600Q85.jpg |
Thanks to 5 buddies, we got the bed off mid October. I then spent a day on removing the rear end and rear suspenion.
I thought it was interesting how this LWB frame is braced: http://inlinethumb18.webshots.com/44...600x600Q85.jpg http://inlinethumb37.webshots.com/47...600x600Q85.jpg http://inlinethumb36.webshots.com/44...600x600Q85.jpg Before (nice drive shaft!): http://inlinethumb39.webshots.com/49...600x600Q85.jpg After: http://inlinethumb41.webshots.com/46...600x600Q85.jpg http://inlinethumb01.webshots.com/46...600x600Q85.jpg I then pulled the original 318/727 and stripped the cab inside and out, prepping to take it off the frame. http://inlinethumb16.webshots.com/49...600x600Q85.jpg Thanks to my crew for helping get the cab off the frame! http://inlinethumb01.webshots.com/46...600x600Q85.jpg http://inlinethumb37.webshots.com/48...600x600Q85.jpg |
I started tearing into the frame, stripping it of the factory trans cross member. I first pulled the two pieces of the 4spd bell housing cross member by grinding the heads off all the rivets and knocking them out with the air chisel.
http://inlinethumb32.webshots.com/49...600x600Q85.jpg http://inlinethumb32.webshots.com/47...600x600Q85.jpg |
From there, I knocked out the hardware for the overload brackets then jumped on the frame splices.
Bill was 100% correct, this frame had an approximate 14" splice welded into the frame. I marked the welds with a silver sharpie. http://inlinethumb22.webshots.com/47...600x600Q85.jpg http://inlinethumb50.webshots.com/50...600x600Q85.jpg http://inlinethumb23.webshots.com/49...600x600Q85.jpg Get the exterior brace off was fun (deep sarsasm there) since none of the rivets wanted to come out after I ground the heads off. I put my air chisel through the paces yeterday for sure. I'm sure my neighborhood hates me. You can see where the hole for the spring eye bolt was hand torched: http://inlinethumb38.webshots.com/47...600x600Q85.jpg http://inlinethumb18.webshots.com/47...600x600Q85.jpg This plate is stitch welded into the interior of the frame rail. I'm debating on removing it or fully welding it in after I have the frame blasted. Unfortunately the bottom sections of each side of main frame rails are rusted pretty badly because of the amount of moisture retained at these joints. The scale literally fell out in chunks. http://inlinethumb22.webshots.com/36...600x600Q85.jpg I still have to break the other splice down before I have the frame blasted. The frame measures approximately 19' 7" BTW. http://inlinethumb46.webshots.com/42...600x600Q85.jpg |
The front axle is an '88 or so Chevy D60 and the rear is Dodge D70U. I've got a pair of SRW hubs for the 60. I plan on locking both axles with something like a Detriot in the front and an ARB in the rear along with 4.10 gears.
http://inlinethumb61.webshots.com/43...600x600Q85.jpg I've developed a good relationship with a local media blasting company that does great work for cheap and is fast! MD guys around Baltimore, call up Bay Town Painting and talk to Ray Sr. At the shop: http://inlinethumb31.webshots.com/45...600x600Q85.jpg Axles, axles, everywhere.. Both my 5 y/o and 7 y/o boys helped me unload the media blasted axles and get 'em into the garage. We then ran the freshly blasted knuckles and caliper stands to Chesapeake Coating, Inc. to be powder coated black. I'd rather spend the money up front versus the parts sitting in the garage, rusting after being blasted. I should hopefully have an update with coated parts next week. http://inlinethumb32.webshots.com/46...600x600Q85.jpg http://inlinethumb47.webshots.com/24...600x600Q85.jpg http://inlinethumb50.webshots.com/43...600x600Q85.jpg |
I've torn down two D60s and one D70 over the last few months.
My back says that stuff is heavy.. I'm having bad luck with D60 shafts..the inner shafts from one of the 60s are pitted really badly and it looks like the one of the inners from the other D60 has already started to fail..Bummer..When the time comes, I'll order a set of after market inners. If I do that, I might have the hub gear broached to 35 spline and go with a set of after market outers too. http://inlinethumb55.webshots.com/48...600x600Q85.jpg http://inlinethumb21.webshots.com/26...600x600Q85.jpg Since I plan on replacing the D70 wheel bearing nuts with Stage8 X-Lock retainers (http://www.stage8.com/offroad.html) I removed the factory nuts (2 9/16" I believe) with a hamer and chisel while being realy careful not hit the end of the spindle. http://inlinethumb08.webshots.com/41...600x600Q85.jpg From there, I used the air chisel to remove the hubs by chiseling against the back of the drum. Removing the back plates including all the drum brake hardware was just a matter of removing the four nuts that hold the backing plate to the axle housing. http://inlinethumb19.webshots.com/24...600x600Q85.jpg I pressed out the wheel studs to separate the heavy drums from the wheel hubs. http://inlinethumb46.webshots.com/48...600x600Q85.jpg I had a number of parts media blasted including the body and motor mounts I removed from the '68 frame. You gotta love the super hack job on slotting the motor mounts.. http://inlinethumb17.webshots.com/36...600x600Q85.jpg http://inlinethumb38.webshots.com/48...600x600Q85.jpg |
New parts rolled in this past summer including the wheels and coil overs.
At first, I just ordered a single 17x9 Cragar Soft 8 w/5" of back spacing wheel from Summit to check fit. These have a 3650lb load rating. It fit great so I then ordered four more in chrome which 3 months to get.. Wheel on the '91 Dodge D60 http://inlinethumb38.webshots.com/48...600x600Q85.jpg http://inlinethumb27.webshots.com/46...600x600Q85.jpg http://inlinethumb02.webshots.com/47...600x600Q85.jpg http://inlinethumb25.webshots.com/12...600x600Q85.jpg Wheel on the '92 Dodge D70 http://inlinethumb55.webshots.com/20...600x600Q85.jpg http://inlinethumb62.webshots.com/45...600x600Q85.jpg |
It was Christmas in August:
Cragar Soft 8s: http://www.summitracing.com/parts/CRR-3988980/ http://inlinethumb50.webshots.com/48...600x600Q85.jpg FOA 10" remote reservoir coil overs: http://inlinethumb46.webshots.com/46...600x600Q85.jpg |
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I'm now looking for 2nd gen CTD Dodge parts including an NV4500-6BT engine plate, NV4500 bell housing, and all the clutch parts.
For the input swap, I'm leaning towards the HD input shaft found in NV4500s that came behind the Cummins in the 2500 and 3500 Dodges. NV4500.com: "The spline of the input is 1-1/4” diameter 10 spline and protrudes approximately 7-1/2” from the face of the transmission. This input shaft can be interchanged with other New Venture input shafts with this 5.61 1st gear ratio. The front bearing retainer index is 5.60”, and has a snout diameter of 1.75” for the release bearing. http://quad4x4.com/images/qu10076.jpg Input shaft bearing and race http://quad4x4.com/images/qu10124.jpg http://quad4x4.com/images/qu10125.jpg http://quad4x4.com/images/qu10042%5B1%5D.jpg |
After a ride through the beautiful hills of PA on Saturday, I have a 6BT donor truck! Thanks again to Austin, Phil, and my son Jake, for making the trip.
It's '91 (Nov. '90 production date), D350, auto, with a service body. It went up for sale because the engine mounted trans cooler went which wiped out the trans with engine coolant. The owner stated that it only has 180K on it but documentation I found while going through the truck makes me believe it's closer to 250K. None of the tampers on the injection pump have been tripped and it runs great. I'm zero out of pocket on it so I'm pretty psyched. It's a non-IC motor but am in the process of finding parts for the IC set up and the NV4500 conversion. http://inlinethumb41.webshots.com/46...600x600Q85.jpg http://inlinethumb53.webshots.com/48...600x600Q85.jpg |
heck of alot of labors. but gonna be sweet when its done.
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It's my intention to replace the first gen. pump to a later model pump, from a truck that came with hydro-boost brakes. I'm going to have PSC check to see if the pump, in stock form, flows enough to power hydro-boost and hydro assist steering. Thoughts?
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