W350 Dodge Crew Cab (ground up)

OldKoot

New member
Hello anyone who would like to follow along, and welcome to this folly. This project has been long in the making. Like decades, let me explain a bit.

First what we are starting with is a 1985 W350 Crew Cab. We have owned this truck for roughly 17 years or so. It started life as a U.S.A.F. truck, standard issue 360/727 Dana 60's. It had 17K on it when we bought it. How we acquired it is a bit of a story. We were moving my parents from Wis where we lived at the time, to Neb. My thien girlfriends big block 1986 Chevy C20 got enclosed trailer load #3 to Nebraska and about 12 miles from our destination, it broke the crankshaft. It manged to stay running, we made it to her new home, and that was the end of that engine.

A local car dealer had this W350 for sale, wanted far more for it than I was willing to spend. The long story short, a cash offer, his annoyance with non paying Ebay bidders (he had the sold the truck 4 times on E bay) and his need to sell, and he grudgingly accepted my offer. We hooked my 28' enclosed trailer with my wifes C20 in it, and headed home to Wis. I had to rebuild the carb on a picnic bench at a rest area, redo the trailer wiring that was set up so the first time I turned on the headlights at 60mph it locked the trailer brakes, and other fun adventures. The hood ended up in the trailer somewhere in Iowa (overheating) it bruised my now wife's kidneys, and got us home at about 50mph and 5mpg.

Due to our trip home and what we had learned I should have sold the truck. But my now wife loved that old thing, it was growing on me also, and well..... a new 500ci Big block, a built 727, 4.56 gears, a rear 14 bolt, a pair of lockers (detroits) and some 39" Xml's, a 4" Alcan set of springs, and we now had a truck.

We drove it this way all over the USA/Canada and Mexico to the tune of about 100k miles or so...many grand adventures, a LOT of gas, a few sets of tires, and it was getting used up. Then we moved to Nebraska..... and it got taken apart to swap in a new engine.... and life got in the way, and it has just been in pieces ever since. Many projects latter, and like 12 years, and we now have a barn find Crew Cab Dodge in a few 100 pieces. (we have most of the pieces I hope LoL)

So now that I wrote a book, lets get on with the project... next post the "plan"
 

OldKoot

New member
As you can see we have a few Dodges....
YrkqyLy.jpg


I know you guys like pictures (I lurk allot) So anyway, on with the plan, it's quite simple. Build a old Dodge we love and is part of the family, and have some fun traveling around. My wife and I love to travel, explore, go places most never see, and well in a short we need a "expo" type truck. We have a 2016 F250 Crew/short box on 35" rubber we have used for this purpose for a few years now. It's been a good truck, but the 6.2's miserable economy, our annoyance with power windows, navigation, bells beepers and alarm systems have run their course.

Another picture to keep you amused. Said F250... 35" Genral Mt's, a rear grizzly locker, and not much else has gotten us around quite well....
N3NcRh8.jpg


ok... as promised the Dodge Project... The "plan"
A cummins 12V engine, a Nv4500, Dana 60 front, 14 Bolt rear, some lockers, larger rubber (larger than 35's) A step side box, a winch, the usual stuff with a few "twists".... should be simple LoL

Nothing with a old Dodge is ever actually simple, but we shall try.
 

OldKoot

New member
We have a bare frame..... a body, somewhere I have a step side box or two, and lots of old parts laying around. I have a almost brand new high nickle block 12V cummins and new Nv4500 on my shop floor we have removed from the Ramcharger in the above picture. They have maybe 10k miles on them. That will be the engine/trans we will use.

Ok, the first picture of the project.....
z765GAk.jpg


We got the frame completely stripped, glass blasted, and it's in fine shape given it's age. Then....

RNLLTib.jpg


It's been sprayed with SPI epoxy and that's how it sits ATM on our hoist ready for the next step. If you peer closely you can see the crew's body in the background....now time for me to stop typing and get in the shop and get to work.... it's begun, I will update as we progress.
 

OldKoot

New member
Well we got some work done today....also broke my phone, sand blasted my hand and banged my head on the hoist hard enough to see stars. So I guess a typical day, minimal blood loss therefore a win.

I spent a bit with the hole saw opening the larger hole to 2" to fit the heavey duty shackle hangers. Also we opened the retaining bolt hole to 1/2"

acA28zX.jpg


These are the shackle frame weldments. "Jungle Jim" over on Ram charger Central sells these and other nifty parts for old Dodges. A considerable upgrade from OEM, Urethane bushings, grease-able and much heavier built. They now have a fresh coat of epoxy.
yQadWYs.jpg


Test fitment
TRcaUiQ.jpg


The spring to the right is a 52" Chevy rear 2100a# spring, the left is a Alcan 4" spring for a Dodge. I am going to try the longer Chevy springs, in theory they should hold up the Cummins and ride a bit smoother. If not I can swap back to the Alcans which we were happy with if required.
vfknPAO.jpg


Much larger bushings in the Chevy leafs. Part why I desire to try them.
2tlYkHB.jpg


I also got the Dana 60 front knuckles in epoxy
lvA6nMs.jpg


The front HD snowplow 60 housing with fresh epoxy and Yukon Gears new king pins and bearings.
ckh8NMU.jpg


The front spring hanger also a Jungle Jims upgrade. This will allow the longer Chevy springs to fit, moving the axle forward roughly 1 inch which will help with the tire to fender fitment, as well as tie the front frame together much better than the OEM hangers.
kYu0N4W.jpg


And just for fun and a bit of a test, we sprayed and cooked the Great Lakes Off Road front diff cover with Cerakote. It oddly matches the SPI epoxy almost perfectly. Time will tell, but it should hold up better than paint.
 

OldKoot

New member
I should have posted the Diff cover pic huh?
WjWy0UH.jpg


The media blasting, painting, test fitting is never a fast process. Slow but sure it will get done.

I ordered a Grizzly locker from Yukon Gear for the front axle. Hopefully it will show up early this week and I can get that installed. At that point I can reassemble the front 60 with 35 spline outer axles, all new Spicer/Yukon parts internally, and get it under the frame.

As a side note, I was going to run a ARB I own in the front. On further reflection I enjoyed the Detroit it used to have many years ago, and decided that given the trucks intended use, the Grizzly was my preferred choice for the front axle.

More updates as it progresses.
 

OldKoot

New member
Sorry no exciting pictures really....I have a few.

My wife and I got the 52" chevy springs painted. Ignore the pair of NV4500's behind the hoist. (they aren't painted lol)
jJvdMp4.jpg


The front spring hanger.
nLfoD1h.jpg


The shackles.....I might have a "problem" I hit the frame with the buffer and some compound...I may do the rest at some point just for amusement while having a beer or something.
ic84dcF.jpg


The new Grizzly locker from Yukon showed up yesterday ,so with some luck I may have the almost completed front axle under it next week. The rear 14 bolt has been glass blasted, checked for wear (almost none on the 40K diff) and as soon as I weld the axle tubes to the center, cut off some of the "lip" to increase ground clearance, and then weld on the spring perches, it will be ready to be slung under the frame on the 63" Chevy 3/4ton Leafs.

The present problem to solve is the fuel tank issue. I could run a 33 gallon Ramcharger tank, but I dislike how low they hang. I could use a mid 80's Bronco tank...it would sit a bit higher in the frame according to the tape measure. Or I have a 100 gallon 6" thick "farmer tank" I could set up in the box behind the cab. I am not sure I want to give up the bed space. I have considered sliding the bed back say 8" and moving the fenders on the step side. This would allow me a full bed and tuck the tank between the bed and cab.... still thinking on this. Any ideas post them up.... Happy Turkey day you all!!!
 

plumber mike

Adventurer
Looks awesome so far. I’m not sure if the body will allow, but since it’s diesel, would some outboard of frame saddle tanks work? Like a 73-87 Chevy pickup? 87-91 if you want the pump in tank. Just a thought. I’ll be watching. I’ve got a 1990 W350 sitting around waiting for some attention. Maybe you can pass along the motivation....
 

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