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Old 03-30-2018, 05:27 PM   #1 (permalink)
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05 2500 SAS, The Red Rocket

Ok, Time to start a build thread on what is basically my first major build that I have actually owned.

I'm starting with a 2005 Chevy 2500 extended cab short bed. its powered by a LQ4/4l80E combo. 84k miles and no body rust (which is amazing since I live in WV.). it spent most of its life in Grand Junction CO. I picked the truck up from a coworker for $3,000 who was going through a custody battle and needed some extra cash. I was able to drive it home, but it had some electrical problems that he couldn't figure out.






After getting the truck home it was immediately clear that the electrical issues were serious. There were lots of dings and blinking lights plus a turn signal that was just always on and poor engine performance. I opened the fuse box immediately to look and found that mice had gotten under it and chewed up a ton of wires. I assume the previous owner knew this and that was part of the low price point. Anyway, a few new sections of wire and some heat shrink and every thing was functioning semi normal.


I got the truck licensed and let my dad drive it for nearly a year to work the bugs out while I gather parts and finish my current project, a stretched 1 ton JK for my buddy




I ended up having some more electrical system troubles. Most of them were typical chevy things like the ignition switch, headlight switch, blower motor resister and so on. I tinted the windows, threw on a set of tires and added some ebay chevy tow mirrors. That pretty much catches the truck up to where it sits currently as of 3/30/2018.



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Old 03-30-2018, 05:38 PM   #2 (permalink)
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Ill outline my plans for the truck here so that I can stay on track and so you all can see where Im going with the build. The main goal is to build something that can do Ultimate Adventure. Im not sure that I will ever actually apply but I like the style of those rigs.
Driveline
LQ4, 4L80E
o Tuned by 150 tunes, add some power and drivability
o HD2 shift kit to tighten up 4l80E
05+ SD Dana 60 front
o 5.38 gears
o Lunchbox locker
o Factory drop in 1550 shafts
o Motobilt SD60 cover
o Artec slim truss
Factory AAM 10.5 (14 bolt)
o 5.38 gears
o Lunchbox locker
o Artec truss
o Wheel spacers to convert to 8x170mm and match track width
NWF EcoBox,
NP241C, JB conversions super short SYE, 1350 flanges
Suspension
3 link front
Single triangulated 4 link rear
14 fox 2.5 coilovers from Accutune offroad
Wheels & Tires
40x13.50-17 Nitto Trail Grapplers
Trail gear creeper locks
Chassis
Chop frame down until rear tires almost touch the cab and build a little flat bed
I have been gathering parts ever since I got the truck. I think I have things well planned out after seeing a few different threads on here.
https://www.pirate4x4.com/forum/chevy...ab-2500hd.html
https://www.pirate4x4.com/forum/chevy...0-14b-40s.html
https://www.pirate4x4.com/forum/chevy...500hd-sas.html
https://www.pirate4x4.com/forum/chevy...max-build.html
https://www.pirate4x4.com/forum/chevy...ado-build.html
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Old 03-30-2018, 05:56 PM   #3 (permalink)
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Here are some pics of the junk that I have gathered so far
SD60 $370 bucks at the local junk yard after some haggling

32 spline NP241C, I tripped over this one in the grass at the local yard. $75 I found another one 2 weeks later at the same yard in the back of the truck when I was pulling factory floor shifters.

The truck started its life in CO as a pilot car, naturally there was a bunch of shit wiring done by the finest truck drivers with wire nuts and lots of. Marker lights in the bed below the tailgate had the taillight wires jacked up. They had a CB mounted in the dash which left a big hole, there was switches everywhere and aftermarket security crap. I found these pretty cool switch panels from Long Horn Fab shop to cover up the hack job from the CB
Spruce up the Interior of your Duramax LLY | Quick Install | Cheap

Then I snagged a JK switch panel thats like a Chinese sPod from eBay. This seemed to be the cheapest and easiest bet for some more circuits



I hated the factory tow mirrors and the passenger side was broken. I couldnt find a replacement for less than $250 so I got some sweet ebay knock off 2015 style mirrors for $170. Pics are above in 1st post
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Old 03-30-2018, 08:20 PM   #4 (permalink)
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Look forward to seeing the build

You didn't mention a cage, do you plan on internal or external?

How much lift are you targeting? With a gasser you've got the 10.5 AAM 14b right, do you plan to keep that?
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Old 03-31-2018, 04:30 AM   #5 (permalink)
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For not being rusty or falling apart that was a good deal on the truck for sure. If your not going to use the bed that's worth a few bux to sell. I can't believe how cheap i am seeing you guys pay for the sd60, tha'ts great..!!
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...1983 chevy stepside...
358, dual carbs,propane,465/205 d60,14b 456s,
53 inch alcans, diy4x shackle flip 52s.
39-18-16.5 boggers( in pieces)

...2003 chevy 2500hd...
Texas speed 408 tvs2300/4l80e/np241/d60/14b/513s
4 link, kings, radflo bumps, bds leafs/air bags
37/12.50/20 stt pro's

Last edited by flatblack83; 03-31-2018 at 04:30 AM.
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Old 03-31-2018, 05:13 PM   #6 (permalink)
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Originally Posted by fl0w3n View Post
Look forward to seeing the build

You didn't mention a cage, do you plan on internal or external?

How much lift are you targeting? With a gasser you've got the 10.5 AAM 14b right, do you plan to keep that?
I do have plans for a simple cage that will be a hybrid interior/exo. Mostly exo accept the B pillar, that will be internal and tied through the roof so I can keep functional rear doors.

I'm looking to get it down to about 5-6 inches of lift with decent up travel incase I decide to go fast lol.

I am using the factory 14b, nothing too special. 5.38s, lunchbox locker and the motobilt 13b cover.

Here are a few pics of the mini shave and welding up the AAM drain plug.

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Old 03-31-2018, 05:36 PM   #7 (permalink)
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Originally Posted by flatblack83 View Post
For not being rusty or falling apart that was a good deal on the truck for sure. If your not going to use the bed that's worth a few bux to sell. I can't believe how cheap i am seeing you guys pay for the sd60, tha'ts great..!!
for sure, I jumped on the truck because I could have always flipped it if I decided not to build it and I wont loose any money. I think I already have the bed sold to a guy down the road. lucky for me people love these chevy trucks and all of them are rusted out around here. I'm getting $800 for the bed, tailgate and bumper as long as the guy holds up his end of the deal.

The 05+ SD60 is a no brainer for strength per dollar. I picked up both 1550 spicer shafts for just over $300 for piece of mind and that's all I really plan to upgrade on it other than the diff cover, gears and locker, weld on steering arms and a low profile truss from Artec

1550 shafts are spicer parts from Dennys and they came fully assembled with outer tube seals and new hub seals
Dana Spicer 10013781 LEFT SIDE AXLE ASSEMBLY fits FORD 05 to 15 F-250 and F-350 Super Duty with DANA 60 FRONT Replaces 2013564-2 and 2022234-2
Dana Spicer 10013778 RIGHT SIDE AXLE ASSEMBLY fits FORD 05 to 15 F-250 and F-350 Super Duty with DANA 60 FRONT Replaces 2013564-1 and 2022234-1

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Old 04-02-2018, 01:51 PM   #8 (permalink)
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I picked up the Artec steering arms for the SD60 and a low profile truss. the arms will make it easy to run a straight tie rod with 7/8x7/8 rod ends. Ill be sure to post pics when i get them glued on
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Old 04-04-2018, 10:59 AM   #9 (permalink)
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Is this to wheel or a tow rig?
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Old 04-09-2018, 12:32 PM   #10 (permalink)
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camping and wheeling. possibly towing a small cargo trailer to camp in. I've got a Ram 3500 that will be doing most of the towing.
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Old 04-09-2018, 12:34 PM   #11 (permalink)
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I sent my PCM off to 150Tunes today to get doctored up. also sent the gauge cluster out to get repaired since a couple of the gauges are dead.
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Old 04-25-2018, 04:25 AM   #12 (permalink)
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I made a post over in Gen 4x4 but figured I should ask here also. I'm looking at Metalcloak Duroflex joints for this project and I was wondering if anyone has any experience with them.

https://www.metalcloak.com/Duroflex-...int-p/7353.htm

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Old 04-25-2018, 05:15 AM   #13 (permalink)
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camping and wheeling. possibly towing a small cargo trailer to camp in. I've got a Ram 3500 that will be doing most of the towing.
Why the big mirrors then? the small ones seem like a better fit if you arent gonna tow. I love these being SAS'd tho. Super cool build so far.
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Old 04-25-2018, 05:22 AM   #14 (permalink)
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Why the big mirrors then? the small ones seem like a better fit if you arent gonna tow. I love these being SAS'd tho. Super cool build so far.
I like the way they look lol when they get smashed I'll probably replace them with the small ones

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Old 05-25-2018, 08:03 AM   #15 (permalink)
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Its been a little while since Ive messed with this. I got the PCM back from 150tunes and it runs great! My dad has been driving it a lot. I have been occupied with this Jeep project but I was finally able to drive the Jeep to its home a couple days ago. The owner has a thread started on jkowners if anyone is interested. Since the Jeep is out of the way I want to get started on the red rocket again. Here are some Jeep pics for you chevy people


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Old 12-13-2018, 08:17 AM   #16 (permalink)
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I was looking back at some pics in this thread and I figured Id update it to keep it alive. The truck has been serving daily duty for my dad until recently since its salt season here. I changed the oil and when I rolled under the truck I found some very rusty rockers and cab corners. Who here has done the body work to replace them? Does anyone have any tips on the job? I considered sending it to the body shop to save me the headache but that will hurt the wallet. I poked around a good bit and all the other body panels seem very solid. It was a little discouraging but I still have full plans to go through with the build. Progress is at a standstill because I purchased a house without any shop space. I plan on building a shop this spring so I can get back to work.


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Old 02-04-2019, 02:37 PM   #17 (permalink)
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I was looking back at some pics in this thread and I figured Id update it to keep it alive. The truck has been serving daily duty for my dad until recently since its salt season here. I changed the oil and when I rolled under the truck I found some very rusty rockers and cab corners. Who here has done the body work to replace them? Does anyone have any tips on the job? I considered sending it to the body shop to save me the headache but that will hurt the wallet. I poked around a good bit and all the other body panels seem very solid. It was a little discouraging but I still have full plans to go through with the build. Progress is at a standstill because I purchased a house without any shop space. I plan on building a shop this spring so I can get back to work.


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I've done it, it is really easy, but in retrospect, I wish i had just cut them off and replaced it with squaretube as a slider/step.

The way they curl under, they are always going to rot out, mine are rotting again.
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Old 02-04-2019, 03:02 PM   #18 (permalink)
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lets see some pics of the finished truck
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Old 02-04-2019, 06:20 PM   #19 (permalink)
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but in retrospect, I wish i had just cut them off and replaced it with squaretube as a slider/step.
That's what I did on my '94.....
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Old 02-04-2019, 07:39 PM   #20 (permalink)
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I figured theres no real way to stop it. Especially living in the Northeast. I might look into doing sliders integrated into the cab. It would be a nice foundation for a cage. I was going to build some anyway but I was going to land them on the frame.


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Old 02-04-2019, 07:41 PM   #21 (permalink)
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lets see some pics of the finished truck


Were a long way from that. I did manage to find time to redrill 1 unit bearing and rotor this afternoon between other projects


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Old 03-13-2019, 12:37 PM   #22 (permalink)
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Hopefully the next time its on its wheels the front axle is under it


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Old 03-13-2019, 04:23 PM   #23 (permalink)
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off to a good start, these things always take longer than we imagine.
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Old 03-13-2019, 10:50 PM   #24 (permalink)
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yeah, Buying a house slowed down the project quite a bit. However, having a garage that the truck will fit all the way inside should help. I'm in the process of moving my tools and setting up my new garage for the project.
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Old 03-20-2019, 07:57 PM   #25 (permalink)
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I got the axles and a bunch of my tools moved to my new house today. I have been working for a few min every day after work. I figure 30min a day makes a difference. Im on days off now for two weeks so hopefully there is significant progress made by the time I start working again.


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