96 crewcab dually cummins swap

update time....

got my temp 4" downpipe made.... it will change when i upgrade to multiple turbos


installed... its tight, but it fits. it will get wrapped and i will build a carbon fiber heat shield... probably gonna be a good idea to step up to silicone heater hoses(good to 1200*... $150/20' roll)



i decided to not lower the motor and section the pan.... i think with the 05 gmc clip grafted on, i will be fine on hood clearance when i do the body drop. i did move it back a little bit to make room for the mechanical fan, which i am still experimenting with... turns out my fan hub is bent from the donor truck crash... and the stock cummins fan is about an inch too big to fit in the factory chevy shroud... but i like the factory look, so i was playing with other fans i had layin around trying to come up with a good solution.... nothin functional just yet.

mounts are .250 wall DOM, with poly bushings.... the rest is 1/4 and 3/8 plate. the stock 1/8" +/- crossmember was also plated, to help spread the load.






this is how the trans mount worked out..... unbolted the dodge mount from the trans, built a flat plate to bolt on... drill a couple holes for the chevy mount, and bolt it to the stock loaction trans crossmember.... i really like simple


got a few other obsticles out of the way, the powersteering pump has been a lil concern, so i tackled it this week also.... i hybrid-ized the dodged pump with the chevy res & swapped out the pressure spring... so in theroy the pump output should match the stock chevy system, and all the hoses will go on just like stock... no pics, its really nothing to look at.

glad to see your making progress man

Nice looking work on the engine mounts!

Something that caught my eye, I'd doubt you have 3.73's in the rear unless someone changed them. The most common gear you'll find (original) in the 14 bolt FF is 4.10. You could check the SPID label in the glovebox, RPO code GT4 would be 3.73's, GT5 4.10's. Of course meaningless if anybody has swapped the rear or re-geared it...

I like the 4WD/HD flares on the front fenders. They don't always look good on 2WD's but maybe they look right on yours because of the dark color and being painted to match.

Richard

gotta say i actually like the square mount a little better then my round ones though. You'll like those mounts. my truck barely even moves. like they were made for the cummins.

Where'd you find the interface pieces for your stock gauges? I need to get my gauges working.

Sucks your fan hub is bent. those things are pretty pricey. I need all the front pulleys and stuff off a dodge truck to run a mechanical fan because the freightliner stuff puts the fan up about 6 inches.

here ya go, you will also need a pulse generator for the speedo hook up on the trans. the tach will depend on what your FL motor has if anything, didnt the 6.5 have a tach drive alt??

and for the fan hub.... im gonna pull it apart and see if it is the shaft, bearings or ??? i may just carve out a billet alum housing that drops it another inch....so a stock cummins fan will work if the shaft is good.

the tag says gt5.... so it may have 4:10s, it just seemed like he rpms were low for the gear at 70mph.... of coarse i only drove it about 3 miles before i ripped it apart

im debating weather i should just run direct bolt 19.5's with a taller tire and keep the 70 in it for a while.... after a regear to 3:54's

yeah after you said that I looked. I sent them an email because the trans mph output would still be wrong if the truck was in over or underdrive. I asked if the tach sensor could be set up for a speedo sensor if i had a ring on the output shaft for the sensor to pick up a signal from. Not sure where the tach signal came from. that's all gone anyways. i'm using the alternator off the freightliner.

Wish i could make stuff from billet aluminum.

I think 19.5s look sweet but the tires are pretty tall.

honestly the only reason i go to my job..... is the cool tools i get to use to build my own stuff. in my own shop....other than the basic mig(s), tig, plasma... im slowly aquiring the "cool" fab tools... 12" engine lathe, 36" table bridgeport, and i just bought a cold saw.... the equipment is really cheap when you start figuring the tooling costs associated with each new "investment".

the last 6 months at work, i would guess i have ordered $20k+ worth of tooling for our newest 3 axis VMC... and we have 2 others. we just got a 42" swing bullard verticle lathe, my first thought was to grab some cracked 22.5's and start test cutting.... really dont have the time to "play".

so the relevance to the comment billet comment... if i thought there was a market, i would do an actual file and let the chips fly, but i can build a one off of a simple part like a fan hub way faster the old fashioned way.

and here is what i have for the tire sizes for comparison...

225/75/16 29.28" (truck tire)
225/70/19.5 31.9"(truck tire)
285/40/22 30.97" (suv tire)
285/35/22 29.85" (suv tire)

i personally dont like the rubber band look of the 35 series, so that leaves the 285/40's if i run 10 lug wheels, right now they just arent an option.... i dont want to do the rest of the mods to run them. so i give up (or gain) an inch of height with the bolt on 19.5's.... and i think for the time being, and my static drop, they will be fine

nice build! i love having a cummins in my crew cab the best thing i have ever done! i have 3.42 in my 14 bolt now im thinking of getting 3.21's from what i can tell the cummins sweet spot for mpg is around 1900rpms to 2200rpms after that mpg drops big time!

nice build. im actually in the process of finishing up a 93 crew cab bodyd on 22's with a lb7dmax, 04 gmc front end, 04 dash, cluster, dual climate control, steering column.

nice to see builds like this more.

josh