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Old 10-08-2010, 10:20 PM   #1 (permalink)
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Project to heavy 91 Cummins

Well it's about time I start a build thread so here it is.

I bought a 91 Dodge Cummins 3/4 ton about 5 years ago. Truck used to be my daily driver. Four years ago I moved to town and became self employed. Now it sits more than it drives. Felt like a good time to start building.

This is not a rock crawler, and I'm not a fan of pushing the limit till stuff breaks. I'm building this for off the beaten path exploration. I like going in comfort where most take their sled / quad.

In the end I intend to make this rig 6x6 on rockwells or portals, but first steps first....

The last few years of pics.

Nat

Last edited by nat_ster; 10-09-2010 at 09:13 PM.
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Old 10-08-2010, 10:24 PM   #2 (permalink)
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What this truck is being built for.







A friend and I spent a week out there that winter. Pics taken on Cross Lake Alberta Canada.

Nat

Last edited by nat_ster; 10-09-2010 at 03:05 AM.
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Old 10-08-2010, 10:35 PM   #3 (permalink)
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Pics of fixing the heater core leak. I wound up redoing the whole cooling system.







Pics of the rad in my 93 parts truck. It turned out to be no good also.






Nat
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Old 10-08-2010, 10:45 PM   #4 (permalink)
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Installing the new heater core in the heater box.











Big hole in the fire wall with out the heater box installed.



No rad.





Figured I'd remove the mechanical clutch fan while I had room to work.
Trying to free the 32mm left thread clutch fan nut.



That did not work. I also tried using a strap wrench with no luck. I finally removed two of the 10mm hub bolts and used my angle grinder wrench to hold it.



Also tried a chisel and hammer. All that did was this.

Nat

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Old 10-08-2010, 10:48 PM   #5 (permalink)
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Ready for the scrap pile. Maybe now the truck will warm up properly in winter.



All done, just have to rehook the coolant lines.



Nat
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Old 10-08-2010, 11:03 PM   #6 (permalink)
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Figured I'd replace the serpentine belt while I was at it. Also replaced the tensioner pulley.









Got tired of ruining my knuckles.



New belt on.





Fired it up only to have a brand new serpentine belt start to squeal and smoke. After installing and removing the belt about 16 times, spinning every pulley on the truck by hand, removed and inspected the fan pulley, I still could not find the problem. I even removed the water pump. Also there were aluminum bits everywhere. Finally one of the 10mm fan hub bolts that I thought had fallen on the ground dropped into the front cross member. The treads on it were all chewed up. I still don't know where it was stuck.



Nat
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Old 10-08-2010, 11:14 PM   #7 (permalink)
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Cleaned up my battery terminals a bit. There were lots of frayed wires everywhere.



I found this 79 ford one ton while driving tow truck a year ago. Finally went back and bout it for $150.





Towing it home behind my dodge on a strap. It was only 4 miles out of town on a dirt road.



Striped the flat deck off and sold it to the neighbor for $150.



Kept the deck for my truck. It's made out of 3" square tube for the main supports and 2" by 3/16 for the rest.





Just needs a sandblasting, and some 2x6 to redeck it.

Nat

Last edited by nat_ster; 10-08-2010 at 11:16 PM.
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Old 10-08-2010, 11:27 PM   #8 (permalink)
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Blew a Selectro Hub while out Ice fishing last winter. Could not find any on the net for the 35 spline external hub that attaches with 8 bolts. So I had these made by my local welding shop. The flange was cut on the water jet from 3/8” mild steel. The splined part is from the hub. Then they welded both peaces together on both sides.

Since then I found a few I could have ordered for cheaper than it cost to make thease.





Needed something to keep the dirt out of my hubs while not running the drive flanges, so I made these. Used epoxy to glue a pipe cap in the outer aluminum part of the hub.





You can see where the aluminum splines sheered off inside the poorly made hub. I can't beleave they are made this way.







I added a grease nipple to pump it full of grease rather than use RTV evertime I do the swap.



Nat

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Old 10-08-2010, 11:33 PM   #9 (permalink)
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I wanted to see what it was going to take to make my new trail tires fit my truck 18.4 x 16.1 ag tires, so I installed one on my spare frame from a 93 of the same truck. With 2" backspacing I get within 1/4" of stock steering lock, and will only need about 6" of lift if I move the front diff 7" to 8" forward. Frame is jacked up in the pic. Spring keepers have been cut and the upper shock bolt removed to allow drop. Stock ride height was 1/2" from the bump stops and had no flex at all.





A re-center job I did for measurement sake. I will probably use it for a spare when I get my centers cut out of 3/8”.



Nat

Last edited by nat_ster; 10-08-2010 at 11:41 PM.
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Old 10-08-2010, 11:58 PM   #10 (permalink)
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I went to change my air filter and sand dumped out of it. The stock position for the air intake was under the pass headlight. This had to change. So off to the ag wrecker to get a air box and a dust bowl. Both came to $150 with a new bowl for the dust bowl.

This air box is off a massey ferguson combine with a cat diesel much larger than my 5.9 Cummins. It has a primary and a secondary filter all in this box. Filters cost what a stock one did, and can be cleaned at the local parts place for $23.









It will not work in it’s stock form. Once mounted under the hood there would be no room to remove the filters and both the inlet and outlet are on one end. The reworking begins.





I could not find the right size hole saw in my little town, so I did this.







The outlet to the turbo now fits in the lid. Both filters will now mount on the lid. Intake will be on the opposite end.



Nat
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Old 10-09-2010, 12:01 AM   #11 (permalink)
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The rest of the airbox pics. Pirate will only do 10 at a time.







Where it will mount when done.



I haven't welded it all back together yet. I'm waiting till I rebuild my wheel wells.

Nat

Last edited by nat_ster; 10-09-2010 at 12:03 AM.
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Old 10-09-2010, 12:07 AM   #12 (permalink)
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The last time the truck will look like this.



Started cutting.







Doing this made it much easier to get to the bolts.



Test fitting







Nat

Last edited by nat_ster; 10-09-2010 at 12:11 AM.
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Old 10-09-2010, 12:13 AM   #13 (permalink)
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I hate high lift jacks. This is my new $800 rad.







Nat
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Old 10-09-2010, 12:19 AM   #14 (permalink)
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I begun cutting the old spring hangers off.



















Nat

Last edited by nat_ster; 10-09-2010 at 12:21 AM.
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Old 10-09-2010, 12:22 AM   #15 (permalink)
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Wheel wells and old spring hardware gone.









Nat
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Old 10-09-2010, 12:31 AM   #16 (permalink)
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Last time you will see a steering box in my truck. It was leaking out the input shaft seal because I hit a curb doing about 70 km/h on icy roads.



I scored some new rubber. 4 like new firestone 21.5 x 16.1 ag tires fror $1000. They are $1200 each new.





18.4 x 16.1 on the left. Will now be my trail spare.



21.5 x 18.1 on the left, 18.4 x 16.1 on the right. The 21.5’s are about 22” wide, the 18.4 is about 18” wide. They are both about 45” tall with 5 psi in them.



Nat

Last edited by nat_ster; 10-09-2010 at 12:33 AM.
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Old 10-09-2010, 12:49 AM   #17 (permalink)
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This is what my new headlight bezels will be made of. It’s 3/16” aluminum checker plate.



I ground out the three rivets holding the upper front spring shackle mount to see what shape it was in.



I had to drill pilot holes in the remaining part of the rivets to get them to pound out.









Nat

Last edited by nat_ster; 10-13-2010 at 08:40 PM.
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Old 10-09-2010, 12:51 AM   #18 (permalink)
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Looked fine so I bolted it back in with some grade 8 bolts. I got them tight, then tack welded the treads so they could never back out





I ground this bolt down to clear the long sweep of the new 8" shackles.









Nat

Last edited by nat_ster; 10-09-2010 at 12:53 AM.
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Old 10-09-2010, 12:59 AM   #19 (permalink)
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Old shackles were 5.5” long and 1.5” by Ό” thick. New ones are 8” long and 2” wide by 3/8” thick. Cost without drill bits $3. Tack welded them together to round the corners and drill the holes. ½” on the frame end, and 9/16 on the spring end.









Stock shackle in with the new.





Nat
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Old 10-09-2010, 01:13 AM   #20 (permalink)
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Begun making some front spring hangers from scratch. It takes to long to get stuff shipped here from the US. Used 3” od box tubing by 3/16 thick. This have me 2.75” id which fit the spring bushing perfectly. The springs needed in the front Ύ” bolt holes.

I will be using 2000 Ford F-150 rear springs up front. They are 56” long, with the center pin at 27” to the short side. Stock springs were 48”. This will put my front diff the 8” forward I was looking for. I didn’t know how much they would compress with the weight of the Cummins on them, so I made multiple holes in the front hanger.



















Nat
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Old 10-09-2010, 01:18 AM   #21 (permalink)
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In order to use the longer ford springs, and move my front diff forward 8”, I needed to move my front spring hanger as far forward as I could. So I welded the original stock bumper hangers in place. The extends the frame about 8”.







I welded every seem, just don't have anymore pics. Also 5 bolts pass through both the frame pieces so they are definitely solid.

Nat

Last edited by nat_ster; 10-13-2010 at 08:36 PM.
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Old 10-09-2010, 01:28 AM   #22 (permalink)
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It was time to see how the spring would do with the weight on them. I did a quick temporary mount and hung the springs for the first time.







Front diff ready to roll back under.









Partial weight on them.







Nat

Last edited by nat_ster; 10-09-2010 at 01:29 AM.
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Old 10-09-2010, 01:41 AM   #23 (permalink)
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With all the weight on them my shackle is at to much of a angle. I need to move the front one hole forward. I now have 6” between the bump stop and the spring where there used to be ½”. I can lift the front about 10” before the tires come off the ground.

I still need to do a lot of fender trimming.





I think I will add one more leaf out of a spare pack I got to each side. Now it’s time to pull the front diff again, and build a proper front spring hanger.

Temporary hanger gone.





Beginning of the new hanger. 4” x 4” x 3/8” angle Iron. I would have liked 5” but this will do.











Nat
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Old 10-09-2010, 01:47 AM   #24 (permalink)
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Front spring hanger parts getting ready to weld together. Once again all from scratch.















Starting to add peaces. Each side will be held on with 8 5/8" grade 8 bolts.



Welding a few together.



Nat

Last edited by nat_ster; 10-09-2010 at 01:48 AM.
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Old 10-09-2010, 01:52 AM   #25 (permalink)
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Tacked, making sure it all lines up.



New shackle angle without front diff.



Nat

Last edited by nat_ster; 10-09-2010 at 02:03 AM.
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