'89 3/4T 'burb front-end swap to '66 C20

[Hilandr451]

Well I know it looks like it but to be honest, this really didn't happen in 3 days - you see I started this part of the project over 2 years ago. I bought all the parts back in 2005. Then in 2007 I tore down that front-end, cleaned it and replaced all the bushings, ball joints & tie rod ends. I was in the process of putting it back together when I had what I thought was a stroke.

Turns out, I had an aneurysm on my aorta just above my heart. 2 surgeries totaling 23 hours, 15 days in ICU, for a total of 33 days straight in a stinkin' hospital bed, 2 months medical leave from work, a year of recovery, a bankruptcy and finally, I get to pick up where I left off before the operation.

Ironically, my progress is a result of the recession. The company I work for makes me stay home one week out of every month, so I finally have time to work on my truck!!

I'm broke as hell and if I hadn't bought $10,000.00 worth of parts back in '05 I would have had to sell or junk my truck months ago!

So if you really look at it, 3 months vs. 2 years - I'd say you're making a lot better time than me!

[jason65]

It looks good dude. Looks like your drinking my kinda beer to.

[Hilandr451]

Day 4: Grinding Screeching Halt (or "90 Miles an Hour Into a Brick Wall")

I spent 3 hours of my day chasing brake line fittings, a power steering return line and lug nuts. Then, while I was running the tubing for the fronts, I thought I'd dry fit the power steering pump so I could know where not to route my lines.

Big surprise! Even though the newer generation 5.7L (a.k.a. "metric 350") is drilled for the old style power steering bracket, it won't fit because the harmonic balancer interferes with the bracket. What I didn't notice was it's 1.25" larger than the old 350 I pulled out.

Now I need to make my way out to P-N-P tomorrow and see if that p/s pump I yanked is still sitting there on that truck I saw 2 weeks ago.


I did get the front brake lines in. I installed an inner fender so I could get the lines where I wanted without interfering with the fender when it comes time to replace the "dog-house"


I had to get creative with the brake hose feed-through retainers - turns out nobody in the world carries these. I know, I looked!


I was able to put the new shocks on too. I ran the back brake line across the back of the cross-member (not shown 'cause I'm too fat to get a picture of it) to the last run up to the proportioning valve. The line I bought for that is about a foot too long. I'm buying a shorter one tomorrow.

I'm pooped!

[816allen]

Dam man lookin good real good!

[66GMC-Canuck]

Really nice work.

[Hilandr451]

Day 5: Slowly but surely making progress. or "One step forward, two steps back."

I spent 3 hours at the junk yard today picking through Chevy trucks looking for the right power steering pump set up. I pulled 3 pumps all with different bracket arrangements. I finally found the one I was looking for: the pump is swung off of the water pump.






This configuration will not work with the '66 p/s pump because the harmonic balancer won't allow the lower bracket to bolt on the block. So....




I had to buy another power steering pump, with brackets, and a tall water pump with alternator brackets & all the pulleys to go with the new configuration.





That brings me to the missing bracket. I couldn't find this bracket anywhere, so I had some 2-1/2" x 1/4" flat bar lying around and decided to make my own bracket for the adjustment bolt on the new p/s pump.



First the cardboard mock-up....



Then the bracket dry fitted in place. This will be the new configuration.



Although I don't particularly like the alternator on the passenger side (gonna be a pain in the butt when I install A/C), This configuration does allow me better access to the p/s pump and belts should be a breeze!

There was a silver lining today; the p/s pump I picked out ('75 C20) just happens to have the same guts as my '66 so I can still use the re-built pump I bought at Napa! I saved myself $55.00!!!

I took the case apart of the late model pump, cleaned it & painted it. I also spiffed up all the bolts, brackets & pulley wheel. They should be dry and ready to re-assemble tomorrow. While I was at it, I painted the water pump & the new adapter plate I made too.

[joe231]

looking very nice!!

[Hilandr451]

Day 6: Back in the Groove (or "Where the heck was I?")

The day went pretty good, I started the day by sitting at the bench swapping the re-built innerds from my old style p/s pump over to the cleaned, prepped & painted used one I pilfered the day before. Then it was all about geometry.

But, by the end of the day, I had cleared the back bench of "parts what needed to be put on" - and that's always a good thing!


I still need to position the idler arm, drill the holes and mount it. I'll measure everything up tomorrow & nail it down.



All the brake lines are secured & tightened, the power steering lines installed and the huge 1-1/4" sway bar is in!!!!




Another look at that hefty sway bar with the brand new blue neoprene bushings!!! That truck ought to corner beautifully now!



Here's the current configuration - the p/s pump is on the inside or middle pulley, and the alternator is on the out side pulley. I think I'll drive the water pump off of both belts for redundancy.

[Eagar1]

This set up looks interesting, makes filling the pump easy.

[ChiefRocka]

Originally Posted by Hilandr451

Day Two Continued:


Removing the dirt was easy - I just transferred all of it to my body! My wife tells me I'm a dirt magnet & I guess this is proof!





Oh & just so you know, you do need your beauty sleep.

YOU GOT THAT RIGHT !!!! Now why is John so clean and Greg so dirty...get off your a$$ and get to work !!!!

Originally Posted by Eagar1

This set up looks interesting, makes filling the pump easy.

Sweet....I guess you could use the Marine stuff

[Hilandr451]

Day 7: Git-'er-done! or ("This is Going to Really Hurt Tomorrow!")

Today was all about tightening your guts out while laying on your back, up & down exercises and crap in your eyes. While I had just a little bit of fabricating to do, alternator bracket spacer, welding the steering shaft, etc., the bulk of the day was spent tightening, bleeding & lubing.

How to position & mount the Idler arm:
First, center the center link between the frame rails while securing the idler arm to the frame using a welding clamp.



Measure the driver's side inner tie rod end out from the cross-member and down from the frame.



Then transfer that measurement to the passenger side by moving the idler arm around on the frame until the two sides are equal.




Mark the holes and drill. Use grade-8 3/8" bolts, nuts & washers to fasten it permanently.




There it is - wheels on & down from the stands. For the first time in 3 years this front-end has the full weight of a truck on it. Cool!!

[Chevy Fleetside]

Originally Posted by ChiefRocka

YOU GOT THAT RIGHT !!!! Now why is John so clean and Greg so dirty...get off your a$$ and get to work !!!!






Sweet....I guess you could use the Marine stuff

I know how to work and not get dirty.

[ChiefRocka]

Looks great Greg !!!

Do me a favor...can u spray a little paint on that crank pulley...its really bugg'n me.....

[Hilandr451]

Originally Posted by ChiefRocka

Looks great Greg !!!

Do me a favor...can u spray a little paint on that crank pulley...its really bugg'n me.....

I will as soon as you squirt a little paint on yours!

[Hilandr451]

Day 8:

The Big Finish (or Gotta Get it Done Today - I have to Work Tomorrow!)

The day started with a hot bowl of steel-cut oats and that was just the fuel to put a head of steam into the task at hand. We bled the brakes again - 3 times. Then backed 'er down the driveway to put the dog house back on....


John the shot hog...



Ali-oop! This wasn't as easy as the guys on "Trucks!" made it look...I smashed Johnny's hand putting the isolators under the core support. But then I sliced my fore arm open while trying to mount the fan shroud.


There! you... can't tell we did anything to it. All that hard work covered up by sheet metal.

Small note here: notice the missing bolt on the driver's side bumper? That's because the REZ kit we installed to upgrade the steering interfered with the bumper outrigger. We'll need to do some adjusting to get that part to fit there.



You can see a little bit here, if you really look hard...



You can see a little bit here, but not really....




Here's the Swap Meet / Scrap pile! This is everything we replaced on this build - cool huh?




Ahhh there now! You know, there ain't nothin' like a clean shop after a build.....

What's next you ask???

I think it just might be time for....
Phase 3: Pullin' up the Rear!
New Shocks, New Springs, new rubber bumpers, New Trailing arm bushings, panhard bar bushings, bed wood, bed rails & hardware!

[joe231]

the question remains.....
How does it drive now?

[Hilandr451]

How does it drive? hmm..... well, with the big fat sway bar it corners like a car, what used to take 3 turns of the wheel now takes 1, the squeaks, rattles & pops are all gone, the suspension is tight like a new truck, the steering is so responsive that I find myself swerving on the freeway. Oh, and parking is a breeze now. "look ma, one pinkie!" It doesn't feel like a 3/4 ton anymore!

Let's put it this way: my wife actually got in and drove it for the first time in 10 years - and liked it!

[joe231]

Originally Posted by Hilandr451

.....Let's put it this way: my wife actually got in and drove it for the first time in 10 years - and liked it!

that alone makes it all worth it

[iehotrod]

Wow.... That must feel GOOD... to get it done.. awsome work... talk about doing something and doing it right the first time Superb... you got one heck of a friend to help you... no one likes to help me because they say I'm to picky but when it comes to their cars they dont have a problem with it.

10 years and your still add it, that makes me feel bad for selling my 55 chevy 2 door wagon after 5 years and only took it apart and sold it. I will not ever do that again... I am now looking for something to redeem my self. I like what you did I will for sure keep this in mind if I go with a truck. I have my 87 silverado but that I think is staying as it is...

btw I like all of your comentary through out and your homepage is awsome... how far is that show from Los Angeles area?

[Chevy Fleetside]

For those of you that don't know. I am the John that helped him.

[iehotrod]

Cudos to you.... I never knew you can use an 89 front suspensions on these c-10's awsome deal nice job John...

[Eagar1]

Suburbans and blazers retained the same suspension and body panels as the 81-87 c10-20's thru 91. They did get a new core support, and newer headlight arrangement. but 90% of it was still the same.

[iehotrod]

any one know of anyone selling c10 shorty in california, nevada or arizona? at a fair price?

[joe231]

[iehotrod]

joe231 youknow anyone?