Project Crewcab Dually has begun.

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Project Crewcab Dually has begun.

Postby lugnutz » Wed Dec 08, 2010 10:00 pm

Okay guys, I pulled the trigger yesterday. I have officially started in on my Crew cab project. I have been finishing up other projects and collecting parts and info for a few years now so that I can do this build.

I have followed along the threads of other Crew cab conversion projects on this site and on Cummins forum and thought that I would start a thread on my transformation.

The basics are it will be a Cummins powered Crewcab 4x4 Long Box “Dually”

I still have to find a few parts (NV5600 output shaft and a 29 spline NP205) and figure out a few details and I am sure many more things as the project grows.
I will update its progress as I go, hoping others will chime in when I run into issues.

It started out life as a 1985 D300 2x4 long bed, 360/727 (ex-Air force) and I picked it up in Great Falls Montana.

I have it stripped down to the frame at this point. I know everybody likes pictures so I have added a few to start with.

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Last edited by lugnutz on Thu Dec 23, 2010 12:38 pm, edited 4 times in total.
1998 Freightliner FL70 Crewcab, Cummins 8.3


Sold :-( 1992 W350 Clubcab, Getrag
BHAF, Stans 4" exhaust, H1C, GDS 60mm, 16cm housing, tweaked pump, Kdp, Autometer guage package.
lugnutz
fuel screw!!!!
 
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Re: Project Crewcab Dually has begun.

Postby BobS » Thu Dec 09, 2010 11:21 am

I like your wooden cab dolly. It's a good idea that I may copy.
BobS

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91.5 W250 NV4500 Conversion
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Re: Project Crewcab Dually has begun.

Postby lugnutz » Thu Dec 09, 2010 11:59 am

Here's a better shot for you than. Swivel casters on all four corners.

Image
1998 Freightliner FL70 Crewcab, Cummins 8.3


Sold :-( 1992 W350 Clubcab, Getrag
BHAF, Stans 4" exhaust, H1C, GDS 60mm, 16cm housing, tweaked pump, Kdp, Autometer guage package.
lugnutz
fuel screw!!!!
 
Posts: 93
Joined: Sun Aug 08, 2010 10:46 pm
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Re: Project Crewcab Dually has begun.

Postby superbeemike » Thu Dec 09, 2010 3:54 pm

I'm working on the same thing, except I'll be converting to 4x4 after I get it on the road. I'm interested on what your plans are for the 4x conversion. I was planning on grinding off all the rivets and pulling the front cross member and 2wd stuff. I'm not a big fan of splicing frames together. Good luck with it. Mine has been alot of work but fairly simple. Almost like it was made to be there. I will be checking on your progress....

Mike
1985 D-350 Crew Cab SE Royal Prospector, 92CTD/A-518
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Re: Project Crewcab Dually has begun.

Postby PToombs » Thu Dec 09, 2010 7:05 pm

Wow, that's really stripped down. Where the hell do you find time for projects like that? I have a JD "R" that I started to restore 5-6 years ago and is about 2/3 done, then life got in the way. Darn kids, too young to help and too old to sell. :roll:
Good luck, should be fun when you're done!
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Re: Project Crewcab Dually has begun.

Postby lugnutz » Fri Dec 10, 2010 12:06 am

superbeemike wrote:I'm working on the same thing, except I'll be converting to 4x4 after I get it on the road. I'm interested on what your plans are for the 4x conversion. I was planning on grinding off all the rivets and pulling the front cross member and 2wd stuff. I'm not a big fan of splicing frames together. Good luck with it. Mine has been alot of work but fairly simple. Almost like it was made to be there. I will be checking on your progress....

Mike


I have read several threads where it goes back and forth about welding versus drilling the rivets and I’m sure somebody will chime in here about their preferred method too.

I am actually doing the cut and splice method. However, at first, I did plan to drill the rivets until I started asking questions from people that have experience in the area, and I will give you the examples that were given to me.

It started with, back in the day (and I thought oh great here we go) people would weld old Nova, Camaro, or even the Mustang II front clips onto old street rods, and now people buy front or rear clip assemblies from companies like Art Morrison or Chassis engineering to put under their cars or trucks. Its mild steel, people have been doing it for years without any issues.

Another one that was brought up was the Dodge Mega cab trucks that don’t have the long bed option. There are companies lengthening the frames the distance that is needed to install the long bed. So you have two welds on each frame rail instead of just one.

I also checked with a few collision shops. The census was, measure twice, cut once, good prep work and a good welder, reinforce it, no worries.

And lastly, I just finished drilling the rivets tonight to remove the fuel tank brackets off of a Ramcharger frame and the rear cross-member off the CC frame. Eighteen rivets in all. In my opinion, it was a pita, way too much time and energy to do the job. I will stick with splicing it. Hope this helps.
Last edited by lugnutz on Fri Dec 10, 2010 4:46 pm, edited 1 time in total.
1998 Freightliner FL70 Crewcab, Cummins 8.3


Sold :-( 1992 W350 Clubcab, Getrag
BHAF, Stans 4" exhaust, H1C, GDS 60mm, 16cm housing, tweaked pump, Kdp, Autometer guage package.
lugnutz
fuel screw!!!!
 
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Re: Project Crewcab Dually has begun.

Postby lugnutz » Fri Dec 10, 2010 12:23 am

PToombs wrote:Wow, that's really stripped down. Where the hell do you find time for projects like that? I have a JD "R" that I started to restore 5-6 years ago and is about 2/3 done, then life got in the way. Darn kids, too young to help and too old to sell. :roll:
Good luck, should be fun when you're done!


Well, I’m not married and I have no kids. :lol: So, I have most evenings and weekends free, and I say most because I have a very understanding girlfriend. She says that she doesn’t have the Redneck gene so she doesn’t understand. Ya see, very understanding..LOL!

I have actually been working on finishing up other projects for a few years now so I can get to this one. It's not gonna be a fast build. Time and money (as with all of us) will dictate how fast I get to build it. And I'm sure the gf will have her say so in the matter too.. :D
Last edited by lugnutz on Mon Dec 13, 2010 8:35 pm, edited 2 times in total.
1998 Freightliner FL70 Crewcab, Cummins 8.3


Sold :-( 1992 W350 Clubcab, Getrag
BHAF, Stans 4" exhaust, H1C, GDS 60mm, 16cm housing, tweaked pump, Kdp, Autometer guage package.
lugnutz
fuel screw!!!!
 
Posts: 93
Joined: Sun Aug 08, 2010 10:46 pm
Location: Tacoma, Washington
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Re: Project Crewcab Dually has begun.

Postby superbeemike » Fri Dec 10, 2010 8:46 am

Lugnutz,

Limo's have the frames stretched too but it scares me a little. Maybe mine will stay a 2wd since a I have a decent Ramcharger to get around in bad weather. Maybe your project will convince me to cut and splice. I don't know, we'll see. Looks like your making quick progress so I will keep up with what your doing. Why the RC fuel tank? Is it an extra or are you passing on the saddle tank?

Thanks
MIke
1985 D-350 Crew Cab SE Royal Prospector, 92CTD/A-518
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Re: Project Crewcab Dually has begun.

Postby lugnutz » Fri Dec 10, 2010 10:26 am

superbeemike wrote:Lugnutz,

Why the RC fuel tank? Is it an extra or are you passing on the saddle tank?

Thanks
MIke


Hey Mike,

It's just for an Auxiliary fuel tank. We like to go on road trips during the summer for camping. Never know where we'll end up.
1998 Freightliner FL70 Crewcab, Cummins 8.3


Sold :-( 1992 W350 Clubcab, Getrag
BHAF, Stans 4" exhaust, H1C, GDS 60mm, 16cm housing, tweaked pump, Kdp, Autometer guage package.
lugnutz
fuel screw!!!!
 
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Joined: Sun Aug 08, 2010 10:46 pm
Location: Tacoma, Washington
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Re: Project Crewcab Dually has begun.

Postby dazedandconfused » Fri Dec 10, 2010 1:38 pm

Rivets are a piece of cake to get out. 4" angle grinder with cut off wheel and good grinding disc. Cut off the head as close as possible to bracket, lightly grind it. Use a good air chisel and they pop right out the other side. I've done many frame brackets this way. It's fast and clean. I've used a die grinder for the hard to get to ones. I want to find a 2wd crew cab rolling chasis in good shape.
Big Andy
1983 Dodge D150 that has been repowered with a 93 Cummins/518 running gear AKA The Ugly Duck! I would much rather build them then buy them.[
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Re: Project Crewcab Dually has begun.

Postby lugnutz » Fri Dec 10, 2010 4:53 pm

dazedandconfused wrote:Rivets are a piece of cake to get out. 4" angle grinder with cut off wheel and good grinding disc. Cut off the head as close as possible to bracket, lightly grind it. Use a good air chisel and they pop right out the other side. I've done many frame brackets this way. It's fast and clean. I've used a die grinder for the hard to get to ones. I want to find a 2wd crew cab rolling chasis in good shape.


Assuming you can get the grinder into the area to get to the rivets, it works either way.

I guess it comes down to personal preference. Just seems easier and less time consuming to cut and paste.
Last edited by lugnutz on Thu Dec 23, 2010 12:41 pm, edited 1 time in total.
1998 Freightliner FL70 Crewcab, Cummins 8.3


Sold :-( 1992 W350 Clubcab, Getrag
BHAF, Stans 4" exhaust, H1C, GDS 60mm, 16cm housing, tweaked pump, Kdp, Autometer guage package.
lugnutz
fuel screw!!!!
 
Posts: 93
Joined: Sun Aug 08, 2010 10:46 pm
Location: Tacoma, Washington
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Re: Project Crewcab Dually has begun.

Postby dazedandconfused » Fri Dec 10, 2010 5:05 pm

I'm just not a big fan of cutting on frames when it can be helped. I know it's just as strong but it's everyones preference.
Big Andy
1983 Dodge D150 that has been repowered with a 93 Cummins/518 running gear AKA The Ugly Duck! I would much rather build them then buy them.[
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Re: Project Crewcab Dually has begun.

Postby lugnutz » Fri Dec 10, 2010 6:12 pm

Here are a couple of pictures of what I got accomplished last night, if anybody likes looking at progress pictures. The girlfriend calls it truck porn. LOL!!

I drilled out the rivets on the rear cross member of the CC and the fuel tank support brackets on the Ramcharger clip. I have not drilled the holes in the CC frame to mount the brackets yet. I hope to get that done over the weekend. I’m suppose to pick up the front 4x4 frame clip on Wednesday so I want to have this part done by then.

Earlier today, I received a tip on the whereabouts of a fuel tank from a 91 Ramcharger. So, I had to go check it out. It was still there and it had not received the hole punch treatment yet. It was also sporting a real nice grille that I might have to go back and get. I want to check out mine again and compare the shape.

I'll have more next week some time.

Image
The shiny bolts are holding it together to take pictures. My cell phone doesn't take good pictures after dark.
Image
1987 Dodge Ramcharger rear frame clip. Pull-a-part special but, they always punch a hole in the bottom of the tank.
Image
Image
Factory Crewcab rear cross member.
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1991 Ramcharger fuel tank.
Image
Brackets sitting in the CC frame.
1998 Freightliner FL70 Crewcab, Cummins 8.3


Sold :-( 1992 W350 Clubcab, Getrag
BHAF, Stans 4" exhaust, H1C, GDS 60mm, 16cm housing, tweaked pump, Kdp, Autometer guage package.
lugnutz
fuel screw!!!!
 
Posts: 93
Joined: Sun Aug 08, 2010 10:46 pm
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Re: Project Crewcab Dually has begun.

Postby PToombs » Fri Dec 10, 2010 7:24 pm

I wasn't as lucky as you, I had to build my brackets for my RC tank. Worked out good, so all is well. I've been to Indiana twice with it now, I like not having to stop for fuel. 8)
Only thing is the sender isn't 100% compatable with my fuel guage. When the tank is empty, the guage is just barely above "E", and when full, just below "F".
pete

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Re: Project Crewcab Dually has begun.

Postby KTA » Sat Dec 11, 2010 8:28 am

I am good with a torch so I just burn the rivet heads off and then knock them out with a punch while they are still glowing and they fall right out. I have yet to nick a frame or crossmember in the process as the rivets are pretty soft metal so they burn up easy. 8)
Fleet of Junk: 1989 D350 627rwhp 1300 tq B-1/Hx60 twins, KTA pump/injectors, ported head, BIG fuel supply. 13.75@ 109.5mph 1/4: 1992 W350 Cab-chasis, 1993 W350 ext cab cust.370 inj Hx40/16cm 290rwhp hydroboost brakes,1984 D350 crew-cab another project.
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