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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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Hey Great project you have there...and I agree that you made a great choice going with a cummins/5speed set-up instead of the BB. I have always loved those early D/W Dodge trucks....I'll be watching with interest.
As for the power steering pump on the motor. If it's a Non-IC motor then they run a different Vacuum/power steeing set-up then the IC trucks. If you get an IC vacuum/power steering set-up it should work...since they used the same set-up from 91 to about 2000? on all the cummins trucks. |
Nothing on the truck will require vaccum so can I remove the vaccum portion off the new pump?
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Nice looking project! You most certainly can remove the vacuum portion of the pump, I stripped both diaphragms and fabed up some aluminum plates to block the ports and ran it. As you are aware the mount set-up prevents removing it entirely as the ps is driven off the back of the vac, but you can definitely streamline the system.
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You can definitely do as Bearvally says....as long as it's the Non-IC style with the pods. But if you keep your eyes open on E-bay you can get a straight power steering set-up from a 4bt cummins motor, and some industrial 6bt set-ups. No vacuum pump portion, just straight PS.
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nice project! you have my attention!
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I found an engine plate and a clutch fork but I'm still looking for a bell housing.
Heading to the classifiedes now.. |
As an avid off roaded(last truck 93 dakota w 60's) and 4 door owner and ctd 92, i love this project. Look forward to seeing more
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I appreciate the kind words and have some updates:
About three weeks ago I decided to link and bag the rear of truck. I've got high expectations for this truck and think the additional cost will be worth it. I admit it, I'm not breaking any new ground and linking/bagging a truck has been done plenty of times. As a matter of fact, take the time to read this thread in which the fabricator 4 linked and bagged a brand new F450 because the owner was really disappointing with how it carried a load. The truck is now 4 linked (w/ a track bar), bagged, has a simple air system and the owner is still happy with it about 4 years later and several 6K lbs payloads later. http://pirate4x4.com/forum/showthrea...highlight=f450 The tentative plan is to use a pair of Goodyear air bags (http://www.sdtrucksprings.com/index....ducts_id=16373), a stand alone compressor, along with the same joints that I'm using on the front end. Will it cost more and be a hell of alot more work, absolutely. But I think it'll be great in the end and exceed my expectations. |
My polybushings.com Cummins motor mounts arrived a few days ago, the air bags yesterday, front and rear trusses, link brackets, and more bushings, are on the way. I've emailed the .DXF files to about 4 places and am supposed to have some quotes today. My buddy Barrett, the CAD guru has done in a few more drawings for me including some adjustable bracket plates. I spoke to Dave and Allen Ballistic Fab about stepping it up on the motor mounts but I'm not holding my breath..
Motor mounts: http://polybushings.com/pages/2710.html http://inlinethumb57.webshots.com/50...600x600Q85.jpg http://inlinethumb39.webshots.com/48...600x600Q85.jpg Air bags: http://inlinethumb26.webshots.com/48...600x600Q85.jpg http://inlinethumb21.webshots.com/50...600x600Q85.jpg Laminate plate drawing: http://inlinethumb15.webshots.com/47...600x600Q85.jpg |
I've been making some progress behind the scenes but have not touched the truck for a few weeks.
I sent my CAD drawings to several local Baltimore companies who have CNC cutting capabilites. They either came back at over double my budget or never got back to me. I then sent the drawings to Kert @ DIY4x.com who came in under budget and has been great to work with since. He's going to start cutting the plates on Monday and is making a set of mounts for the air bags too. The bag mounts will be similar to these but super sized to fit the 11" diameter air bag. http://inlinethumb12.webshots.com/47...600x600Q85.jpg http://inlinethumb17.webshots.com/34...600x600Q85.jpg The trusses arrived a couple of days ago and are awesome. My inner over killer is is very happy. Also, Allen @ Ballistic sent me a finalized version of the motor mounts for the Cummins conversion. http://inlinethumb12.webshots.com/49...600x600Q85.jpg Once I get the plates from Kert, and if the weather is decent, I might start welding 'em on the frame. |
Kert @ DIY4x.com came through like a champ. He cut me an unbelieveable price for the air bag to axle mounts, air bag top plates, inner and outer frame plates, some tabs, and shipping. Here's just a sample of his work:
http://inlinethumb42.webshots.com/47...600x600Q85.jpg http://inlinethumb55.webshots.com/49...600x600Q85.jpg http://inlinethumb38.webshots.com/46...600x600Q85.jpg to http://inlinethumb44.webshots.com/50...600x600Q85.jpg to http://inlinethumb58.webshots.com/47...600x600Q85.jpg I'm looking forward to working with Kert again. |
More of Kert's work:
Concept http://inlinethumb12.webshots.com/47...600x600Q85.jpg Drawing http://inlinethumb17.webshots.com/34...600x600Q85.jpg Final product http://inlinethumb14.webshots.com/49...600x600Q85.jpg http://inlinethumb26.webshots.com/47...600x600Q85.jpg |
Since we were on the subject earlier:
A comparison of the vaccuum pumps from an early first gen versuses a later first gen: 1990 (non-IC): http://inlinethumb27.webshots.com/49...600x600Q85.jpg http://inlinethumb62.webshots.com/47...600x600Q85.jpg 1992 (IC'd): http://inlinethumb35.webshots.com/47...600x600Q85.jpg http://inlinethumb35.webshots.com/49...600x600Q85.jpg |
Subscribed to this thread. Interested to see how it will turn out. Great work BTW. Awesome project!
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Very cool! Keep up the good work.
I really enjoy watching big projects like this. You will really have something when it is done. |
This thread needs some updating..
Mid January I pulled the stock vaccum pump and power steering pump off the motor. Prior to the sending the assembly to PSC for a high flow pump, I had a friend machine a pair of aluminum plugs to close the vacuum ports. http://inlinethumb03.webshots.com/28...600x600Q85.jpg http://inlinethumb03.webshots.com/50...600x600Q85.jpg http://inlinethumb59.webshots.com/49...600x600Q85.jpg I received several parts orders and picked up a late model 14 bolt. Motor mounts (that may or may not work..... :bang: ) http://inlinethumb28.webshots.com/66...600x600Q85.jpg Axle truss for the front D60: http://inlinethumb37.webshots.com/50...600x600Q85.jpg Diff. covers: http://inlinethumb37.webshots.com/16...600x600Q85.jpg Couplers (for the tube that will span between the coil over hoops, and run over the engine): http://inlinethumb58.webshots.com/49...600x600Q85.jpg Below are some pictures of the 14bolt axle out of an '06 2500HD. I like the idea of running this axle because it has factory disc brakes with an integrated parking break from the factory. 14bolts are known their beefy center sections, 10.5 ring gear, and 3rd pinion support bearing. The newer 14b's have disc brakes; the calipers are dial pistion and the rotors slip on. This one has 4.10s (and a posi) that match the ratio in the D60. I was hoping not to have replace a bunch of parts on it but it needs all new e-brake hardware.. http://inlinethumb38.webshots.com/37...600x600Q85.jpg Super *%cked e-brake hardware: http://inlinethumb13.webshots.com/50...600x600Q85.jpg Slip fit rotors: http://inlinethumb47.webshots.com/56...600x600Q85.jpg |
I had the had the housing blasted and starting torching off the brackets.
http://inlinethumb03.webshots.com/96...600x600Q85.jpg I finished stripping the 14 bolt then tore into the 6BT donor truck.. http://inlinethumb57.webshots.com/50...600x600Q85.jpg I got the D350 all stripped including the motor and all the wiring then banged out a temporary cart for the 6BT. http://inlinethumb05.webshots.com/47...600x600Q85.jpg http://inlinethumb24.webshots.com/46...600x600Q85.jpg http://inlinethumb55.webshots.com/50...600x600Q85.jpg http://inlinethumb26.webshots.com/50...600x600Q85.jpg |
It's been a busy couple of weeks. After tearing the '91 D350 down, Carl and I hauled it to the recylcer which made quick work of turning it into a steel pancake.
http://www.youtube.com/watch?v=6IiGcz2_XKs I've since been focusing on the frame; I decided to back half it; putting new material in place to mount the airbags and the goose neck mount. I cross braced the rear half w/1" x 16ga. square tube then cut the last 8' off the frame. I had it media blasted this past Friday and am ready to start mocking up the 6BT. http://inlinethumb59.webshots.com/49...600x600Q85.jpg http://inlinethumb18.webshots.com/47...600x600Q85.jpg You can't beat an electromagnetic base drill press. U http://inlinethumb10.webshots.com/48...600x600Q85.jpg http://inlinethumb37.webshots.com/50...600x600Q85.jpg http://inlinethumb53.webshots.com/47...600x600Q85.jpg http://inlinethumb61.webshots.com/48...600x600Q85.jpg http://inlinethumb30.webshots.com/50...600x600Q85.jpg http://inlinethumb22.webshots.com/49...600x600Q85.jpg http://inlinethumb05.webshots.com/48...600x600Q85.jpg |
http://inlinethumb18.webshots.com/48...600x600Q85.jpg
http://inlinethumb23.webshots.com/50...600x600Q85.jpg My steering package also arrived but PSC installed a factory style can on the pump instead of a remote reservoir can. PSC made it right and the pump is on it's way back from Texas with the right can. Remote reservoir: http://inlinethumb18.webshots.com/46...600x600Q85.jpg |
I started welding together the link mounts for the front suspension. I'm going with 3/4" hardware so I started by drilling the plates to 3/4"
http://inlinethumb17.webshots.com/50...600x600Q85.jpg I then started welding the brackets together using some mock up Grade 5 hardware and these aluminum spacers that I had made to 0.01" wider than the actual suspension joints. The thought is that when the brackets cool, that the steel doesn't pull together, preventing the suspension joints from going in. I accomplished the same thing with tape during the CJ build but I wanted to something better this go around. http://inlinethumb43.webshots.com/47...600x600Q85.jpg http://inlinethumb43.webshots.com/47...600x600Q85.jpg It worked great because the joints went right in after the brackets cooled. http://inlinethumb52.webshots.com/47...600x600Q85.jpg http://inlinethumb52.webshots.com/47...600x600Q85.jpg This is roughly where the brackets will go.. http://inlinethumb13.webshots.com/49...600x600Q85.jpg http://inlinethumb14.webshots.com/50...600x600Q85.jpg |
I stripped and trimmed the firewall to clear the #6 valve cover. I know I've seen it before but some please remind me of the significance of the number on the firewall?
http://inlinethumb51.webshots.com/49...600x600Q85.jpg http://inlinethumb13.webshots.com/47...600x600Q85.jpg Thanks to my six buddies that came over this evening to help put the cab back on the frame. I'm using the Energy Suspension '72+ body mount kit. I hope to get going with the motor mounts Friday. http://inlinethumb53.webshots.com/35...600x600Q85.jpg |
PSC fixed their mistake and sent the pump back with the correct reservoir can free of charge.
http://inlinethumb07.webshots.com/50...600x600Q85.jpg I've been working on getting the engine in place, it's been slow going but I hope to be there in the next two weeks or so. I started out by leveling the frame: http://inlinethumb14.webshots.com/50...600x600Q85.jpg http://inlinethumb43.webshots.com/50...600x600Q85.jpg With the firewall cut and with my mod'd motor mounts, I got the engine as far back as I could before things started interefering. http://inlinethumb27.webshots.com/47...600x600Q85.jpg http://inlinethumb31.webshots.com/49...600x600Q85.jpg I took some measurements and put this diagram together real quick so I had something to refer to once I get rolling. From it's current position, I'd like to bring the motor back 2" and down 3" That'll leave 1" between the firewall and the downpipe; .5" once I go to 4" exhaust. It'll be tight to remove the #6 valve cover but I'll double check it once I have the motor roughed in. http://inlinethumb50.webshots.com/50...600x600Q85.jpg |
cool build and digging the fab work!
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So hows the build coming I know I'm a late arrival but sweet build dude did you see the truck that was in the latest issue of Diesel Power? looks dang sharp!!
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I just subscribed because I think I'm going to LOVE this truck!
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