Platform Selection

[Wyohab]

I’ve been lurking for a few years now, have learned a lot, and am amazed at the tremendous amount of savvy available from those that frequent this forum.

I am now ready to begin the process of ‘assembling’ a vehicle to serve my future requirements, and am keen to receive comments/suggestions from those that have been down similar paths.

I currently work outside the US, and will be ready to semi-retire in about 3years. So, I have about that much time to finish the project.

My plans are for extended trips into the Owyhee country of NV, and the Absaroka and Big Horn mountains of WY. There is a possibility that I would ship the vehicle to Russia or Nicaragua where it would be used for backcounty trips for the remainder of its useful life. Priority Nr. 1 is - Reliability. It is a long walk out from many of the places I will spending time in. There will be a max of 2 persons travelling; and about half the time, there will be 2 hunting dogs along as well.

First step is to decide upon, and acquire ‘the platform’ that will underpin the build-up. I’m pretty locked in on a full-size extended cab diesel pickup, with an 8ft bed, and a Caravan Camper (Reno NV) built about 12in taller than cab high.

From the many hours of researching info contained in this forum, I’m currently considering 2 different platforms for the reasons stated below:

92-93 Dodge: intercooled, minimum engine electronics, robust rebuildable drive train.

2006 Dodge: pre-smog, ‘most stuff fixed by 2006’, robust auto transmission

I can not say that ‘cost is no object’, but I do understand that I will be spending a considerable amount to result in a truck I am comfortable with. If I could simply buy a new truck to meet my needs, I would certainly do so. However my mind set of: “simpler=more reliable=less breakdowns and subsequent hikes out” is leading me toward buildups of one of the two platforms above. I would expect for either route to ultimately cost about the same, i.e. the 92-93 would require more work than the 2006 to be ready to go.

I’d be curious as to:
1. Comment related to my choices for platforms. And alternatives with reasoning
2. Shopping tips, i.e. where to look, and what to look out for
3. What suspension upgrades would make for the most comfortable ride for hours on end of washboard roads at 40mph
4. Recommendations for custom shops / individuals that I could entrust the build-up to

I’ve got lots more questions I’m eager to test with those in the know, but I’ll hold these until I’ve finalized the decision on the platform to be used.

 

[bobcat charlie]

I'm biased, but I think the 305 HP '03-'04.5 are the 'pick of the litter'. No smog equipment, and fewer injection events means better milage. Running a Smarty Jr. I'm geeting 21.5 mpg highway, 17 mpg around town with 35" MT's! I 'believe' the '03-'04.5 auto transmissions are very reliable at near stock power levels. Replace the stock lift pump with an aftermarket and there are no other reliability issues. That said, a rebuilt Gen 1 Dodge Cummins with a good lift pump and the KDP repair would be the simplest, most reliable, easilly maintained choice.

BTW, how do you split between Moscow and Wyoming?

 

[my1stcummins]

I have an early 07, last of the 5.9's that doesn't have the smog stuff you are talking about when they switched to the 6.7 in '07.5 model year. I think it's the cat's meow(for 3rd Gen.) as I am not a fan of the headlights on the 06. According to the factory manual, in '07 DCX added the one touch-3 blink turn signals too which is a decision maker right there

Today I started receiving my Thuren suspension components which I will install to help alleviate the stiff factory suspension and gain some ride comfort, control and articulation off-road. A must for any HD Dodge.

If your budget allows, I would lean towards a quad cab 3rd gen Cummins with an appropriately modified suspension system for strength, power, reliability(my personal experience) and creature comforts that you wont have in the earlier models. When you are racking up the miles you will appreciate those engineering and fit and finish advancements.

 

[Wyohab]

Thanks for your comments

my1stcummins:
Other than lifting the hood, are there any other ways of telling the 5.9 from 6.7? Such as from a photograph?

bobcat charlie:
Is it possible to describe in a few words the changes in fuel injection and smog systems that occured between the 04.5 and 05 model years?

I work in Russia, but call WY home. For now, I get back to WY about 3 times a year to survey my 'money disposal projects' camouflaged as riparian habitat restoration projects

 

[my1stcummins]

IIRC the 07.5's had an additional decal/badge on the left side of the tailgate that said Bluetech. Also, looking under the truck you can see the extra DPF catalytic converter.

vs.

 

[Metcalf]

When I build the next one it will be a 3rd gen. If you only have one/two people I would do a regular cab with the 8ft bed. The newer regular cabs are pretty dang large. I think the added wheelbase is avoided if possible.

The 3rd gen dodge is probably one of the best overall base vehicles IMOO. You can build it into anything from a 1000hp drag racer to a great pre-runner to an expedition truck.

The wheel openings on the 3rd gen are some of the largest. 37" tires can be fit with without any cutting if you shift the axles a touch. For me this would have been a HUGE time saver. I think a full size truck needs a larger tire to work well. Most will argue this, but when your trying to get 7-10,000lbs to float in the sand or not get hung up in ruts on muddy tracks, you need larger tires. For a light weight full size truck I think something in the 37x12.5 range works well IF you can install them without adding too much 'lift' to the suspension.

The 03-04 Cummins seems to get the best mileage. If your into making power the deeper piston dish and one less injection event seems to help a bunch. The factory lift pump needs an upgrade, and there are non-electric options in that area too.

The auto transmission can be made bomb-proof just like many others. The manual is a good one and only basically needs a clutch upgrade. All in all, I would probably take the 'easy' way out and go automatic on my next truck.

Good luck with your project....

 

[Wyohab]

my1stcummins:
Thanks for posting the pic's and info on the '07. Opening up my search to include early '07 models with the 5.9l has resulted in many more individual trucks to consider

Metcalf:
I agree with the benefits of a standard cab, and am leaning that way. As soon as I can get Caravan Camper Inc. to confirm that they do make a robust 'lift open window / door' I'll be convinced that the standard cab is the way to go. I do want the ability to jump out of the cab and 'get to stuff' without opening the rear camper door (which will likely have a swing-away spare carrier in front of the door). If I'm going to give up space behind the seat, I want to make sure that I can go in through the side of the camper easily.

 

[Metcalf]

Another idea I have been tossing around......

Use a boot between the camper shell and truck cab. Remove the rear window in the truck and the front window in the camper. Then install a 1 foot deep and 18" wide aluminum mesh basket in the front of the bed that goes from side to side at the top of the bedrail height.

This would let you have a lot of storage area for larger stuff like coats and bags, but you could still get at them without getting out of the truck.

It could let you heat the camper shell. This could be good or bad.

You could also crawl back into the camper area without getting out of the truck if your agile enough. Or crawl back into the cab if you don't want to go outside....Zombies or whatever.

Just an idea....

 

[RU55ELL]

Not a bad idea. I wonder how hard it would be to keep the boot sealed off on the body and the shell.

 

[Wyohab]

Regular Cab

With benefit of info provided here, I've pretty much settled on an 07, 5.9l long box. There are a few to choose from, so I'll not be in a huge hurry.

An open connection between cab and camper, as discussed by Metcalf below, is something I certainly want to explore further. Jackets, hats, glooves, binoculars, lunch, et. al. don't require a full extended cab, and the shelf suggested by Metcalf would be perfect. All the functionality required, with the convenience of a shorter wheelbase unit.

But... the seal. My research has turned up nothing more interesting than the age old solution of tire tube stuffed in between cab and shell, and then inflated. Surely there is a more robust solution out there than this. Isn't there?

 

[my1stcummins]

When I got my Leer canopy they offered a seal like you are talking about.

https://www.custompickup.com/shop/index.php?action=category&id=18

Like that?

 

[Metcalf]

I think making a seal would be the best bet. I think gutting an aluminum rear slider frame to form a lip that would allow the attachment of the new seal AND allow the frame to be in the factory weatherproof rubber seal on the cab of the truck would be the way to go on the 'truck' end.

On the camper end I think the boot ( if you didn't want a window ) could just be attached to the camper opening.

I'm still playing around with this idea. I think its a really good option for the regular cab truck that needs a little more storage room. Being able to move back and forth to the camper shell area would also be nice.

 

[Metcalf]

That stuff looks PERFECT!

www.accordionboot.com

They have all the size and install information....

Now I just need to find a way to have a window hinged at the TOP in the front of the camper shell to allow the area to be blocked off....

SWEET!

 

[lstzephyr]

There is a thread with a t100 that the guy did just that. Except he added a rollup rear window. I thought it was brilliant. I will try to find it.

I currently have a platform at window height in my bed and I can't tell you how useful it is with two people in the cab to just throw stuff back there and out of the way. I have just been squeezing through the slider lately and its not as bad as I thought. Its nice to be able to move around under the cap without going in the back. My bike is blocking the back anyway.

 

[Metcalf]

I am going to do something like this on my truck. I just need to figure out the flip up window on the camper side. I'm probably going to have my full size spare standing up against the bed rail just behind the driver. This will probably get in the way of my flip up window so I will need to make it split on one side or something. I am just going to make a 6" deep basket that sits on the bed rails or something. I want to be able to get my 'bed roll' under it still.

I want to be able to look to the rear, but something like a thick curtain could work really well to separate the two areas