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Old 05-13-2008, 09:16 PM   #1
JohnnyU
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Default Build Thread - 1-ton Chevy Swap

I'm fairly certrain that most of you guys won't be interested in this project since it's not a Ranger . I reserve the right to remove any posts that are made in an effort to start an argument or otherwise add no value to this thread. This will highlight the build process of the truck that is replacing my Ranger as far as wheeling duties are concerned. The truck is a 1991 Chevy 1/2 ton. I bought the truck shortly after my 16th birthday. I plowed snow with it, pulled trailers, and DD'ed it until last May. It had the solid body and frame, good v-8 and built auto trans that the Ranger only dreamed of, so it was deemed as a better platform to continue building from.

I got an awesome deal (free) on a 14FF rear axle from a 1-ton dually.


Tore it down and did some cleaning/rebuilding:

MMM, full floating axle shafts.... 1.458" at the flange, 1.351" operating


I decided the drums had to go, so I swapped on some disc brakes using caliper brackets from Ballistic.


I bought a pair of diff covers (one for the front Kingpin 60 as well) from GreatLakeOffroad - Awesome Product!


All cleaned up, painted and reassembled.


I also welded the tubes to prevent them from inadvertently spinning under high-torque conditions. It's a common problem as the plug welds the factory uses are really not sufficient.



This is as far as I've made it to this point. I've got most of the parts to proceed, I will be rebuilding the front 60 as well as installing the new rear springs and shackle flip kit. Stay tuned for more progress.
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Last edited by JohnnyU; 05-13-2008 at 09:50 PM.
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Old 05-13-2008, 10:00 PM   #2
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FINALLY! I've been waiting for this build. All the work looks good as usual. What gears do they have? Locker maybe or what the hell is that in the diff?
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Old 05-13-2008, 10:32 PM   #3
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only got one word and a smiley: NICE, oh yeah, and one comment, AS LONG AS YOU'RE HAPPY, who cares what other people say, i say way to go. and one question how hard was the disk brake conversion, i have drums front and back and want to covert to disks up front
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Old 05-13-2008, 10:45 PM   #4
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I don't care if you want to deal with crap.
Posting it here is just asking for a fight, As usual.
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Old 05-13-2008, 10:52 PM   #5
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Originally Posted by Dangeranger3 View Post
FINALLY! I've been waiting for this build. All the work looks good as usual. What gears do they have? Locker maybe or what the hell is that in the diff?
The axles both have 4.10's in them now. Not great, but it's better than 3.55's or anything less. My plan for now is to run them as-is just to get them under the truck. Once I have the truck rolling on the new axles and the suspension dialed in, I can start thinking about regearing. The 14FF has an open carrier but uses the "orb" method for a locker. Basically, the four spiders and the side gears were welded into a ball or "orb of traction" as seen here:

This picture is from biggervalves as I didn't take any pictures when I welded mine up.

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Originally Posted by gotmudd View Post
only got one word and a smiley: NICE, oh yeah, and one comment, AS LONG AS YOU'RE HAPPY, who cares what other people say, i say way to go. and one question how hard was the disk brake conversion, i have drums front and back and want to covert to disks up front
The disc conversion was simple, its essentially all bolt on parts. You will need to do some modification to your brake hydraulic system to make them work properly, but that will be covered later. Check out Pirate's tech section for more information on brake swaps. Billavista has done a GREAT job with those articles.
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Old 05-13-2008, 11:12 PM   #6
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I don't care if you want to deal with crap.
Posting it here is just asking for a fight, As usual.
What do you mean by this?

I am anxious to see what the outcome looks like John.
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Old 05-13-2008, 11:26 PM   #7
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Originally Posted by JohnnyU View Post
The axles both have 4.10's in them now. Not great, but it's better than 3.55's or anything less. My plan for now is to run them as-is just to get them under the truck. Once I have the truck rolling on the new axles and the suspension dialed in, I can start thinking about regearing. The 14FF has an open carrier but uses the "orb" method for a locker. Basically, the four spiders and the side gears were welded into a ball or "orb of traction" as seen here:

This picture is from biggervalves as I didn't take any pictures when I welded mine up.



The disc conversion was simple, its essentially all bolt on parts. You will need to do some modification to your brake hydraulic system to make them work properly, but that will be covered later. Check out Pirate's tech section for more information on brake swaps. Billavista has done a GREAT job with those articles.

the 4.10's should be plenty for most needs, i know guys runnin 38's + with 4.10's, and if u were to drop a sm465 into her, witha 205 case, then u would have a mean granny gear in it, and then ud have a pretty much bullet proof drivetrain for trucks under 40's, im a equal oppritunity offender, i build everything, aslong as it wheels it dont matter to me
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Old 05-13-2008, 11:36 PM   #8
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I was wondering if you were gonna post a build for that truck here. Depending on how big of a tire you go, 4.10's wouldnt be bad if you had a doubler. Speaking of that, what are you gonna run for a t-case(s)?
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Old 05-13-2008, 11:47 PM   #9
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Looking Good! I am excited to follow along.
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Old 05-14-2008, 02:08 AM   #10
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excellent, I was gonna ask you when you were gonna start working on that baby. do you have any deadlines/dates for completion?
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