Project: 1972 502 HO 4x4 Suburban

[k5kev]

Well I actually started this project a couple years ago, but I thought I'd go ahead and start a project thread for it. I'll get you all up to speed where it is now and then start posting as I make more progress.

Started out with a 1972 3/4 ton 2wd Suburban. This is what it looked like just before I drove it to the body shop. I stripped it down about as far as I could and still be able to legally drive it down to the shop.






Instead of converting the 2wd chassis to 4wd, I bought a 4x4 truck frame and started building a 4x4 suburban chassis from there. This is the way to go when coverting to 4x4, especially since I was pulling the body off anyway. I put on 4" Tuff Country springs, a Dana 60 front, and a 14 bolt detroit locked rear.



More to follow........

[1956cameo]

Looks like an awesome project. Glad you got a good foundation to begin with. Definately keep us posted on this build. Not enough blazer and suburban builds on here for my taste.

Also I noticed all of the patch panels in the back of the suburban. Your project doesnt seem rusty; it really needs all of those panels replaced?

[k5kev]

Originally Posted by 1956cameo

Looks like an awesome project. Glad you got a good foundation to begin with. Definately keep us posted on this build. Not enough blazer and suburban builds on here for my taste.

Also I noticed all of the patch panels in the back of the suburban. Your project doesnt seem rusty; it really needs all of those panels replaced?

Yep, those are the patch panels I knew I needed before sandblasting it. It needed the normal 72 Chevy stuff: rockers, floors, front pillar, and kick panel patches,..... on both pass and driver side. Otherwise the rest of the body looked great.

As you'll see later I ended up needing even more patch panels after sandblasting!

[k5kev]

So then I drove the Burb to the body shop, were the pulled the body off the frame and took the front end off and apart.

Also had them build a tube steel dolly so the could move the body around and trailer it down to the sand blaster.

Here is the 2wd rolling chassis I've since parted out and/or scrapped.

[k5kev]

I'll continue on with the body,....

So the body went of to the sandblaster, and here is what she looked like when she came back,...along with some self-etching primer.

Firewall and interior looked pretty good, except the rockers and floors of course!





Passenger side looked awesome.



Roof looked real good.




And last but not least the drivers side was a mess!



By the way those are new door skins on both doors.

[1956cameo]

Don't you hate it when you find more body damage after the paint comes off? Still; from what I can see that is a great looking project suburban. Can't wait to see more progress of it. Quick question, when you took the upper chrome moulding off of the suburban. How did you get it off of the upper tailgate hatch. I cant see where it bolts in. Was it a glue on piece? Thanks.

[thirdstreettito]

Nice project!

[Hart_Rod]

Burbs rock!!!!!

[k5kev]

A few more pics of the Burb at this point of the project:

[ChaseDale3and8]

Great looking project! I really like that shade of blue on these trucks! ...Joe

[k5kev]

So now for the difficult body work. Here is the damage again on the driver's side,....pretty nasty. You may also see some of the layout lines for the patch panels. We are attempting to "Frankenstien" this side together with 4 patch panels. A long bed lower front quarter, a shortbed bedside, a lower rear Suburban quarter, and a Suburban tail light section.

[k5kev]

We wanted to get the body bolted to the frame before we started cutting sheet metal. Probably a good idea just so the body doesn't twist up or loose its shape. If we tried cutting it up on the dolly who knows what may have happened. So with the body bolted up he started cutting:

[k5kev]

Before I could get back to the body shop my guy already had the bedside patched welded up. I think it turned out pretty good.

[k5kev]

Then he buttoned up the lower rear quarter and tail light section:








and that's where its at right now. I dropped this thing off at the body shop a year ago. Its been a slow go, but hopefully six more months and I get it back with all the paint done. We'll see

[MrBeast]

Cool build, I am subscribed.

[MrBeast]

Just a thought, but have you test fit your fuel tank yet?

Also you might consider having your body man install the gas door out of a 88-98 pickup, it will look way cleaner.

[k5kev]

Originally Posted by MrBeast

Just a thought, but have you test fit your fuel tank yet?

Also you might consider having your body man install the gas door out of a 88-98 pickup, it will look way cleaner.

Since you mentioned gas tank let me share what I did. I know the stock gas tank capacity isn't going to cut it with a 502.

I decided to try and install a Northwest Metal Products 37 gallon tank for a 69-72 Blazer. As you can probably guess from my screen name I've got a K5 Blazer too, and its also a 72. I figured since the truck and suburban frames are close to the same, the Blazer should be too, and I didn't see why a "Blazer" tank wouldn't fit. As it turns out it does fit. I'll confess its slightly off center between the frame rails, and I sorta ditched the directions provided and figured out how to mount it myself. I don't know if this was due to it going into a Suburban, or just manufacturing variances from Northwest Metal Products. Again I think it turned out allright.

[LEEVON]

Better fill that puppy up while gas prices are low Love the build!

[k5kev]

Originally Posted by LEEVON

Better fill that puppy up while gas prices are low Love the build!

I know what you mean! Heck, by the time I get this thing on the road gas could be $10 bucks a gallon!

[msgross]

cool build..

[nuke1]

looking real nice and clean, job well done so far, what rims and tires do you plan on running?

[k5kev]

Originally Posted by nuke1

looking real nice and clean, job well done so far, what rims and tires do you plan on running?

Thanks for the complements and ecouragement.

I guess I'm kinda going with a semi-stock/resto-mod/sleeper look. Just drivetrain upgrades and mild lift. Also going with a stock interior,....3 rows of bench seats,....stock door panels etc. So with that in mind I'm leaning towards some stock steel wheels and chrome 3/4-1 ton hup caps, along with some Goodyear MTR's,.... 33's or 35's. Not sure if this thing is going to fit thru my 7' garage with 35's and a 4" lift, so that'll determine the tire size. Can't be leaving this baby parked outside with all that's invested.

[MrBeast]

Cool, and the upside is, that tank is a good ways forward, so if you should go through the very unfortunate experience of being ass ended, there is a much smaller chance of bursting into flames.

[FRENCHBLUE72]

Nice job job far..

[k5kev]

So finding a set of headers was a serious challenge,...BBC in a 4x4 frame with a SBC crossmemeber. GM Performance Parts tells you to use 2" primary and 3" collector headers for the 502HO. Not to many header companies make 2" primary headers, and I definately didn't want to choke down the motor with some 1-3/4", which everbody makes. I think just Hedman and Hooker make 2" BBC headers. I ended up going with Hedman. It still wasn't simple, I tried 4 or 5 different sets, and the only way I was able to make it work was by combining 2 sets. I used a 67 chevelle driver side and a 72 Chevy 2wd truck for the passenger side. Since Hedman sells a drivers side only for the 67 Chevelle, so I only actually paid for a set and a half of headers. I still also had to do some grinding to the frame to squeeze them in, and I shortened (cut and re-welded the flange) the driver side collector by about 4",...it was too long and too close to the trans crossmember,...not enought room to bend the exhaust pipe over the transfer case.