96 Dodge Build

[Deleted member 12023]

Hello everyone! I have lurked for a long time on here and at one point started a build thread but have since lost it and my old screenname. So here is a new one.

My girlfriend and I have recently returned from a 5 month road trip throughout the US and parts of Canada. The website is here http://onpa.webs.com/. Sorry about the lack of updates on the site...we found it more fun being outside instead of in a library making updates. Someday I will get around to finishing it.

So since returning we have decided to start planning for our next trip of driving through Central and hopefully South America. The previous trip was intended to go through Central however the US ended up being a trip in itself.

We got back in October and the truck has been turned back into my work truck. I will slowly be documenting the next build. There were some things that worked for us and some that didn't, so we are looking at it as a shakedown trip for the real deal.

The truck is massive but we enjoy the extra space, so we will continue to use it for further trips.

Here are some things that did and didn't work on the trip:

Toyo Open Country A/T (285/75 R17)- Awesome tires, didn't have one flat, and our truck was HEAVY! The mileage seems to be doing alright as well. I am thinking about going to 35x12.5 mud terrains next time.
Engel MT-45- I consider this the most essential piece of equipment we had
Coleman dual fuel stove- Worked great except at high altitude. I think we may go propane for the next one
Truck cap and sleeping platform- Worked well for what we were doing, but there is a real lack of upright space when there is inclement weather. Plus we feel that the security on it was not up to par.
Veggie oil system- works awesome when you have grease...not the best off road. We had a major spill in the back and still have VO on our packs and shoes. Best part is that it happened at dusk in the middle of bear country! Plus a 60 gallon tank takes up a lot of space. Grease hunting is also VERY time consuming on the road. We will be removing the system for the trip south to reduce headache.
Tire on the Roof- Did not work, way to much noise and resistance. I plan on welding a bumper and swing out tire carrier.
Auxillary Battery system- Life saver, we actually had it go dead on us a couple of times in hot weather and were still able to start the truck without missing a beat. This will definately be joining us next time.
700w inverter- Nice for watching movies in the back at night, if you are in stealth camping mode..aka Walmart parking lot.
Open Diffs- No good. To easy to get stuck. The truck is way to large to have open differentials off road.
Automatic Transmission- The transmission is very strong and healthy, however definitely had some over heating problems when wheeling, and through slow mountain passes.


The everchanging shopping list for the truck is as follows:

Carli Front Springs
Blisten 5100s all around
Custom Bumpers front and rear with a swingout tire carrier
35x12.5 Toyo MT or BFG KM2- Have not decided yet.
Build a "Four wheel camper"...I know crazy right. (Allochris has inspired me to build what I want instead of buy it- http://www.expeditionportal.com/forum/showthread.php?t=4811)
Rear Locker- Detroit for simplicity sake
Front Locker? Not sure yet, leaning towards an OX locker. I would go ARB front and rear, but I want things simpler than simple. Maybe a limited slip will work instead?
Aux Tranny Cooler- Would love to do a NV4500 Conversion but it would be expensive, and my transmission was built by Mass Diesel a year ago...who knows maybe it will happen
Auxillary Lighting
Hi-lift Jack
Sand Ladders
Winch?- undecided if I will go with a winch or not
FBD 4" exhaust to keep those EGT's down

The first purchase we made was Rosetta Stone Spanish levels 1-3. Both of our Spanish is rough right now so we are starting over.

Like I said, this will be a slow build, as we are still recovering from the previous trip. We will be leaving for the next trip 1-2 years from today. I know it is best to keep things simpler when it comes to overlanding...so any input on the list would be greatly appreciated. I really like the looks and capabilities of Desert Proven's truck http://www.expeditionportal.com/forum/showthread.php?t=18396&highlight=dodge..and this is kind of what I am after.

 

[iigs]

Specs look good. Saw the pics on your site, have more? Would be great to see it in detail.

 

[hillbillyjake]

sounds like a good truck. i really like the old 12 valves fo r power and simplicity. one suggestion. i f i was going to go threw the trouble of swapping in a manual trans i would just swap the nv5600 and be done with it. a friend swapped in 2 nv4500 before going to the 5600 in his 89. just my opinion. welcome and keep us posted.

 

[Deleted member 12023]

Specs look good. Saw the pics on your site, have more? Would be great to see it in detail.

Unfortunately I do not have that many pictures of the truck set up. We were in a rush when we were building it. I have a few to share so you can get the general idea.

If you look closely you can see the veggie tank in that back...used as a headboard. There was a 12v plug and an inverter on it. The auxillary battery was just below it in a hinged compartment.

This it at my camp in Vermont. You can see the drawer and folding bed so we were able to access the bins underneath. We left for the trip with 100 gallons of veggie oil...you can see some of it on the porch.

Badlands Mud/clay.

I'm pretty sure I still have some caked under the bed from a few months ago.

Our canopy doesn't really stand up to snow loads very well.:ylsmoke: The tire was removed from the roof at some point in the trip to increase gas mileage. It was put in the back with the fridge. Imagine a 34" tire and an 45liter fridge in the back seat of the truck!! It was pretty packed in there.

The water felt a lot deeper than it looks in the picture...maybe I'm just a wuss.

Sadly this is the only picture of the interior that I took. You can see that the rear seat was removed. This is before we put the tire in there.

 

[Deleted member 12023]

Sweet Unimog in Squaw Valley

Also, I saw this rig next to my buddy's house in Tahoe...any idea who's it is? I didn't have a chance to stop and talk to the owner.

 

[1speed]

Welcome fellow Dodge driver! Nice simple ExPo rig you have there, looks like you had a great trip.

I'm planning on pulling the back seat out of mine and building custom storage and fridge shelf, looks like there is a lot of room back there.

 

[chasespeed]

Welcome back. Looks like a good trip.

Gotta love these trucks...

Anyway, depending on how often you DRIVE your truck, a limited slip in the rear, with a selectable in the front(I have been looking at the OX as well), would probably be a better idea. At least thats the route I plan. Yes, these trucks are definitely too heavy to be playing in off highway....

The only issue with a larger exhaust, that I have found, is clearance. I am going to try to find a shop, in the area that can bend 5in, and move the tailpipe out from behind the rear wheel.

I love my 4500. I have been entertaining finding an auto to put in its place... but, not seriously looking, I tow a lot. Gonna see if the wife can pick up driving this thing first....

Now, where did you locate the extra battery? The bed? I have been trying to find a spot to put my inteverter(1500w, pure sine), its big, and needs air....

Chase

 

[Deleted member 12023]

Thanks for the welcomes! It was a great trip, it was my first time out of New England...aside from flying to other countries.

1Speed, How do you like those KM2's on your truck? They are D rated correct? Can you tell the difference? I have been following your build for a while now. It is coming along very nice, I'm jealous.

Anyway, depending on how often you DRIVE your truck, a limited slip in the rear, with a selectable in the front(I have been looking at the OX as well), would probably be a better idea. At least thats the route I plan. Yes, these trucks are definitely too heavy to be playing in off highway...

I love my 4500. I have been entertaining finding an auto to put in its place... but, not seriously looking, I tow a lot. Gonna see if the wife can pick up driving this thing first....

Now, where did you locate the extra battery? The bed? I have been trying to find a spot to put my inteverter(1500w, pure sine), its big, and needs air....

Chase

Yeah I was debating a limited slip, but I have heard they have limitations. Personally I have never driving a truck with one, just going on hearsay. Typically do people put the rear locker in first? Or the front?

Let me know if you want to make a swap for that NV 4500 :ylsmoke: I was able to find one locally for $2500 sold as a "kit". I believe it comes with the transfer case, but I have no idea of the condition, and that it not the first mod on my list. By the way, the guy is selling the 12valve engine and P-Pump, $2200 I think, if anyone is considering a swap

The battery was in the bed with the solenoid and the fuse panel. I have since removed it because I do not have the cap on right now. I put a HUGE truck box in the back now...It crossed my mind to put the Engel/battery in there for the summer, cold beer all the time!:wings:

 

[1speed]

...1Speed, How do you like those KM2's on your truck? They are D rated correct? Can you tell the difference?...

Yes they are D rated. I posted some thoughts about them a few months ago here. http://www.expeditionportal.com/forum/showpost.php?p=470397&postcount=165

I finally got my second spare recently and rotated them for the first time with about 8,000 miles on them. Even though the front end needs some work http://www.expeditionportal.com/forum/showpost.php?p=539475&postcount=202 they were wearing evenly. I'm still very happy with them but unfortunately they have seen nothing but pavement since that trip. I'll be taking the truck to the Overland Expo in April so I hope to get a trail run or two in while I'm there.

 

[Mighty Dodge Ram]

Welcome to the full size forum. Nice to have another Dodge guy around. I also have a '96 but alas, a 1/2-ton gasser. Still, at 205,000 miles it continues to serve me well. Looking forward to your build. :sombrero:

 

[Mr. Moore]

I wish mine was a deisel! mine is an 05 2wd.....Looks like you had a great time and i like your setup. I can't wait to get out there!

 

[Deleted member 12023]

Last night I installed some larger wheel cylinders in the rear drums. I guess it can be considered a mod.:ylsmoke:

I got the idea from CumminsForum for installing 1-ton Chevy cylinders in place of the smaller 3/4 ton dodge cylinders. I believe the bore difference is about 6 or 7 millimeters. NAPA part No. 37337, for only $9.96 a piece!! Best cheap mod I have done. Sorry about the poor picture quality...it was not my camera.

It was a fairly simple process (except for fighting with rust).

Steps to removal and installation are:

-Remove Wheel and PB Blast the crap out of the drum in order to remove it. On one side I had to remove the plug and back the auto adjusters off a little to get the drum off. I really wish I didn't live in the rust belt...talk about premature wear.

-Remove Drum and clean up excess brake dust

This is the old cylinder...

-Remove brake line and 2 hex bolts holding the cylinder on the backing plate. You only need to remove one spring in order to get it out. Remove wheel cylinder.

-You can see the difference between the bore of the two. The new one is much larger but the body size is pretty close.

-Put a small amount of red RTV around the rim and install new cylinder.

-Bleed brakes, install spring, install drum, install wheel and test drive.

If your wheel adjusters are working proper, all you need to do is hit the brakes moderately hard while reversing a few times and they should tighten. In my case, I had to pull the drum off again and tighten by hand until the drum just barely fit over the shoes.

What a difference!! The truck now stops like a sportscar. The nose diving under hard braking was eliminated and it stops fast. This is how the truck should have come from the factory. I highly recommend it.:smiley_drive:

 

[1speed]

Very nice! I may do that to my mom's truck. She has an early 01 2500 with drum brakes. I'm glad mine is a later 01 with rear discs.

 

[hillbillyjake]

if you haven't yet, check out turbodiesel registry. tons of info.

 

[MrKen]

I also have done the brake cyl mod, works great. I have read that if the drum is hard to take off, leave one lug on, with the rear on jacks, spin the tires in gear and then put on the brakes and the drum will pop right off. Remember to leave one lug on or the drum will go somewhere.
Ken