2002 Tahoe "Expedition" build
- Thread starter 02TahoeMD
- Start date
skysix
Adventurer
Great idea - tyhe roftop tent I have sits on the standard rack with an extra crosspiece - and it flexes to where the bolts hit the roof when 2 adults are in it.
However using the hardpoints on the roof I am sure some aftermarket rack base could be designed. This would allow an 18" wide box the whole length of my tent (Autohome Overcamp medium) and a forward basket to put a 10' zodiac in above the area where some have a sunroof (unfortunately forward of the existing rack - hence the need for a custom rack that extends further...)
02TahoeMD
Explorer
Update on latest mods
It has been a very busy couple of weeks for the Tahoe as I am getting ready for a trip out West in May. The latest and greatest (well, for me anyways...)
National Luna Dual Battery kit from Sierra Expeditions
I ran a 6 gauge supply feed from my aux battery to the back of the truck to provide a power point for a few other mods. (there is a 12V power point back there built in by GM but it has tiny 16 or 18 gauge wiring. yuck! ) I added a Edgestar fridge back there and hardwired it in, to avoid any potential problems with loose cig adapter plugs.
I used a GM alternator plug set that I got from Pep Boys to complete the hard wire of the fridge. Just spliced it into the Edgestar wiring harness using heat shrink tube to seal it up. It clicks in positively and is not coming apart unless you pull it apart.
Next up was to wire some work lights up into my lift gate. I got the idea from our work trucks, which the shop adds a dome light to the lift gates so you can have a well lit work area at night. However, I wanted to mount something that was flush with the trim and was LED powered for low power use. I had some 4" white round LED lights left over from a project that fit the bill perfectly. I cut the holes out of the trim using a Roto-zip, routed a feed line from a switched source on the "D" pillar up into the lift gate, and mounted it all up:
So, just the right amount of light for camping, not overpowering. In reading up on Mark D. Stephen's awesome Nissan Frontier build, I saw where he put a gas piston on his KMA spare tire carrier. I did this mod, but mounted it to the top of the bumper instead. Just used a Strong Arm gas piston with one of their mounting kits, attaching it to a plate I fabbed up and the top of the bumper near the back edge. Works GREAT! No more swinging spare to worry about....
Thanks to all who have given me compliments on my build since joining here, as well as for all the ideas for the mods I have gotten to do.
So, that is it. For now. Other stuff to do before I leave in May....
It has been a very busy couple of weeks for the Tahoe as I am getting ready for a trip out West in May. The latest and greatest (well, for me anyways...)
National Luna Dual Battery kit from Sierra Expeditions
I ran a 6 gauge supply feed from my aux battery to the back of the truck to provide a power point for a few other mods. (there is a 12V power point back there built in by GM but it has tiny 16 or 18 gauge wiring. yuck! ) I added a Edgestar fridge back there and hardwired it in, to avoid any potential problems with loose cig adapter plugs.
I used a GM alternator plug set that I got from Pep Boys to complete the hard wire of the fridge. Just spliced it into the Edgestar wiring harness using heat shrink tube to seal it up. It clicks in positively and is not coming apart unless you pull it apart.
Next up was to wire some work lights up into my lift gate. I got the idea from our work trucks, which the shop adds a dome light to the lift gates so you can have a well lit work area at night. However, I wanted to mount something that was flush with the trim and was LED powered for low power use. I had some 4" white round LED lights left over from a project that fit the bill perfectly. I cut the holes out of the trim using a Roto-zip, routed a feed line from a switched source on the "D" pillar up into the lift gate, and mounted it all up:
So, just the right amount of light for camping, not overpowering. In reading up on Mark D. Stephen's awesome Nissan Frontier build, I saw where he put a gas piston on his KMA spare tire carrier. I did this mod, but mounted it to the top of the bumper instead. Just used a Strong Arm gas piston with one of their mounting kits, attaching it to a plate I fabbed up and the top of the bumper near the back edge. Works GREAT! No more swinging spare to worry about....
Thanks to all who have given me compliments on my build since joining here, as well as for all the ideas for the mods I have gotten to do.
So, that is it. For now. Other stuff to do before I leave in May....
FurthurOnTheFly
Glamping Society
Wow I really like the rear light idea! Any more pics of the install and a source on the lights? This might be a good project for the 4Runner!
02TahoeMD
Explorer
Well, only one extra photo of the install, where I mounted the switch for the lights, right next to the power locks button:
Pretty basic install. Just disassembled all the door trim to include the grommeted boot that holds the rear defroster wiring. Fed a line of side by side "zip" wire through the boot and into the metal housing of the lift gate, where the zip wire got connected to the LED lights. Then reassembled all the trim pieces. After that it was just a matter of connecting the zip line to the switch and ground. The power for the switch came up from my 6 ga supply feed I had run from the aux battery. If you want, I can do an actual diagram, scan it, and post it up. Happy to help any way I can.
Pretty basic install. Just disassembled all the door trim to include the grommeted boot that holds the rear defroster wiring. Fed a line of side by side "zip" wire through the boot and into the metal housing of the lift gate, where the zip wire got connected to the LED lights. Then reassembled all the trim pieces. After that it was just a matter of connecting the zip line to the switch and ground. The power for the switch came up from my 6 ga supply feed I had run from the aux battery. If you want, I can do an actual diagram, scan it, and post it up. Happy to help any way I can.
JamesDowning
Explorer
Wow, you've got some great ideas! I may have to steal the tailgate light idea for myself. I've got a few tricks up my sleeve for the coming months too. Maybe at that point I'll do my own build thread.
Seeing as we are only 30 minutes apart, we should do lunch sometime, compare notes, trade ideas, etc.
Seeing as we are only 30 minutes apart, we should do lunch sometime, compare notes, trade ideas, etc.
02TahoeMD
Explorer
Thanks much James. Anytime you want to meet just drop me a PM and will try to set something up.
Latest mods, worked on a LOT the past 2 weeks, was to add an on board air system. I mounted up a Viair 40040 air compressor, 2.5 gal tank, 2 air outlets, Autometer air gauge, and a Grover air horn. The compressor and tank got bolted up where the factory spare tire mount used to go, with air outlets mounted to the rear bumper and inside the engine bay. Mounted the air horn to the skid/splash plate of my ARB bumper.
I routed a seperate feeder line for the compressor's air filter and mounted the filter itself inside of my cab, in the cargo area. That way I dont have to worry about the compressor injesting water at any time.
Air outlets
Update on how my console is now laid out with the addition of the air gauge, hard mount of the National Luna controller, and air horn switch
And a short video of the Grover Air Horn sounding off
A huge thanks goes out to my brother in law Ryan for his help with this project. He donated much of his secondhand equipment to this project and all of his first-rate knowledge in getting it all put together. He has been working with on board air systems for several years now and without his wisdom on the subject I doubt I would have ever tackled it.
Latest mods, worked on a LOT the past 2 weeks, was to add an on board air system. I mounted up a Viair 40040 air compressor, 2.5 gal tank, 2 air outlets, Autometer air gauge, and a Grover air horn. The compressor and tank got bolted up where the factory spare tire mount used to go, with air outlets mounted to the rear bumper and inside the engine bay. Mounted the air horn to the skid/splash plate of my ARB bumper.
Air outlets
Update on how my console is now laid out with the addition of the air gauge, hard mount of the National Luna controller, and air horn switch
And a short video of the Grover Air Horn sounding off
A huge thanks goes out to my brother in law Ryan for his help with this project. He donated much of his secondhand equipment to this project and all of his first-rate knowledge in getting it all put together. He has been working with on board air systems for several years now and without his wisdom on the subject I doubt I would have ever tackled it.
UCBerzerkeley
Observer
i might have missed this, but what did you do about lockers and/or improving traction? i am unfamiliar with what Tahoes come equipped with. Thinking of my dads, I think it just has 2H, 4H and 4L but no locking differentials?
02TahoeMD
Explorer
No locker on it.....yet.
You are correct, the Tahoe does not come with locking differentials. So far, in 20 + years of driving, I have only been stuck off road once. So, the stocker drivetrain of this truck as well as several Broncos and a pickup or two have served me well. I am not really into bogging or rock crawling either, so most trails I run are mild stuff and well within the capabilities of the factory drivetrain. And I usually travel alone so I am pretty cautious about where I drive.
That said, one of the reasons I put the air compressor on is to add an ARB Air Locker to the rear axle either next year with tax money or sometime later this year with overtime money. Of course, I am looking at about $1K+ to install an ARB locker so it will take a good chunk of OT to pay for that!
Part of the reason I have tackled this build is to do something different and forge my own way. It has been a lot of fun modifying things for it, or figuring out how to make an idea I had seen on another rig work on it, and also fun to shop around seeing what I can possibly get for it, whether it is made for the Tahoe or not....
You are correct, the Tahoe does not come with locking differentials. So far, in 20 + years of driving, I have only been stuck off road once. So, the stocker drivetrain of this truck as well as several Broncos and a pickup or two have served me well. I am not really into bogging or rock crawling either, so most trails I run are mild stuff and well within the capabilities of the factory drivetrain. And I usually travel alone so I am pretty cautious about where I drive.
That said, one of the reasons I put the air compressor on is to add an ARB Air Locker to the rear axle either next year with tax money or sometime later this year with overtime money. Of course, I am looking at about $1K+ to install an ARB locker so it will take a good chunk of OT to pay for that!
Part of the reason I have tackled this build is to do something different and forge my own way. It has been a lot of fun modifying things for it, or figuring out how to make an idea I had seen on another rig work on it, and also fun to shop around seeing what I can possibly get for it, whether it is made for the Tahoe or not....
gary in ohio
Explorer
02TahoeMD
Explorer
console
Here are some of the details. My only correction to the original posting is that I actually used a Gamber Johnson MCS 13" used police console I got off of eBay for $40. Then just browsed the Jotto Desk faceplate catalog to find the plates that would work for my radio. Got Home Depot to make me a qt of paint to match the interior trim, lots cheaper than getting the automotive equivalent mixed up.
Here are some of the details. My only correction to the original posting is that I actually used a Gamber Johnson MCS 13" used police console I got off of eBay for $40. Then just browsed the Jotto Desk faceplate catalog to find the plates that would work for my radio. Got Home Depot to make me a qt of paint to match the interior trim, lots cheaper than getting the automotive equivalent mixed up.
JamesDowning
Explorer
Did the Tahoe come with an optional rear locker? For the TrailBlazers, option G80 was an Eaton rear auto locker. It may be cheaper for you to find an axle from a Tahoe with the factory locker, and swap the axle out. Alot of the cost of installing a locker comes from all the shimming...
Thanks for blazing the path for us Chevy guys! I've loved following your build, especially since mine's kinda similar.
Last edited:
xx.xii
Observer
nice tahoe, lot of practicallity involved. ur rear bumper is nice, i have a 99yukon and was thinking of fabbing up a carrier so i wouldnt have to put my 37'' tires all the way up on my roofrack,glad i came across ur thread i will look into that bumper and see if it might be easier to buy than make, was it made for urs or did u have to do some fab to fit?
02TahoeMD
Explorer
Thanks 20 12. The bumper was ordered directly from Kennesaw Mountain Accessories, I submitted a design that modified their basic Tahoe version just in that it had the two different carriers on it. KLMore has done a splendid job of cleaning up the fitment of the KMA bumper on his project, the only fitment that I did for mine was to drill the holes to mount it up. That was my biggest complaint about the bumper, since I went through 4 drill bits drilling out the mounting holes. It is beyond me why they dont cut the holes when KMA builds them....but when they are pretty much the only company out their making that stuff, guess they can do whatever they so choose.
James, I have not heard of a locker option for the Tahoe....dunno if they ever offered one. Lockers have been discussed over on the z71 forum I frequent and nobody ever mentioned one being a factory option. I think I will stick with getting the ARB locker, I do the vast majority of my own mechanical work on the truck and have a friend with an auto shop that I can go to for help so it shouldn't cost me a few body parts for the install.
James, I have not heard of a locker option for the Tahoe....dunno if they ever offered one. Lockers have been discussed over on the z71 forum I frequent and nobody ever mentioned one being a factory option. I think I will stick with getting the ARB locker, I do the vast majority of my own mechanical work on the truck and have a friend with an auto shop that I can go to for help so it shouldn't cost me a few body parts for the install.
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