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View Full Version : My TRUGGY project .... updated 11-6-09



jim91303
07-13-2009, 10:12 AM
i am working on a 78 K5 and 78 GMC 1/2 ton. using the K5 frame and the cab forward off the 1/2 ton truck. a set of 1 ton axles 14 bolt corp rear ( dana 70) and dana 60 front.

i will post pics of the ground up build as i SLOWLY make progress.

please ... if you have Good advise to share when i get pics and more done to it ... please share it. i want to build it right and rock solid.

please keep all posts to this .... my truggy project. thanks in advance. i have seen too many posts not related to the thread subject in other threads and forums.

SirFuego
07-13-2009, 10:51 AM
SB406 built a buggy out of his K5 -- though it sounds like you aren't planning as much cutting as him. I know he's done quite a lot of tweaking to leaf springs, axles, and other stuff, so reading his build thread might be helpful to you.

Partial build thread:
http://www.pgh-offroad.com/forum/showthread.php?t=6681

Full build thread:
http://www.wnyoffroad.org/forum/viewtopic.php?t=3341

Hope you find this helpful!

Looking forward to seeing what you come up with!

sb406
07-13-2009, 03:20 PM
SB406 built a buggy out of his K5 -- though it sounds like you aren't planning as much cutting as him. I know he's done quite a lot of tweaking to leaf springs, axles, and other stuff, so reading his build thread might be helpful to you.

Partial build thread:
http://www.pgh-offroad.com/forum/showthread.php?t=6681

Full build thread:
http://www.wnyoffroad.org/forum/viewtopic.php?t=3341

Hope you find this helpful!

Looking forward to seeing what you come up with!
That thing's a turd.

What T-case? What gears in axles? Building for mud or rocks?

jim91303
07-14-2009, 09:34 AM
i am bulding rock ready ... but gearing in the middle for both mud and rock. i will see more mild trails and mud then rock but yet it needs to be rock cappable for places like rock run and roushcreek.

sofar i have the K5 stripped to bare frame, i have the rear dana 70 under it, only to find that i need to move the perches out 5/8'' on each side. the front fits fine.
as of now still have the stock hanger on it ... waiting on the 4'' lift reverse shackle kit to arrive. i have the 6'' block lift in it for now to help me picture finnial ride height. now its on a 6'' lift and 36 tires ... when done it will be on a 4'' lift and 42 pitbull rockers. so i figure the ride height will be close to same when done as it is now.

while waiting on the kit .... i am cutting up a truck frame to box in the K5 C channel frame.

jim91303
07-14-2009, 09:36 AM
i will try to post pics tonight

sb406
07-14-2009, 10:03 AM
i have the rear dana 70 under it, only to find that i need to move the perches out 5/8'' on each side. the front fits fine.


You used a rear axle from a 1 ton, huh?
If you used one from a 3/4, the perches would have lined right up.... I did the exact same thing you just did.
Speaking of which, your 1st post is a little confusing.... you using the 14bFF or a D70?

I made my own rear shackle flip and run 52's up front for a very cheap 4" lift. Plus, I carry 1 spare main leaf that will fit any corner.

It flexes OK for leaf springs.
http://i135.photobucket.com/albums/q159/sb406/Big%20Dogs%206-09/th_BigDogs046.jpg (http://s135.photobucket.com/albums/q159/sb406/Big%20Dogs%206-09/?action=view&current=BigDogs046.jpg)
http://i135.photobucket.com/albums/q159/sb406/Big%20Dogs%206-09/th_BigDogs047.jpg (http://s135.photobucket.com/albums/q159/sb406/Big%20Dogs%206-09/?action=view&current=BigDogs047.jpg)

jim91303
07-16-2009, 12:46 PM
i am running the 14 bolt corp axle .... GM stopped using the dana70 and changed to the GM corparate 14 bolt in late 70s early 80s



You used a rear axle from a 1 ton, huh?
If you used one from a 3/4, the perches would have lined right up.... I did the exact same thing you just did.
Speaking of which, your 1st post is a little confusing.... you using the 14bFF or a D70?

I made my own rear shackle flip and run 52's up front for a very cheap 4" lift. Plus, I carry 1 spare main leaf that will fit any corner.

It flexes OK for leaf springs.
http://i135.photobucket.com/albums/q159/sb406/Big%20Dogs%206-09/th_BigDogs046.jpg (http://s135.photobucket.com/albums/q159/sb406/Big%20Dogs%206-09/?action=view&current=BigDogs046.jpg)
http://i135.photobucket.com/albums/q159/sb406/Big%20Dogs%206-09/th_BigDogs047.jpg (http://s135.photobucket.com/albums/q159/sb406/Big%20Dogs%206-09/?action=view&current=BigDogs047.jpg)

jim91303
07-18-2009, 05:03 PM
ok ... not much done yet. i have the K5 stripped and started pullin out the stock 10 bolts

http://i31.photobucket.com/albums/c353/jim91303/truggy/Picture009.jpg

having trouble gettig the bolt out on the front left hanger. here are the axle that going under it
http://i31.photobucket.com/albums/c353/jim91303/truggy/Picture001.jpg
http://i31.photobucket.com/albums/c353/jim91303/truggy/Picture005.jpg
http://i31.photobucket.com/albums/c353/jim91303/truggy/Picture002.jpg

jim91303
07-18-2009, 05:10 PM
before ya can say it .... yes the 6'' blocks are coming out ... as soon as i get the reverse shackle kit in

here is the A/C compressor i found for my onboard air system
http://i31.photobucket.com/albums/c353/jim91303/truggy/Picture014.jpg

http://i31.photobucket.com/albums/c353/jim91303/truggy/Picture015.jpg

http://i31.photobucket.com/albums/c353/jim91303/truggy/Picture018.jpg

jim91303
07-18-2009, 10:59 PM
had some time tonight to work on my rig. got the old 10 bolt out and got the corperate 10 bolt in. soon as i find one a dana 60 will replace it.
http://i31.photobucket.com/albums/c353/jim91303/truggy/Picture020.jpg

had a heck of a time getting the front eyelet bolt out. had to torch it and i need new bushings anyhow.

jim91303
07-18-2009, 11:00 PM
for those who are wondering ,those are 36'' super swampers 12.5 r16''

when time comes for the tires ... i'm lookin at the pittbull rockers 42''

sb406
07-20-2009, 09:12 AM
had some time tonight to work on my rig. got the old 10 bolt out and got the corperate 10 bolt in. soon as i find one a dana 60 will replace it.


had a heck of a time getting the front eyelet bolt out. had to torch it and i need new bushings anyhow.

I have a D60 for sale in the classifieds section. (Shameless plug)
http://www.pgh-offroad.com/forum/showthread.php?p=166168#post166168

Do yourself a favor now and use poly bushings in the springs. The set is only like $40 from summit. If you end up doing crossover steering, the rubber bushings flex a lot and bring the suck.

jim91303
07-22-2009, 12:03 AM
yea so far just mocking up the chassis ... i plan on the poly bushings.


QUESTION FOR YA'LL right now there are 6 leafs in front and 7 in rear .... should i pull 2 or 3 leafs from each leaf pack ?

sb406
07-22-2009, 11:29 AM
I wouldn't pull any leafs until you have the final weight on the chassis. They will settle quite a bit with the drivetrain and body on.

jim91303
07-23-2009, 08:37 PM
i'm just worried with all those springs... it will be a stiff ride.

jim91303
07-25-2009, 06:12 PM
well .... i didnt get as much done as i hoped for this month. i need new U bolts for the rear and bushing for the hangers and the leafs as well as some grade 8 hard ware.

i wont get a chance to work on it again til late Aug. :(
atleast i should have money then to get what i need to get more done. :)

jim91303
07-25-2009, 06:23 PM
here is a PAINT SHOP sketch of my finnal look for this project.

http://i31.photobucket.com/albums/c353/jim91303/JIMSTRUCK2.jpg

Barillms
07-25-2009, 07:13 PM
Looks like fire truck.

jim91303
09-04-2009, 11:00 PM
FINNIALLY !! got my bills cought up :) wife is back to work now after almost 3 months with out a job !

now i can get parts to continue my build..... :)

jim91303
09-05-2009, 07:23 PM
ok ... question .... i have alittle money to order parts ... where should i start?

1. ) get shackle flip kit
2. ) get bushings for leafs and shackles
3. ) U bolt flip kit

i can order only 1 of the 3 options at this time ... what would you get first ?

need bushins to install leafs to frame ... need u bolt kit to get rid of 6'' blocks .... need flip kit to set height .

YZEATER
09-09-2009, 09:53 PM
get rid of the sway bar also. you can put 52" springs up front since your gonna go with x-over steering. you'll get better flex.

btw 14 bolt and dana 70 are 2 different axles.

gonecheenin
09-10-2009, 07:22 AM
A rule of thumb in suspension work is;

A properly designed suspension only uses the springs to set ride height - the shocks, bump stops, & links/anti wrap devices control the axle.

Course you can make the springs do those jobs too with a leaf setup, but it usually ends up not working as well as it could have.

Christopher
09-10-2009, 07:43 AM
Congrats on the job and bill paying, buy something fun.

If choosing I'd say buy your flip kit. you can clamp your axle to springs good enough to roll the chassis around.

no bushing in the spring yet shouldn't effect your mock up that much unless you were altering the wheel base. Putting a bolt through will hold it under the chassis

my opinion

dan58
09-10-2009, 07:53 AM
btw 14 bolt and dana 70 are 2 different axles.


And most importantly with those two, the gearing choices are much different. A D70 goes up to 7.17s. You will can only go to 5.38s with the 14b, and with 42s, you'll want the 5.38s for sure.

jim91303
09-11-2009, 12:37 AM
i was lookin at a frame i have layin out back ... i may not need a flip kit. it's the rear hangers off a pick up frame. that will work .... bolt the leaf to the hanger ... set the frame levl with the front and weld & bolt the hanger in place. that should work huh?
the rear leafs are 52'' ..... need to measure the front ... if they are short then i do have another set of 52'' .... might even have 56'', would that be too long for the front ?

jim91303
09-11-2009, 12:38 AM
yea ... when i go for gears ... i was lookin at 5:38 to 4:88

jim91303
09-11-2009, 01:40 AM
ok ... just measured the front leafs ... 48'' well guess i'll be pullin the front out again :) i think i'm gonna send the leafs to uniontown leaf and spring and have the leaf pach rebuilt and have a military wrape put in. plus i noticed tonight that in one of the rear packs that the 3rd leaf up if cracked across the center pin.

jim91303
09-11-2009, 01:54 AM
as to my last post about switching hangers .....
from this:
http://i31.photobucket.com/albums/c353/jim91303/truggy/DSC01445.jpg
to this ;

http://i31.photobucket.com/albums/c353/jim91303/truggy/DSC01446.jpg


that will work instead of buying a fip kit. then i should spend my 'play' money on rebuilding the leaf and or bushings.

jim91303
11-06-2009, 10:30 AM
well ..... still workin at her slowly ... hunting season has put a holt on things.

i recieved some new toys ..... plasma cutter :) cordless impact

stated to narrow the core support .... should be done with it tonight .
still waiting on $$ to finnish suspension. still need bushings ... and U bolts for the rear axle.

post pics of the core later tonight.

jim91303
11-06-2009, 09:46 PM
well .... i got the grill narrowed

http://i31.photobucket.com/albums/c353/jim91303/truggy/Picture005-1.jpg

http://i31.photobucket.com/albums/c353/jim91303/truggy/Picture010-1.jpg


13 '' shorter.

limegreentj
11-06-2009, 09:48 PM
nice job! you just cut the center out?

jim91303
11-06-2009, 09:50 PM
yeah ... i can get another 12'' out but that may be too much

limegreentj
11-06-2009, 09:51 PM
its hard to judge...it still looks super wide, but im used to looking at jeeps...lol...i'd maybe take 6 more inches out of that. (giggity)

(stay out of that one you dirty fawkers)

jim91303
11-06-2009, 09:51 PM
http://i31.photobucket.com/albums/c353/jim91303/truggy/Picture009-1.jpg

http://i31.photobucket.com/albums/c353/jim91303/truggy/Picture012-1.jpg

jim91303
11-06-2009, 09:53 PM
it lines up with the insides of the tires now.
.... about 56'' over all width

jim91303
11-06-2009, 09:57 PM
next i'm making my shackle flip out of an old set of pick up truck hangers .... going to box them and add 3/8'' angle for the mounting plate ... angle will bolt to frame and the frame will sit on the angle ... 3''x 4'' angle

http://i31.photobucket.com/albums/c353/jim91303/truggy/Picture013-1.jpg

YZEATER
11-06-2009, 10:55 PM
be sure to set your shackle angle correctly before welding or bolting those on.

jim91303
11-06-2009, 11:09 PM
yea .... no idea what the correct angle is ! for that much i dont have my leafs yet ...LOL ! i may have them by middle of next week.