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Old 05-11-2014, 08:52 PM   #1 (permalink)
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91 d21 SAS project

This is a project a couple buddies and I have been working on. It's a 91 d21 that we are completely rebuilding, originally the truck was a 2wd 4 cyl 5 speed.The plan for now is 10 bolt chevy front 14 bolt 6 lug rear chevy 350 TBI turbo 350 trans and a np 205. We're waiting on a shipment from ballistic fab now but here's where we're at so far.

whole truck was pretty roached from living in NY it's whole life and 350,000 miles














That's where we ended the first night


Back at it the next day
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Old 05-11-2014, 09:00 PM   #2 (permalink)
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Cut the frame just behind the rear cab mounts the back was so rotted it wasn't worth trying to save and it's easier to build from the new back half.


After the amount of rot we cut out and replaced it would have been less time consuming to just build a new frame but it's all solid now.


Seeing how the new back half fits.


Brought the front axle home.


And this is where we finally called it quits last night at 4:30 in the morning backhalf is welded in and front axle is torn apart.
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Old 05-11-2014, 09:05 PM   #3 (permalink)
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This is where she'll sit until our order from ballistic comes in then we can start fitting the front end up. We'll keep this updated as we go it'll be a slow build as we usually only get to work on it until the weekend.
Until next time,
83s10

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Old 05-12-2014, 05:21 PM   #4 (permalink)
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You killed that truck in a day! Wow. Good luck putting it back together.
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Old 05-12-2014, 07:05 PM   #5 (permalink)
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You killed that truck in a day! Wow. Good luck putting it back together.
There was 3 of us working so it wasn't too bad to rip it apart going back together will definitely take awhile only thing nissan will be the cab and half the frame. We're hoping to be wheeling next spring.
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Old 05-22-2014, 10:01 PM   #6 (permalink)
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We picked up a sf 14 bolt for too cheap to turn down




Started sand blasting and painting the axles





Started locating the front axle and that's up to date won't be working on it again until next week
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Old 07-24-2014, 10:05 AM   #7 (permalink)
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We've been working just havnt had time to post in a time crunch now to prepare this truck and my own truck for a cross country move from New York to California here's some pics of the progress more to come tonight












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Old 07-24-2014, 11:07 PM   #8 (permalink)
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This is as far as we got tonight if anyone has anything to say please chime in this is the first full on build that either of us have done


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Old 07-28-2014, 01:42 PM   #9 (permalink)
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you're not going to seriously leave that overload spring in the front there, are you? I don't know what those springs are from but they look like overkill for the weight of what that truck will be.
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Old 07-28-2014, 10:55 PM   #10 (permalink)
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The springs are from the back of a mid 90's Yukon and no when we pull them out to clean and rebuild them overloads will be coming out surprisingly tho they flex real easy, when we mount the rear axle we'll be able to actually flex it out and see how it works should be ok though. Thanks for looking and appreciate you looking out like I said earlier this is our first build and were learning tons from this project
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Old 07-30-2014, 09:58 PM   #11 (permalink)
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It's alive!!

We got the motor up and running mon just now uploaded so nice hearing the motor rip to life for the first time
http://s1291.photobucket.com/user/87...szmqo.mp4.html

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Old 07-31-2014, 08:44 PM   #12 (permalink)
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That sounded awesome!
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Old 08-06-2014, 02:28 PM   #13 (permalink)
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Got a nice order in thanks Barnes4wd was sent fast and arrived fast highly recommend those guys, we will be hanging the rear suspension tonight

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Old 08-06-2014, 08:05 PM   #14 (permalink)
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since you have the floorboard all cut up. you should add a NP205 and make a 203/205 doubler.
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Old 08-06-2014, 10:17 PM   #15 (permalink)
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We got the rear axle hung after putting weight on the springs it's obvious that the front mount has to be moved to fix the shackle angle but were waiting until the strait shackles show up from our last order.


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Old 08-06-2014, 10:22 PM   #16 (permalink)
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since you have the floorboard all cut up. you should add a NP205 and make a 203/205 doubler.
Doubler may come down the road right now we need to get it together and ready to haul it from New York to California. The rear d-shaft would prolly be pretty short with a doubler though as it sits it's only around 105-106 for wheelbase.
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Old 09-22-2014, 09:42 PM   #17 (permalink)
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Well we've been working on the Nissan havnt updated in awhile so here's some pictures to show the current progress.
For the first time in months it rolled outside


Gusseted the front spring mounts

Fabbed up the motor mounts

Made the transmission mount the mount and belly will have a full skid

Lastly for tonight we mocked up the front bumper, we've been working on the back half cage too I'll have some pics of that tmrw
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Old 09-23-2014, 10:44 PM   #18 (permalink)
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Damn it's slow in this section, but here's today's update. We finished the floor a few weeks ago I just didn't have a pic

We started the back tube work hoping to be done with it tmrw



There will be an X between the rear bars

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Old 10-07-2014, 11:54 AM   #19 (permalink)
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Well the back cage is all wrapped up were waiting on our steering valve to finish the hydro steering then just have to wrap up all the coolers and wiring

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Old 10-08-2014, 07:35 AM   #20 (permalink)
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Progress looks good! Keep it coming!
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Old 10-08-2014, 08:51 AM   #21 (permalink)
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Impressive! keep posting!
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Old 10-16-2014, 10:44 PM   #22 (permalink)
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Well the owner of the truck is off in California now, I'll be finishing this up enough for him to ship it out there, tons of work still left all the little things take forever. Here's the only recent picture I have with all the tool boxes in. Im trying to get him to join so we'll see if he shows up in here. More progress to come when I pickup another spool of welding wire.
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Old 10-17-2014, 06:17 AM   #23 (permalink)
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I like how you are using those "over the wheel well" toolboxes. Very original.
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Old 10-18-2014, 10:27 PM   #24 (permalink)
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I like how you are using those "over the wheel well" toolboxes. Very original.
You can never have too much room for tools and spares, the goal was to use all the space possible for storage and with the 3 tool boxes I think we achieved that. No progress yet been lazy and still need welding wire
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Old 11-17-2014, 07:00 PM   #25 (permalink)
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My truck

I can not wait to get to the garage to finish this thing fingers crossed we will be able to do some snow wheeling
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