Thunder: a 2003 Tahoe build

[Tonyrodz]

started out trying to find the extent of the damage and started got the grinder and flap wheel out.
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Knocked out a bit then went to scrapers to remove a larger amount quicker. It was 1/4” deep in some places!

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Hand made some outer skin pieces also

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one of the Mount holes

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It's nice when you can do your own rust repair.

 

[outcast99]

I pretty much have to, no shop in town will touch it “it’s a liability” or some ****…

anyways, passenger side is done except for the finishing body work. This is a lot of work… I got a 6’x8’ fireproof blanket that I’ve been putting inside to protect my seats and stuff.






the pieces that were cut out. The one on top, I thought I got all the rust, but looking at the backside of the metal, I missed some so I got the rest in another sliver out.

 

[outcast99]

Still doing rust repair, slowly. In the Meantime I’m building my stereo system with 4 Skar EVL 12, Taramp MD8000.1, and a Taramp 800x4 for components

The box a Buddy designed and is building for me

My cousin insisted I need a custom bass knob so I chose Gizmo

Shipment 1, 50’ of Sky High oversize 1/0, some brass lugs and shrink tubing, 6 lug battery terminals, dual 1/0 amp inputs, and some waterproof grommets

I’m using Ogre 1/2” techflex on all my 1/0. This shows 2 out of the 4 new subs in. I had 2 used ones in a ported box and someone scooped that up with my old RP2000 amp for little more than I paid, so I’m buying 2 more new 12s so they all break in together.

Box builder sending updates. this is port wall and dividers going up. I like how he’s taking his time to router the ends

 

[outcast99]

Box walls going up

Meanwhile I also installed the torsion bar keys, chopped a coil off the back and I like it. It’s still fairly smooth, the back is noticeably higher but I figured once I add 150lbs of subs, sub box, amp and wiring… should be close to 800lbs to squat the back a bit more leaving it close to level

 

[outcast99]

Box is now done and installed with 4 Skar EVL12s

 

[Rocket Man]

Moving right along. Take that thing out in the desert over there and crank it up- you’ll hear it for miles.

You realize you probably won’t be able to keep any bondo attached though, right? Gonna punch it right off with those Skar’s.

 

[outcast99]

So the box sounds amazing, but I noticed the holes for the subs were cut out too large. Rather than bills another full baffle, the builder CNC’d up a piece of 9 ply maple and then made some recessed sub mounts.

Here it is at pick up, looks amazing

Used some Unicorn SPiT stain to make it stand out. Here is “Dragons Belly” and “Lavish Lovebirds” on the piece. I put a Skar sticker down first and stained over it, Peeling it after I was done.

That wasn’t enough gloss for me or protection so top coated with bar top epoxy. In the epoxy I mixed additional “Lavish Lovebirds” in for more flake. First later was good but the second coat made it pop.

So now I’m going to build a base for the box to bolt to, then it’ll be going back in.

 

[outcast99]

On the Tahoe side, I noticed some rust creeping in here n there, as well as clear coat peel. Already planned on repaint but I still have more body mods to do. Found a clean parts Tahoe so I scooped it up cheap.

Straight clean doors, hatch, and a front clip that will set me in a alternate direction.

So now I have a new plan.

Drop the back end more
Shave the green hatch off the wiper, wiper rest, and squirter (less rust)
Escalade d pillar covers
Throw the black doors on
Cat eye swap
SS bumper and grill
New headlights
TBSS wheels or something light like Cosmis
Reupholster front seat bottoms
Replace dash top
Debadge and remove moldings
Repaint rear quarters black
New license plates to say EVL HOE

 

[outcast99]

Progress pics. My doors had the delamination rust at the bottoms, the driver rear window wasn’t working, and the mirrors were bad so they got swapped also.

Here’s first fender on

Full clip on

Nicer doors on

All in all it was a fairly easy swap. I’m gonna throw a thick fender washer to space the bumper up some here soon to tighten that gap. I have new headlights, grill, and bumper cover coming.

Today, I will be demolding and debadging the black doors, putting my subs back in also

 

[outcast99]

Well I suck at replying…

Here’s the update! We moved into new home we are buying, 2017 stick built Hayden home so that’s been taking my time for the most part.

On the Tahoe, I’ve managed some stuff also though.

The led taillights decided to exit stage left thanks to the subs breaking the tabs. They might’ve been loose or something too though. All I know is when I pulled in my brother pointed it out.

Got the roll pan on, along with shaving the hatch of the wiper and wiper arm rest.

I needed time to do the rest of the roof, and start body work so I did the only thing a car guy seems feasible, bought another daily for my daily, to drive while my first daily is down.

2005 Sierra SLT. I took the push bumper, tool box, and running boards off for that clean look. Proceeded to raise the front a couple inches with the leveling kit, and take those cheap fake fender vents off also…

 

[outcast99]

A lot has happened and to save the boring story here’s a quick run down. The roof rust ended up extending further than I was oKay with, the windshield frame was gone, only held in by a seal. So I pulled my stereo, and sold it cheap.

I did go big on my Sierra though, 22x12, 2” spacers, 37x13.50, Move bumper, custom back lit pods and light bar

 

[outcast99]

In the spirit of going bigger though, I also picked up some super duty Dana 60 axles. These will be going under my truck soon so I needed something to drive while it was down. What better than another Tahoe? Found a nice (body and paint, no rust, interior needs typical Chevy Tahoe work) 02 Tahoe that I’m going to put my lift and wheels on, along with my unused 1.5” body lift from my Sierra. If it won’t fit the 37s decent I’ll drop to 35s, no worry.

A few pics

 

[Rocket Man]

So the Tahoe formerly known as Thunder went from a few paint flaws to completely rusted out? That sucks! Well now you got a nice Sierra, at least I hope so! I assume you’ve thoroughly checked for rust on this one?

 

[outcast99]

So the Tahoe formerly known as Thunder went from a few paint flaws to completely rusted out? That sucks! Well now you got a nice Sierra, at least I hope so! I assume you’ve thoroughly checked for rust on this one?

Yea the more I dug into Thunder the worse it got. They covered their tracks well with bondo and paint. This one is rust free. Minor surface on rear section of frame but I’ll be cleaning it up soon.

 

[outcast99]

Should I start a new thread?

 

[Rocket Man]

Start a build thread on your pickup. We love build threads!

 

[outcast99]

I took some time to think about life and what I want, and how these builds fit into it. Decided ultimately I’m happy with the Sierra height, I have a 1.5” body lift I’ll throw on it to stop the minor rubbing, and then just clean it up.

The Tahoe, Neytiri, has parts ordered and arriving daily almost.

 

[outcast99]

All 4 wheels are here and 3 out of 5 boxes of the lift kit are here. I’m waiting on the other 2 boxes from RC that has to be sent back out, then I may powder coat lift parts. The tires haven’t even shipped yet. I’m going to order control arms, tie rods, hubs and 07 CV axles next

 

[outcast99]

So FedEx lost 2 off the lift boxes, called RC and Chase sent them out no problem, huge shout out to Chase! The tires shipped yesterday and I got tracking info today.

They should be arriving tomorrow. I’ll mount and balance wheels/tires Friday if all goes well

 

[outcast99]

Well this pallet showed up today, looks like I mount them tomorrow ‍