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Old August 12th, 2010, 12:55 PM   #1
Raymo
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Default '94 3500-HD tow rig rebuild

Here's an overview of the truck I've been building this year.

I've been workin' on this since I brought it home back in February. It's gettin' there but there's still some long days ahead.

Specs:
'94 3500HD. Originally a 159.5" chassis- shortened 28" to utilize a pickup bed.
'93 Cummins engine, Getrag trans, NP205 transfer case
Dana 60 front with 8-lug 19.5's and 4.10 gears
Dana 80 rear, re-geared to a 4.10
Full 4" turbo-back mandrel bent exhaust

The day it was brought home


The rockers and cab corners were perfect, but the vinyl covering had "had it's way" with the floor, as usual Just yesterday I had put down a very thick layer of a two part urethane bed liner, so after the 18 hours of prep work I'm hoping that last the life of the truck body. I still have to get pictures of the finished product.



So after the floors had been welded up, I had set the engine and built mounts. I used the factory dodge mounts, which, when trimmed fit perfectly into the frame. I built a simple trans crossmember out of some angle, 1.5" DOM and a Chevy 4x4 trans mount.



Then it was on to the core support. I used the Dodge radiator and intercooler. The HD core support really lent itself to the use of the Dodge pieces. I still have to take a pic of the intercooler mounting, but I used the Dodge pieces cut from the Dodge core support to mount the radiator in the Chevy support.





So once the hard work was done on the front half, I moved to the rear. I moved the rear end up 28" by cutting the rivets and using 1/2" hardware to re-attach the spring perches and overload stops. Then I fabbed up some bed mounts out of 1.5"x 3" tall rectangle tube. Luckily, the cab and chassis rear axle is only 10" overall wider from outside tire to tire than a single wheel bed. Bushwacker came to the rescue with their 5" wide cut-out flare, which made up the difference perfectly.


Then comes the 4wd conversion. I used a Dana 60 front from a '79 Dodge W300. With it's 32.5" spring pad width, it was a direct bolt in with the HD leaf sprung front end. I'm not too happy about the height gain, but for the direct bolt in, and leaving the engine crossmember alone, I can live with it. I also used a crossover steering arm on the 60 to keep with the same steering set up these trucks come with.


And with all that, comes to where I'm at now. The part in the build with the 1000 little things to slow down progress.
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Old August 12th, 2010, 07:52 PM   #2
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its tall but looks good should tow anything you want pritty easiely
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Old August 13th, 2010, 05:17 PM   #3
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I love everything but the mirrors. If your going to be pulling an enclosed trailer or someting, I understand, but they are huge.
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Old August 13th, 2010, 05:18 PM   #4
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Quote:
Originally Posted by rpratt View Post
I love everything but the mirrors. If your going to be pulling an enclosed trailer or someting, I understand, but they are huge.
yea i think i would look into a set of towing mirrors off the new GM hd's might take some work but ill bet they'd mount up
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Old August 13th, 2010, 06:05 PM   #5
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Yeah, the mirrors get a lot of hate, but they're handy. This truck will spend 50% of its time with a 30ft Gooseneck hooked to it. (yes the GN fits with the bed rail height )
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Old August 13th, 2010, 06:22 PM   #6
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Nice job!
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Old August 13th, 2010, 08:20 PM   #7
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Looks good. I kinda like the mirrors.
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Old August 13th, 2010, 11:05 PM   #8
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Cool truck... Was it a gasser to start or diesel?
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Old August 13th, 2010, 11:14 PM   #9
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man all of kables trucks are wasted
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Old August 14th, 2010, 09:04 AM   #10
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Originally Posted by boggin-machine View Post
man all of kables trucks are wasted
No bullshit there! This had a 6.5 with 92k miles and they put a rod thru the pan, ripped the pan from one side clear to the other. I got this and it had been sitting for 4 years in the yard across from their shop.
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Old August 16th, 2010, 08:22 AM   #11
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the more i look at it the more it reminds me of the big international 5500 and those alike
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Old August 16th, 2010, 09:49 AM   #12
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Got the new inter-cooler in. Today I'm ordering a new fuel tank, and going to start installing sensors for all my gauges in preparation for wiring. I've got a universal 12 circuit harness and Autometer gauges to replace all the factory shit. I've also got an aftermarket heater to replace the factory unit, I'll probably mount that up today too.

Pictures to follow.
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Old August 22nd, 2010, 11:26 AM   #13
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New fuel tank and mounting hardware is here, waiting to be installed.

Everything under the hood is wired up, and the steering column. Gotta get a battery mounted, and once that and the fuel tank are done it can be fired up again.

On the fuel tank I have to move the filler to line up with the fuel filler location in the bedside. I'll probably just weld in a piece of 2" 90* exhaust tubing. It'll have to be mandrel bent 'cause that #2 diesel comes out of that pump at the fuel station fast.
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