97 tahoe 5 speed swap

[87carl]

Still haven't had any time to work on this project lately but my hours at work are getting cut back to 8 hours a day so I should get back to working on it soon. But plans are changing. She still is getting the 5 speed swap but I got an 87 parts truck yesterday. 87 is square body which has solid axle this truck has one soft spot in the frame but it's small and will be easy to fix. The Tahoe has atleast 5 rotted spots on the old frame so this one will be alot easier to repair. And my motor and 5 speed will bolt rite in this frame. I will have to change the input shaft on the 87s transfer case to 32 spline so it will bolt to the 5 speed. I need to use that transfer case because it's passenger side drop. It is a np208. I plan to start by stripping every thing off this frame so I can box it and fix the rust. Then I will set up the suspension I plan to use the 52 inch rear spring from the Tahoe in the front that should give about a 4 or 5 inch lift. Then I will use the 64 inch rear spring from the z71 and do a shackle flip which should also lift the rear 5 inches and add a couple leafs to each spring pack not alot only one or two I don't want it too stiff. After that is done i will bolt the motor tranny and transfer case together on the frame then after I get the Tahoe off her old frame I will cut the body mounts off that frame and bolt them back on the body and set to body on this frame measure from every angle possible so I know it's square and build whatever brackets I have too to connect the body mounts to the frame. The front of the 90s frame is same width as 80s frame so I was thinking maybe cut the front were radiator core support and bumper bolt on off the Tahoe frame and weld it into the 80s frame but might wait see if I can think of any other ways to do that when I get to it. 3 areas that will need to be figured out still are 1 fuel tank 80s tank is too far forward and can't use hoes tank because this frame is narrower. Was thinking maybe an 80s suburban 35 gallon fuel tank those sit between the rear frame rails I so all I would have to do is build a mount for it. 2nd issue is 4wd shifter linkage the np208 link is on the passenger side and has to move sideways slightly before going into high range I will wait till I have body on to figure that out. 3d issue steering the collumn and steering box should line up close and the 90s steering column will fit onto and bolt to the 80s steering box input shaft but 90s columns are longer then 80s columns so idk if that will need to be lengthened or shortened yet.

Oh and did I mention this parts truck was free and it's motor runs and transmission is good so I can sell them for a profit to help offset the final cost of this project which so far ain't much

 

[Dneel81]

This thing just got real. If you want to keep things simpler, I ford Dana 44 or 60 is driver side drop. That way you can keep the NP241 transfer case where it is and the tranny will be a mate (obviously). You'll have to switch out the hubs to keep your 6 lug configuration but it's doable. The driver side drop is the toughest thing to keep because the ford dana solid axles are tough to find. It might be easier to figure out your mounting cab to frame issues then keep the stock xfer case and cut up the right side of the hump and just plate off the driver's side xfer case hole you have now in the truck.

Also, are cabs that tough to find where you are? I know this square body is free but it's going to induce lots of work when it's all said and done.

I'm following you either way

 

[87carl]

Ford axles can be hard to find I can get 32 spline input shafts and a bearing kit for the np208 online pretty easy 90s chevy frames that aren't rotted or cracked are impossible to find around here and usually if you can find one there not cheap and you still have independent front suspension. When I build body mounts I will build a body lift into them so the floor of the Tahoe will clear the transfer case. Yeah it's alot of work but I like this kind of work and fabrication. Plus I set a goal of no more than a grand invested in this project after subtracting out what I make selling extra parts. I can afford to spend a little more if I have to but I am hoping to keep this project cheap. That's of course not factoring cost of tires that will be at least another 1500 bucks I want to run 35s maybe 37s. Even tho I want to keep the truck cheep I will replace all joints and bushings and shocks and motor mounts and new brake and fuel lines

 

[Dneel81]

cool beans. I would struggle with the fabrication aspects of the build since I have no abilities there. Not your scenario. I'm interested in seeing what you come up with. Good luck!

 

[87carl]

Thanks fabricating ain't to hard just as long as you go slow and take a lot of measurements. The massive cut in my hours at work will leave me with alot of free time to work on this hopefully I can get it done before summer ends.

 

[87carl]

Thanks fabricating ain't to hard just as long as you go slow and take a lot of measurements. The massive cut in my hours at work will leave me with alot of free time to work on this hopefully I can get it done before summer ends.

 

[87carl]

Thanks fabricating ain't to hard just as long as you go slow and take a lot of measurements. The massive cut in my hours at work will leave me with alot of free time to work on this hopefully I can get it done before summer ends.

I got a question on steering. On 80s trucks if you lift them more than 4 inches without modifying the steering the steering links will limit your suspension articulation. That I know from previous projects. Most people use a crossover steering or a I can't think what it's called not the u shaped peice that bolts on top of the knuckle well that peice but modified to allow steering to work with the lift. I have a very different idea. Kinda along the lines of a high steer system.

My plan is to use the steering system from one of the 90s trucks. The steering box sits inside the frame rails and connects to a center link and the other side of the center link is held up by another thing I can't think of the name of tonight on the inside of the passenger frame rail. Then tie rods connect the center link to the knuckles. The inside of the frame rails there are 24 inches apart. Were the knuckles are connected to tie rods is 58 inches apart. On the 87 frame inside of frame rails is 23.5 inches apart knuckles also 58 inches apart. Has anyone ever seen anyone try this? Does anyone think it will or won't work if so why you think that? I was already thinking about welding the front about a foot of the 90s frame onto the 80s frame then my bumper radiator core support and steering will all bolt on. Then weld the front spring perch onto that. I got to move the spring perch forward 2 inches anyway to mount the 52 inch Springs.

 

[87carl]

My phone is retarded lol posted one post twice then put it into next post

 

[87carl]

A drop pitman arm for an 80s chevy is 112 dollars and a raised steering arm (curved peice) is only 50 bucks so less than 200 bucks to get steering back to stock 80s geometry. That's easiest and cheapest solution so that's probably what I will do.

 

[87carl]

Finally got the hoe lifted up and the auto tranny pulled a guy said he will call tomorrow to set up a time to get it. Haven't talked price yet I had it advertised at 500 as long as I get atleast 400 for it I will be happy lol
So that's one part out of my way tomorrow I work 330 to noon after work I got to put up a door on the chicken coop then I will try to pull the motor and cab off the 87 frame. then I will move that over in front of the barn were I can reach it with the welder so I can start working on that. In a couple weeks I will buy some 3/16 plate steel to use to box the frame. I will plate the rusted spot on the inside of the rail to fix that. I will plate both sides there because that's were the front rear spring perch will be when I move it for the 63 inch Springs. I have been searching online you can get 4 37-12.50-16.5 military surplus tires for 500 bucks so that is what I will get I just need to find 6 lug 16.5 rims summit racing has them for 95 each but hoping to find some used somewhere. Also I might have a buyer for the motor from the 87 already, a kid I went to school with was asking about it. So I set an 80s hood I had laying around on it to keep it dry

 

[87carl]

I bought the frame and fuel tank from a k5 blazer if the rain ever stops I will pull the steering box of my 87 so I can bolt it onto the blazer so I will be able to steer the blazer when I tow it home I am only keeping the frame and fuel tank everything else I will take back after I pull it apart.

I will weld the cross members that the fuel tank bolts to, into my 87 frame. The forward spring hanger for the rear Springs from the blazer will be welded onto my 87 frame as shackle hanging brackets for the rear Springs that's the easiest way to do a shackle flip. I found some longer shackles made by rough country there designed to lower a 2wd 80s chevy 2.5 inches but with a shackle flip they will raise my truck 2.5 inches actually they will raise it almost 4 inches because stock 2wd shackles are already 1.5 inches longer than 4wd shackles. Plus a shackle flip usually gives about 4 inches of lift so that's about 8 inches lift total. Those shackles are only 50 for a pair. The rest of the blazer frame will be stripped apart so that all that is left is the c channel side rails which is what I will use to box the 87 frame the drivers side rail will become the inside of the passenger side frame and vice versa I will cut them in sections so they fit tightly between cross members and slide them in so the top of each sections c sits on top of the old frames c. And the bottom of the sections c will sit inside the frames c on top of its bottom then they will be fully welded in. Figured that would not only be a cheaper way to box the frame but it will be easier and stronger by having the tops and bottom of the frame doubled.
I started pulling the 87 apart but haven't made a lot of progress yet lol

 

[87carl]

Just dragged the blazer home the fuel tank and front of the frame will work with my plan but from the forward spring perch on rear Springs back frame is completely different from the 87 truck. Idk if it's because it's a blazer or because it's a 1990 but the rear spring hanger is the same as the Tahoe and z71 not the 87 truck? So I still got to find one of them and the rear section of the frame from an 80s truck.

The only problem with this fuel tank is that it's filled from the passenger side the hoe is filed on drivers side. Idk if can turn it around or just run a long hose across to it? Idk will have to think on that maybe just use this tank for mock up then try to find one that fills on drivers side if there is any. Other question I have is has anyone seen a duel shock setup on an 80s chevy that one's new to me. They both mount to same bolt on the axle but the more inboard shock mounts to frame a couple inches forward of the other one forgot to take pics of that will get some tomorrow after work.

 

[Dneel81]

hows this madness coming? Seems with all the work you're capable of, it would be easier to just fab up some shackle hangers?

 

[87carl]

Summer has been busy. I have been doing 70-90 hours at work every week since end of may. Gotta love farming. so haven't had time to do much at home all my time off work is spent playing with the kids or sleeping lol. I did Get the 87s extra parts off and the z71 got completely stripped and a lot of it has been sold piece by piece. Cold months are starting so hours will be going back down to 40-50ish soon hopefully I can get back to working on it. I also got too throw a motor in my subaru this winter. she died again couple months ago. I am still trying to decide what to do with that. tired of wasting time and money on subaru engines only thing I don't like about the car.and I have a personal attachment to that car so she will get something gm under the hood.

 

[#1taho]

Summer has been busy. I have been doing 70-90 hours at work every week since end of may. Gotta love farming. so haven't had time to do much at home all my time off work is spent playing with the kids or sleeping lol. I did Get the 87s extra parts off and the z71 got completely stripped and a lot of it has been sold piece by piece. Cold months are starting so hours will be going back down to 40-50ish soon hopefully I can get back to working on it. I also got too throw a motor in my subaru this winter. she died again couple months ago. I am still trying to decide what to do with that. tired of wasting time and money on subaru engines only thing I don't like about the car.and I have a personal attachment to that car so she will get something gm under the hood.

I would like to see what you do. Post up some pics when your done