Rocket Man's 02 Denali Build Thread AKA "THE BEAST"

[Rocket Man]

Hard to tell from the pics--Was it scratched up?

Idiots put tint on (and it was a terrible job) even though it’s already privacy glass. You can see what’s happening to the defroster grid as I started pulling the tint off. I mean, it had one broken and missing defroster tab which to me doesn’t give it an A grade to start with but when you combine that with a shit tint job that destroys the entire grid as it’s removed...reminds me of the console fiasco for my Silverado which after 2 consoles they just gave the last one to me and refunded all my money.

 

[Dantheman1540]

Idiots put tint on (and it was a terrible job) even though it’s already privacy glass. You can see what’s happening to the defroster grid as I started pulling the tint off. I mean, it had one broken and missing defroster tab which to me doesn’t give it an A grade to start with but when you combine that with a shit tint job that destroys the entire grid as it’s removed...reminds me of the console fiasco for my Silverado which after 2 consoles they just gave the last one to me and refunded all my money.

Sounds like that same experience I had with HD grill and bumper caps. I still have a brand new HD bumper cap in the box they sent me an extra for my trouble.

Their profit margin must be ridiculous for them to be able to make money with that type of service.

 

[Rocket Man]

I found the leak in the intercooler reservoir just by adding some denatured to the tank and holding it up. It’s dripping from the seam at a mounting hole. I thought that’s where I saw it coming from when it was in the truck. Bummer. It’s in a bad spot. I can’t see in there, can’t shine a light in there even. My only shot is to try the Fusor using a new mixing tip that almost reaches that place from the fill hole and hope it flows enough that gravity will let it fill in that bottom area if the tank. I’m not feeling too confident though. I don’t think it can be fixed from outside. I’ll give it a shot and if the Fusor doesn’t work I’ll order the kit from Whipple.

 

[Rocket Man]

Ok, I used the last of my Fusor. I swished the interior with denatured and drained it twice, then used a heat gun to dry the hell out of it on the inside and outside, then shot the Fusor down into that area while that corner of the tank was pointed down. Then quickly I heated the interior and exterior in that area hoping to make it flow better then swung the tank like a crazy man hoping centrifugal force would help, then put the cap on and plugged one hole and blew in the other as hard as I could... all in the course of a minute and a half or so which is the working time of the Fusor. I feel like a nut. I can’t even see if the stuff went down into the right place to fix it. I’ll let it sit for the rest if the day even though it hardens enough to sand in 10 minutes.

 

[05Single]

Why did you add Flex Tape? Fusor doesn’t need that. I used their 142 Plastic Repair on my custom cluster bezel for structural and their 114LG Finishing for feathering. And I have bent and twisted that with no cracking or separation. The stuff is awesome.

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Honestly it’s my first time using it so I wasn’t sure. A lot of stress/ bouncing/ vibrations in that spot all while holding the fog light horizontally on the valance. The tape gave a cushion to make it snug in the hole. Anyway I usually over engineer things , it’s in my nature lol. No harm in that

 

[Rocket Man]

Looks like the Fusor hit the right spot. It doesn’t leak using the nonpressurized test. I cleaned the tank out and mounted it so tomorrow I’ll fill it up and pressurize the system. Fingers crossed.

 

[05Single]

Looks like the Fusor hit the right spot. It doesn’t leak using the nonpressurized test. I cleaned the tank out and mounted it so tomorrow I’ll fill it up and pressurize the system. Fingers crossed.

That’s how it’s done. Cheap and easy fix

 

[PG01]

That’s how it’s done. Cheap and easy fix

Except for reds torn rotator cuff now...

 

[adventurenali92]

Curious to know why the switch to the 2005 hatch? Hinges spreading from the glass on yours? Sucks that you gotta send it back. Lame that it was screwed up.

 

[Rocket Man]

Curious to know why the switch to the 2005 hatch? Hinges spreading from the glass on yours? Sucks that you gotta send it back. Lame that it was screwed up.

I think it’s a cleaner look with no surround at the sides and bottom. Mines fine except I can’t seem to find the break in the defroster grid that’s keeping the top 1/3 from working. I don’t care for the Esky one with the huge 3rd brake light and this one you don’t see very much. It’s the one with the wide appliqué at the top that was on only some of the 05-06’s. It’s this one, pic is @JollyRoger01

 

[adventurenali92]

I think it’s a cleaner look with no surround at the sides and bottom. Mines fine except I can’t seem to find the break in the defroster grid that’s keeping the top 1/3 from working. I don’t care for the Esky one with the huge 3rd brake light and this one you don’t see very much. It’s the one with the wide appliqué at the top that was on only some of the 05-06’s.

Yeah my 2006 had that one stock when I bought it. I do like the no surround On the sides and bottom as well. But I hated that the handle stuck in the middle of the glass at the bottom. It trapped so much crud in the winter. I did hate the big black plastic trim at the top. Lol. I do wish that there’s a way to make my esky third brake light fit onto my original Yukon hatch. It’s in better shape and the 2004 esky hatch that I have, one hinge is slightly separating from the glass. But oh well. Lol

 

[Rocket Man]

Yeah my 2006 had that one stock when I bought it. I do like the no surround On the sides and bottom as well. But I hated that the handle stuck in the middle of the glass at the bottom. It trapped so much crud in the winter. I did hate the big black plastic trim at the top. Lol. I do wish that there’s a way to make my esky third brake light fit onto my original Yukon hatch. It’s in better shape and the 2004 esky hatch that I have, one hinge is slightly separating from the glass. But oh well. Lol

I haven’t decided but I might CM that top trim. I have paint and clear left over from doing my handles.

 

[Sam Harris]

Got the hatch glass. Returned the hatch glass. Ordered another hatch glass. I don’t know how LKQ makes any money.

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Damn. Wtf..?!

 

[Rocket Man]

Ryan at Performabuilt got back to me about the 1-2 shift. They purposely softened my 1-2 shift with a softer spring in the accumulator valve in the valve body he said, and should be way easier on the hard parts. It shifts smooth and fast, I like it. It has always kind of made the truck shudder under WOT on that 1-2 shift and even under moderate acceleration it hit real hard. It was kind of fun but I can see how it can be ******* things.

 

[Rocket Man]

The tank hasn’t leaked today, I drove about an hour and no drips. The new back glass came in so I picked it up but this time I opened up the package and inspected it first. The only slight imperfections are some light scratches on the exterior; the defroster grid looks great. The trim had some slight discoloring so I’m painting it and the handle satin black. Changed the oil today too, the oil life monitor said it’s time after less that 3k miles, might be the way I drive lol.

 

[Dantheman1540]

Hey I know the 60E is fresh and working good hopefully for many years. But I see a guy is gauging interest on the Adapters you would need to 80E swap. Figured I'd let you know. https://www.performancetrucks.net/f...-adapters-considering-doing-small-run-557247/

 

[Rocket Man]

Hey I know the 60E is fresh and working good hopefully for many years. But I see a guy is gauging interest on the Adapters you would need to 80E swap. Figured I'd let you know. https://www.performancetrucks.net/f...-adapters-considering-doing-small-run-557247/

I have been following the original maker of these for years. Last I saw he was still doing it. I have resisted doing the swap for a few reasons, one being it’s my daily and I don’t want it down for long. But I also kind of crossed that bridge when I originally made my decision to go with a Performabuilt trans and spent about 5 grand between it and the converter which would be a total waste if I changed my mind now. It would basically be an 8-9k cost or more, throwing away the 5k and costing another 3-4K for another trans, converter, adapter, etc. I mean, I could sell the 60 but not for anywhere near what I have into it. I think with what they did to it this last time with the 1-2 shift I should be good to go. Thanks though.

 

[Rocket Man]

I repainted the trim in matte black, popped the glass on, and immediately decided to CM the trim. I’m sanding the texture off it and will get it painted and cleared today. I think it will look sweet.

 

[Rocket Man]

Ready for tomorrow.

 

[Rocket Man]

I was afraid this was gonna happen- way back when I originally had the Esky appliqués CM’d by a body shop, they looked too light. Now it looks to me like the trim on the glass is too dark also which combined with the appliqués is really noticeable to me. It’s weird though because the handle on the glass, which is from the same batch as the top trim, looks too light if anything, at least compared to the tailgate itself. Now I see why my buddy at his body shop has to blend everything when he paints anything on my truck. ( he didn’t have the truck when he painted the appliqués) The appliqués kind of need repainting anyway since they have some chips so I’m gonna repaint them and see how it looks and live with it. I painted the exterior door handles and they look perfect so I’m not sure what’s going on. I really like the new look though.