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Old 03-09-2017, 10:36 AM   #1 (permalink)
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Falkor - 2001 Crew Cab 2500HD

Falkor - 2001 2500HD

I recently purchased at an auction a 2001 GMC 2500HD Crew Cab, long bed with the 6.0L, 4L80E and manual shift NP263 T-Case with only 147K on the clock to replace the Yukon that I built. Now, you may be wondering about Falkor… Well, if you are anywhere near my age you may remember a movie called the Never Ending Story that had a big white luck dragon named Falkor. After rolling my Yukon, in a fluke accident off a sand dune, I figure the truck is big and white and I am going to need all the luck I can get! Plus, this is just the latest instalment of my never ending story of building 4x4’s. You can read the Yukon story here, http://www.pirate4x4.com/forum/gener...gmc-yukon.html. The truck itself is VERY basic, vinyl floor, manual windows, cloth seats and the reason I really wanted the truck, the manual shift t-case.



The plan for the truck is to copy Timzr2’s front suspension design, I have seen and built plenty of suspensions and Tim’s is hands down the best I have seen. The time and effort he put into this is beyond belief and I cannot give him enough props that he shared his design for anyone to use, again this is not my design and Tim deserves all of the credit! I will be using the Super Duty 60 just like Tim and if you want to read Tim’s build you can find it here. http://www.pirate4x4.com/forum/chevy...max-build.html






For the shocks I reached out to Ryan at Accutune Offroad and I will be using Fox 2.5”x8” Factory Series Remote Reservoir shocks for the front with custom valveing and a 450# Eibach spring.



From there I reached out to Green Speed Research here in Boise to help me get all the bending and laser cutting done for the front suspension, a few emails and phone calls back and forth and the plate was into production, Patrick at Green Speed had to slightly tweek the design for the tooling that is available here in Boise, it should all be done in a week or so. If you have a chance check these guys out do, they built a bad ass diesel land speed truck that went 209 mph and they are now building a diesel trophy truck that is off the hook! These guys get off-roading and engineering and they were again super impressed with Tim’s suspension design.



So the back of the truck is where I’m going to go off the deep end… I am going to chop the frame right behind the cab and ditch the bed. I will retain the FF14 bolt out back and will add an Atrec truss along with a dual triangulated 4 link with Smooth Body Fox 2.5”x12”, Low Take Off, Remote Reservoir Shocks, again from Ryan Accutune, and will use Firestone air bags with onboard air to support everything. From there I will wrap everything with a tube bed and incorporate a custom 40ish gallon fuel tank and Decked bed drawers that will be built into the tube bed using the top of the drawers as the top of the bed, so it will have plenty of drawer storage and be strong on top, while still keeping weight to a minimum. I will have to substantially modify the drawers to make them work, but I am confident I can make them work!





For wheels and tires I will be running 40”x13.50”x17” ProComp Xtreme MT2’s and the same Walker Evans Wheels I ran on the Yukon.





At this point I have everything I can think of on order with the shocks being the longest lead time. I should start cutting on it in the next few months. Here are some pics of the truck.
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Old 03-09-2017, 10:36 AM   #2 (permalink)
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Old 03-09-2017, 12:09 PM   #3 (permalink)
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Looking forward to seeing this
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Old 03-09-2017, 12:56 PM   #4 (permalink)
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Man I love Summit Racing! I ordered a 1350 U-Bolt style yolk, u-bolts and a new pinion seal yesterday at 11:48 am and I ran home for lunch today at 12:00 and it was sitting on my porch! That's less than 1 day shipping for free and this isn't the first time this has happened when I order parts from Summit!

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Old 03-09-2017, 02:03 PM   #5 (permalink)
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Truck looks good. Maybe I missed it, but any plans to shorten the wheelbase? That's a big damn truck. Just curious.

Can't wait to see Tim's kit in action on another rig. I'm definitely excited for your build.
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Old 03-09-2017, 02:42 PM   #6 (permalink)
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Maybe I missed it, but any plans to shorten the wheelbase?
Absolutely, the Decked drawers are for the newer F-150 and only 5'5" long and I believe that I can shorten them up even more than that, but I won't know exactly how much until the drawers get here. The placement of the fuel tank will play into the bed length as well, but the idea is to make it as short as possible with a good departure angle and still fit the drawers.
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Old 03-09-2017, 02:54 PM   #7 (permalink)
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Your link to timzr2's thread and your Yukon thread aren't showing up for me.
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Old 03-09-2017, 03:10 PM   #8 (permalink)
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Your link to timzr2's thread and your Yukon thread aren't showing up for me.
Fixed it, Thanks
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Old 03-09-2017, 03:21 PM   #9 (permalink)
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Really looking forward to this build. When I first saw Falkor, I thought he has some ashy skin...then later in life realized he is half dog half dragon... haha
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Old 03-09-2017, 03:52 PM   #10 (permalink)
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Absolutely, the Decked drawers are for the newer F-150 and only 5'5" long and I believe that I can shorten them up even more than that, but I won't know exactly how much until the drawers get here. The placement of the fuel tank will play into the bed length as well, but the idea is to make it as short as possible with a good departure angle and still fit the drawers.
Ah, so you already have the set of Decked drawers. If you have a crew cab and a 5'8" bed, your wheelbase should be that of an Extended Cab 6.5' bed, for reference.

Looking forward to how you package the fuel tank, as I've wanted for a long time to shorten my bed to 5'8", but the fuel tank is the biggest obstacle for me.
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Old 03-09-2017, 05:02 PM   #11 (permalink)
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Will be following this closely. Nice plans so far. Loved your Yukon, can't wait to see how this turns out.
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Old 03-09-2017, 05:46 PM   #12 (permalink)
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Nice k toy! I've been wondering if you were going to start a thread soon. Glad you are, and glad it's in the Chevy section. I'm jealous of your crewy as well lol! Looks very nice. I'll follow along. I'm hoping to start a new build myself within the next year or so, I'll be stealing some of your ideas for sure!
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Old 03-09-2017, 07:08 PM   #13 (permalink)
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Man this thing is going to be super cool.


I really like these trucks and I'm glad you're able to make use of that kit. Can't wait to see it in action!
I think your 450lb front springs are a good choice. I'm sure your guys already know this, but I'd definitely recommend the 18" springs over the 16s. Whenever I first bought my stuff from Poly, they set me up with the 16" springs (i think it was just because they were a little cheaper), but I didn't like the way that they sat on the coilovers. Had to crank the spanner a lot just to get it to touch the spring. Immediately returned them for the 18s and it was much better.


Not gonna lie, there are times where I've wished my truck was a long bed. Simply because I could put an autocrane on the back, and those are cool.
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Old 03-10-2017, 01:11 PM   #14 (permalink)
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Damn, I'd like to find one of those trucks stock. How come all I can find are roached out short beds? Here I need a long bed, and you're going to chop it down

Hope it turns out as nice as the yukon. I haven't done a thing to mine since I totaled the wife's Buick and she's using it for a DD again.
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Old 03-10-2017, 03:17 PM   #15 (permalink)
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Sub'd, looks like an awesome plan!
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Old 03-10-2017, 04:08 PM   #16 (permalink)
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neat project....... i dig the 2500Hd CCLB's.......
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Old 03-11-2017, 10:20 AM   #17 (permalink)
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Subbed! Looking forward to watching this come together.
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Old 03-11-2017, 10:29 AM   #18 (permalink)
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Can you give me an idea of how much it was for your local guy to get the metal and do all of the cutting/forming on it?
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Old 03-11-2017, 08:46 PM   #19 (permalink)
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Can you give me an idea of how much it was for your local guy to get the metal and do all of the cutting/forming on it?
As somehow who manages a custom steel fabrication shop, my advise would be to shop around. Materials costs will not very much as it is typically marked up within a range from a supplier. You may even be able to source the material yourself, although a lot of shops frown against this for a couple of reasons (reasons that actually have merit). The variation will be labor rates, and the available resources. Some shops will vary in how many hours needed to complete a job. We have a 2000 ton break press, and a shop with a 200 ton break press can form some things quicker just due to the operation of the press and the tooling. Also the labor rates will vary significantly as well. Also, some shops will charge you R&D labor for someone to nest/program these pieces in software to use on their cutting machine, while others won't charge you this time as that cost is built in elsewhere.
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Old 03-11-2017, 09:02 PM   #20 (permalink)
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Loved the Yukon looking forward to Falkor.

Best of Luck,

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Old 03-11-2017, 09:28 PM   #21 (permalink)
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It's funny because what's left of your Yukon is sitting in my yard until Russ gets a chance to build from it and I'm in the process of using Tims hard work to solid axle my white Chevy too, albeit a reg cab duramax. Small world!
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Old 03-14-2017, 06:45 AM   #22 (permalink)
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Can you give me an idea of how much it was for your local guy to get the metal and do all of the cutting/forming on it?
Call Green Speed Research, it will probably be cheaper than what I paid since I had to pay to have the engineering done.

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It's funny because what's left of your Yukon is sitting in my yard until Russ gets a chance to build from it and I'm in the process of using Tims hard work to solid axle my white Chevy too, albeit a reg cab duramax. Small world!
Small World for sure! Guess great minds think a like...
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Old 03-14-2017, 01:21 PM   #23 (permalink)
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Can't wait to see what you come up with this time! My only gripe so far, is that every time I click on this thread, I see that creepy ass dog/dragon thing. That shit wierded me out as a kid!
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Old 03-14-2017, 03:50 PM   #24 (permalink)
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Can't wait to see what you come up with this time! My only gripe so far, is that every time I click on this thread, I see that creepy ass dog/dragon thing. That shit wierded me out as a kid!
Sack up man, it's a luck dragon!
I laugh every time I see it because I had a stoner roommate in college that had that same look on his face all the time.
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Old 03-15-2017, 10:07 AM   #25 (permalink)
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More parts rolling in almost daily! All the steel for the SAS is done and Iím 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 themÖ


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