'99 Tahoe - Expedition Build!

[sparg93]

After quite some time planning and the last two months underneath the truck, we're finally getting close to finishing up our expedition build.

I've learned tons of information on this site, so I thought I would share what I'm up to with you guys!

Leaving towards the end of March, we are going on a multi-month expedition throughout the US, Canada and hopefully up to Alaska. On this trip, we are stopping off at a number of national parks, 4x4 events and even being FEATURED at the Overland Expo in May.

This is an offroad trip, so once we leave the east coast, most of the trek is offroad (agenda still to be finalized)

I'm not online as much as I used to b/c i'm literally under the truck 8+hrs/day, but I'll try to respond as much as possible.

Here are the plans for the vehicle:
1999 Tahoe 4dr 4x4

Truck Parts
14bolt semi float swap
4" IFS RCX Lift
Hydroboost Conversion
Custom fabbed tie rods - FFR Fabrication
HD Ball Joints - Synergy Suspension
Moog HD Pitman/Idler Arm
Pro Comp Extreme AT 285/70R17
Mickey Thompson 17x9
Custom rear bumper w/tire carrier - Do NOT purchase from Tactical Armor Group
Custom torsion bars (33% stiffer) - Sway A Way
Bilstein 5100 shocks (5150's were not valved heavy enough)
Vehicle mounted air compressor
Defender 6.5' roof rack
Samlex Pure Sine 1000w PST Inverter w/remote
Volant CAI
BlackBear Tune
12vot guy custom switch panel - AMAZING!
220amp alternator - Iraggi
x2 KC 130w on ARB Winch bumper
Body Armor (skid plate, frame sliders, tank protector, diff protector)
Larger trans cooler - still searching!
ARB front bumper - fitted by Liquid Iron Industries
ARB fridge - 60 Liter
35 & 55w HIDs w/4hi mod

Recovery Gear
Superwinch Talon 12.5k
Viking Offroad - Synthetic Winchline - A MUST have for IFS rigs
ARB 3" Tree Savers
Pull Pal - RW 14,000 model

Trailer:
LV416 Trailer
30 gallons water
20 gallons fuel
Holds lots of spare parts and equip

As I add more and finish up installs, I will update this first page!


Hydroboost Conversion w/PS Cooler - this is all new AC Delco components (base vehicle k2500)..PS cooler from '97 K3500

This was used to delete variable steering from PS pump - GM #19168825

12Voltguy Custom Panel

Mark VIII Efan - custom wiring setup to engage both speeds automatically

Volant CAI:

ProComp Extreme AT 285/70R17

Iraggi 220 alt - 180amp @ Idle!!!

14bsf 6 lug rear w/Blue Torch diff cover - COMPLETELY rebuilt w/Timken Bearings & Tru Trac

Updated Fuel Injector Spider

Timken Hub Bearing Replacement

Manifold Gasket Replacement (clean manifold!)

Plenum Gasket

Electric Air Horn - 300hz

Custom Trailer:

Interior

Trailer Bearing Lube

As you can imagine, I've also swapped out every fluid (trans, front diff, rear diff, transfer case, oil, coolant)

 

[edgaranah1]

Wow thats alot of modding. Looks good and keep em coming

Sent from my VM670 using Tapatalk

 

[WalterMitty]

Neat!

 

[AtomicHoe094]

nicely done. what did the Hydroboost swap cost? part numbers? and scale of 1 to 10 how well does that thing stop now?! haha

 

[01HDtahoeNJN]

Probably like 22 on a scale of 1-10 haha



-Garry (01tahoenjn)

Sent from my iPhone using Tapatalk

 

[sparg93]

nicely done. what did the Hydroboost swap cost? part numbers? and scale of 1 to 10 how well does that thing stop now?! haha

A ridiculous amount of $$ and it stops much better now. I don't have the part #'s on me, but i essentially went to rockauto, threw in '99 K2500 and bought:
x3 power steering lines, power steering pump, hydro unit, master cylinder, gm bypass, hydro pedal, 3/4t calipers, 3/4t pads (need to be shaved for 1/2t discs). None of the parts on your truck will work correctly with the hydro unit...some ppl make it work, but you will develop problems down the road (i.e. t-fitting off stock PS pump) if you don't swap everything.

I also HIGHLY recommend a PS steering cooler. I did a bit of research on the diesel forums and they were somewhat regularly exceeding the recommended temps on their PS fluid when they didn't have a cooler. For OBS, I believe only the k3500 had coolers...but they mount in the OEM location. OEM is $100+, but you can find a rail cooler for $30 from summit (just measure everything before you buy)

Sometime this week i'll do some actual stopping distance tests and release all the findings from vacuum to hydro

 

[AtomicHoe094]

yea ive seen the prices before and was pretty offended. haha But driving the work trucks hydroboosted van, damn that thing lcoks em up pretty good. I actually have a powersteering cooler from a 2000 tahoe limited.. looks exactly like yours

 

[SunlitComet]

hydro setups usually have a cooler installed as standard.

 

[sparg93]

for used units, I think its justchevy on ebay that sells working units. I bought my 14bsf from them and they remove good parts from wrecks and sell them...when i was the re, they have x3 complete setups for $150/ea....AND they save the pedal! (pedal took me months to acquire)

Sunlit - i thought that too about the PS cooler and found two types, frame mounted (actually inside the frame) and the one i have (mounted on the front).

---------- Post added at 09:39 AM ---------- Previous post was at 09:39 AM ----------

Atomic - I have sooo many parts you can buy off me for your collection!

 

[AtomicHoe094]

what kinds????

 

[noJeepshere]

I'm keeping an eye on this! I'd like to one day turn mu Yukon into an expedition/bugout rig, with many of the same mods you're doing.

 

[sparg93]

I can't really think of anything light enough that would be worth shipping....

Except of course for a near mint condition Denali console with all the buttons, cd player, sub and amp

---------- Post added at 10:07 PM ---------- Previous post was at 10:05 PM ----------

I'm keeping an eye on this! I'd like to one day turn mu Yukon into an expedition/bugout rig, with many of the same mods you're doing.

You and I have the exact same rig, if you ever have any questions about the wonderful nuances, just ask - as an example, the nut on the bolt that holds the break pedal in is welded!!

 

[AtomicHoe094]

howmiuch??

 

[sparg93]

Atomic - you got PM.

Some more photos for everyone!

Finished prepping and POR'ing the 14bsf - now I'm waiting for my Wagner severe duty shoes and I'll rebuild the drums and bend up some new brake lines.

before

after

Replaced the Compressor, drier and orifice tube...

After installing the new system, evacuating and filling with refrigerant...the high pressure relief valve went south...and I had to do it all over again!

I also installed a new idler pulley today and fixed my hi beam HIDs!

 

[AtomicHoe094]

nice work, are you also preparing for the world to end? haha

 

[_Dylan_]

I'm digging the hydroboost. I'd love to do that one day.

That trailer is pretty sick. How much does it weigh?

 

[sparg93]

nice work, are you also preparing for the world to end? haha

haha - you're not the first person to ask me that after seeing all this workl!

The trailer weighs around 2500 when fully loaded.

 

[_Dylan_]

Ever thought about swapping the trailer axle to 6 lug for 2 extra spares?

Looks nice so far.

 

[Monstar_est87]

Very nice... Im gonna have 2 do this 2 my LIMITED ... MADMAX edition...

 

[sparg93]

Ever thought about swapping the trailer axle to 6 lug for 2 extra spares?

Looks nice so far.

Yes I did...but from a cost perspective, I've decided to keep it as-is. i will have a bumper + tire carrier on the Tahoe that is carrying an extra spare rim/tire for the truck.


The trailer is also going to be modified to carry an extra tire/rim.

Very nice... Im gonna have 2 do this 2 my LIMITED ... MADMAX edition...

Go for it - and keep it lowered!