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Old September 22nd, 2009, 04:09 PM   #1
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Default SAS in 96 k1500 chevy

hey i'm new here but i've been reading up about this swap for a couple months now and i think i have it down. i'm going to give u a run down of what i plan on getting what i have and what i plan on doing and any help along the way would be nice, i'll start taking pix and posting them up and what not so here we go.

well the plan is to get axles, clean them all up redo the brakes and get them rdy to go. figure out if i need to get a new passanger side knuckle or if the one on the axle will work and get it drilled and tapped, get the steering arm and a 2wd steering box. my father is a great welder so have him make me up a rear shackle flip mount, i'll prolly wait till i have the whole truck taken apart to make a crossmember to go across the front of the frame mount the front shackle mounts on the crossmember then bolt the leaf springs to the axles line everything up and measure measure measure to make sure its right then measure again a couple more times to its right on, i'm not sure how i'm going to do the shackle mounts on the rear of the front leaf spring prolly looking at something like the rear shackle flip brackets that will bolt to the frame, then measure for the front shocks, i'll have a plate that will go on the leaf spring mount with two mounts for the shocks but flex the front end out and measure for the shocks, i dont know if i'm going to buy a shock hoop bar or have my father make one i'll have to talk to him about that, once i have the springs all on get all the tie rods for the steering and i think i'll have to get a custom draglink bar? i'm not sure, run all SS braided brake lines, and figure out about the driveshafts i know of a shop near by so that shouldnt be do bad. i think thats pretty much it so i'll go on to what i have

so all that was just my plan from the start and what i've read that i'll have to do so now we'll go onto what i have for that swap

i picked up a dana 44 front end outta 79 f250 with a driver side drop, a dana 60 rear end outta the same truck both with 4.09 gears. they came with a set of 36.5in tires and 16.5in wide rims. thats really all i have right now i've just been taking them apart i have them all down now i'll post up a pic of the passanger side knuckle so u guys can tell me if i can use if or get a new one, now just see if that knuckle will work and get that drilled and tapped, i'm converting the rear brakes to disc with just a weld on caliper bracket, going to put chevy calipers on the rear also thinking about converting the front to chevy breaks cuz the ford ones are kinda weird, well if anyone has any info and help that would be awesome, or anyone who lives close by that wants to lend a hand or just come by and check out what i got going let me know thanks
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Old September 22nd, 2009, 09:42 PM   #2
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the front cross member is easy Either heavy c chanel or box tubing,depending on how high you want it, weld ears on for spring eyes, if u use the narrow chevy rear springs and mounts they should go right inside the frame where it gets nice flat and straight, I have a budy who did three like that, Ill try to post some pics of it, he used the 4x box and factory pitman then threaded the center link to take a sleeve and tie rod to the right side.
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Old September 22nd, 2009, 11:21 PM   #3
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yeah i figured i'd just use some box tubing and have it go just in between the frame in the front and have the shackle mounts go under the frame rail but then have the bracket for it go right up to the body mount so it goes around 3 sides of the frame. now for steering i think the knuckle i have can be machined drilled and tapped to have the high steer arm bolted to it i'll prolly put the spacer under the arm just to give extra clearance from the leaf spring, but what springs should i get? i hear get them outta a 85 or so chevy. the mounts on the axles for the leafs on the front should be fine cuz i have to mount the shackles anyways but for the rear i have to move the spring mounts 3/4in in on each side to make them line up with the leafs on the truck, if u could get some pix that would be awesome, if u could get as many as u can of the knuckles and how he made his shackle mounts would help me out a lot thanks
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Old September 23rd, 2009, 03:32 AM   #4
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how big of lift springs are you planning on using and how much lift are you planning on building into the brackets?
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Old September 23rd, 2009, 07:44 AM   #5
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i dont really plan on buy new lift springs at all was just gunna look for a good stock set at a junk yard or see what my buddys got hes got a k5 blazer and might have a set around, if anything just get some 2in lift springs, really all the lift i want is gunna come from adding the axle and the rear shackle flip, the shackle mount for the front rear of the leaf i might use the same kinda shackle as for the rear shackle flip. so i dont plan on adding any kinda lift just the axle swap will lift it up high enough for me thanks
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Old September 25th, 2009, 08:58 AM   #6
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well as of today i have the axles all taken apart i'm getting my passanger side knuckle machined to have the three bolts for the high steer arm, prolly gunna order the arm this weekend sometime. have all the gear lub taken out of the axles gunna take them to get sand blasted and powder coated, then i need to get the weld on brake brackets for the rear and start buying all new calipers rotors and pads so wish me luck
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Old September 25th, 2009, 11:31 AM   #7
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why swap in a two wheel drive box? the factory 4x box goes left to right on the 90's body style, you only need to swap 2wd boxes on 70-80's for x over steering.

chevy brakes is no problem on the ford housing, I'm DD'ing mine that way but the ford rear 60 was alot narrower than the front after converting to chev outers and it looked stupid under the truck so I opted for a ff 14bolt outta 79 1 ton chev.

I used 2 1/2" superlift softride front springs for a 88-91 suburban, and had to do a little clearancing on the front xmemeber under the radiator.

your quote "i'll prolly put the spacer under the arm just to give extra clearance from the leaf spring"
no need to mount the tre the way its suppsoed to be in the highsteer arm and RUn a dropped pitman arm from ORU, and the clearance is great. Only problem is the actual tie rod was too close to my leafs (I didnt run a full high steer, only 1 arm for my x over). But my chev flattop knuckles the tie rod dropped in from the top, not the bottom like some do, so I had to get a odd ball TRE that has offset built into it, its a factory gm piece actually.

Unless your building your own axle spring perches WAYYYYYYY outboarded you'll never be able to fit a shock there, the spring runs directly under the frame. of the truck.

For my rear I just ran the 2500 springs with a add-a-leaf and a 2 1/2???" block

I was able to retain my stock driveshafts also, I had to do a little grinding on the tcase yoke just for a little more clearnce because I was afraid the driveshaft might bind at full droop, (it wasnt much)

I'll see if I can dig up a pic of it.

What are you planning on doing about your ABS system?

I kept m
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Old September 25th, 2009, 12:04 PM   #8
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i know now that i can use my steering box so i prolly will.
about the brakes i plan on using stock ford brakes on the front but get all new ones from parts store and get a weld on bracket for chevy brakes on the rear then buy new calipers, rotors and pads.
for front springs i didn't really know what i was gunna do, could get a stock set out of a junk yard cuz money is kinda tight for me but i'd like to just get maybe some used ones off here from someone i'm not sure
the x over steer is gunna be just like urs with only one arm for now maybe add one later
about the shock i plan on making or buying a plate to go over the leaf spring u bolts and the shock will go up to a hoop i'll prolly have to buy.
for the rear i really wanna do the shackle flip but i need someone that has one to measure it up and give me some specs on it so i can make one, i'll prolly use the same style mount for the rear of the front leaves that should give me even more of a lift.
with the 2500 springs in the rear and the block how much did it give u in the rear of the truck?
as for abs i dont really care it goes on and off in the truck right now so just get rid of it but with doing the rear conversion theres a restricter i have to take out so it will push the same to the front and the rear i dont know much about that i need to read a bit more but as for now i think i'm moving along pretty good
i just took the old spring perches off the rear and the shock mounts i need to buy some perches and new mounts for that and weld them on so thats prolly my next step then brake brackets and brakes then if i can get a blueprint or the specs of the rear shackle flip start making those up and the front crossmember that will have the front shackle mounts on them, next will be to start taking it apart really then get the rest of the stuff i need as i go plan on having it up in running within 2 months of taking the tires off well hopefully u can get some pix i'd like to see what other ppl have done thanks
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Old September 28th, 2009, 11:27 AM   #9
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just weld tabs on the axle and use your factory frame end for the shock mounts. thats how the ORU kit does it.
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