Falkor - 2001 Crew Cab 2500HD

[locrwln]

I've bought from and used some wfo stuff. It was all quality stuff. Kind of cool you are near enough to just go by. No cool shops like that on the east coast that I know of.

It was and is great. Everyone there was incredibly nice and more than willing to spend the time with me. Can't say enough good things about them and their stuff is all very high quality for sure.

Krazytoy, do you have a link to Tim's build? I searched under the timzr2's name and the only thing that came up is where you mention it on page one here.

For Tim's build: Pirate4x4, Chevy section, "Multipurpose Duramax Build."
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Jack

 

[Tire_Marx]

Here is the link to Tims build: http://www.pirate4x4.com/forum/chevy/2379705-multipurpose-duramax-build.html

 

[NitroExpress]

Subscribed. I've got a 2002 DMax CCLB that would love this treatment.

 

[krazytoy]

More parts rolling in almost daily! All the steel for the SAS is done and I’m going to pick it up today.
Air Bags for the rear came in yesterday, they are pretty beefy!








The springs for the coil overs came in, wish the shocks were with them…


And, perhaps, the most important part of the build!

 

[krazytoy]

All the front SAS parts laser cut and bent, this is one big jigsaw puzzle!


Received a few more parts for the rear 4 link from Ruffstuff


Got the skid plate tacked together in about ½ hour






Then I said F’ it and started to burn everything in, the fit on all these parts is amazing!




Then I started putting the radius arms together but ran out of welding wire, which is probably a good thing because it was late.

 

[locrwln]

Man those sure are pretty parts. :wings:
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Nice job on the welding also.
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Jack

 

[thezentree]

What'd it cost you to have the plate cut and bent? I just read Tim's thread on PBB and man, that is one cool truck. Really looking forward to watching yours come together.

 

[frojoe]

Subscribed! Couldn't get enough of Tim's build.. looking forward to seeing yours progress! Great what Tim did, sharing the stuff.. since he didn't want to assume liability (makes total sense) then sharing all that excellent work is the next greatest thing, versus having the files just stay trapped on a hard drive collecting figurative dust while so many others drool over the pictures, wishing they had the info!

 

[RedF]

What is the solution for the mis-matched wheel bolt patterns? I'm surprised you went for a 6.0 instead of a diesel or 8.1.

 

[locrwln]

What is the solution for the mis-matched wheel bolt patterns? I'm surprised you went for a 6.0 instead of a diesel or 8.1.

Either re-drill the front hubs to the 8 on 6.5" bolt pattern or add wheel spacers to the rear axle (Ford front 60 is ~71" wide and the rear is around 67" wide) with the conversion built in to go from the 8 on 6.5" pattern to the 8 on 170mm pattern.
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Jack

 

[bigskypylot]

The Mad Scientist is at it again

 

[Tire_Marx]

What is the solution for the mis-matched wheel bolt patterns? I'm surprised you went for a 6.0 instead of a diesel or 8.1.

The solution from Tims build was to run adapting spacers on the rear axle for two reasons; 1) then the rear track will match the front and 2) no concerns about replacing the front hub assembly, as it would be an unmodified unit.

Now what krazytoy does for his solution... no idea

 

[Bojak]

That is some fab porn right there. Read all of Tim's build, thanks for the link. Wish some one would go to these lengths for the gmt400 trucks. I would love to SAS my truck. Glad you're back at it, excited to follow along.

 

[krazytoy]

Correct, I have 1.5" wheel spacers for the rear that change the pattern to 8 on 170mm.

I have been getting the radius arms welded together and holy crap these things are awesome! They have to be the coolest thing I have ever built; the way everything lines up and fits together is absolutely amazing! These are beef too; each one weighs 35lbs after welding and without the joints, and the skid plate weighs in at a hefty 115 lbs! It is all fairly straight forward; however, I did try and get all fancy on the first one and weld in the backbone, it didn’t work out too well for me and I ended up having to cut a bunch of my tac’s apart because I couldn’t get everything to line up as good as it should. I’ll try and put some pictures to the sequence I found to work the best. One more thing, MAKE SPACERS FOR THE JOINTS! I didn’t at first and quickly realized that the heat will tweek this stuff just enough to where you’ll be fighting the joints.
First lay out the bottom and the backbone, they interlock, can’t F’ this up…


Next put the middle piece in that goes under the upper arm, this has tabs on it to align the outer pieces.


Next put the 2 sides on, note the ¼” spacers I used to lift the 2 sides up fairly even with the bottom plate and clamp it together.


Put the top piece on.


And then the top end by the axle bushing.






I used a 12mm bolt and 2 nuts to spread these plates apart a little during welding, worked like a charm.


Then start tacing all you little gussets on, on the uniball end I installed the set screw and the zerk so I didn’t get any weld in them.




Then the backbone cover piece.

 

[krazytoy]

At this point I went ahead and start welding, and welding and welding and welding… You get the idea, there is a **** ton of welding on these arms and letting them cool in between is critical, seriously, it’s a lot of welding. Then I welded in the side plates last.


Finished product, pure sexy!










Well that’s about it for now, the pile of parts is growing and the pile of steel is shrinking! Few more weeks and I’ll start hacking the truck up.