I decided to pull the 6.5L Turbo-diesel out of my '94 K1500 and put a 1st Gen Cummins into it. So I didn't run into any fitment issues, I decided to put a 3" body lift on the truck (some say it's needed...others say it's not)



So far, I have pretty much completed the Cummins conversion, using motor mounts and brackets to fit the GM alternator and A/C compressor onto the Dodge Cummins engine. I have decided to stick with the Dodge A518 transmission and the Dodge cast-iron NP205 transfer case. I have the Dana 60 for the front, and as soon as the springs come in, I'll start on the SAS.


With the engine mounts and brackets, I found the conversion pretty straightforward. The 5.9L Cummins fit right in, and fabbing up a crossmember for the transmission was pretty simple. Once the engine was in, I jacked the transmission up until the tranny pan and oil pan were pretty much level with the frame, and was able to run a piece of "C" channel across the bottom of the frame-rail from one side to the other. I'll have to modify it a little bit once I complete the SAS for clearance for the front driveshaft, but that's no big deal.

I decided to put the radiator and tranny cooler in the bed for extra clearance up front for the intercooler. I made the plumbing for the cooling system out of 2" exhaust tubing and a few bends from the the local parts store. It is possible to get an intercooler from a newer Dodge pick-up and keep the radiator in the stock location, but I chose a 4" thick intercooler and remote mounting of the cooling system. Due to the body lift, I decided to run the tubing across the top of the frame rail, between the frame and the body. I don't have any pics of this yet, but I should have them up within the next few days.

Since I kept the Dodge tranny and transfer case, I'll be using a Chevy Dana 60 for the front axle, and I have a Ford Dana 60 to put in the rear.

I plan on going up about 10" in suspension, and put a 3" body lift on for clearance. The tranny linkage would be up against the trans. tunne.

The transmission mount was a LOT easier than I expected it to be. Once I got the engine bolted in and put the transmission in place, using a set of new transmission bushings (stock dodge bushings), I found that all I had to do was run a piece of C-channel upside down across the bottom of the frame rail. Drill holes for the 1/2" bolts and voila! The cuts are still rough...I've got to do the finishing work on the crossmember and box it in...I will probably have to change the passenger's side for clearence for the front driveshaft also. I plan on going up to the top of the frame rail if I have to to go around the shaft. I'll go get some pics of that and the way I ran the cooling lines tonite and post them to my photobucket site.

Talk about tackling a lot at once! I had 40 days of leave that I took as soon as I got back from Iraq. In actual man-hours, I'd say I only have about maybe 150 hours into the job, but the cummins conversion part of the project is pretty much done. In a day, I could have that finished up if I tackled it hard, but there's no rush since I'm doing the SAS swap too...

As for engine upgrades...I want to get the engine in and running good before I start messing with anything else....plus, I need to build up my savings a little bit before I can do much. As soon as I've got the bugs worked out, I plan on doing the freebie upgrades such as the fuel screw, removing the AFC lever...then of couse, injectors and either a big single or a set of twin turbos.

 

I've finally gotten some springs in and have completed a home-made shackle flip and installed the 5" lift springs in the rear. HOLY COW!!! THIS THING IS HUGE!!! I didn't quite expect for the bed to be up over my head when I was done with it...well, not quite, but it's at least eye level, and I'm 5'11" tall.





I have gotten the front clip back on the truck, as well as the hood. I have the rollbar sitting in the bed, and have my cooling lines ran back to where they need to go. The radiator is hooked up, but I have yet to actually mount it in the bed.





I have also gotten the front springs hung using Sky Manufacturing's shackle hangers and a home-made set of spring hangers in the front...and a Dana 60 sitting proudly under the front of the truck. My crossover is hooked up, and I'm working on the turbo/intercooler. I have aquired a bigger turbo from a dump truck that I'm going to run as a bottom turbo in a set of twins, so that's going to set me back a little while in getting her on the street...BUT...SHE'S GETTING THERE!!!

 

Holy cow man. That thing is frickn' huge.
Good to see another conversion in the works.
I've had mine for three years now with no complaints.

 

Thats actually very nice to see this Thread.. I happen to be starting a 12v swap myself into a 92 K1500.. Was wondering why you are going SAS though? Is it strictly because its an off roading truck? Do you think the stock K1500 front drivetrain will hold up with a 12v pushin it?

 

nice lookin swap ya have there bud. keep us posted on the futher transformation

 

Excellent stuff Thanks for sharing it with us.

 

I decided to do the SAS along with the swap for 2 reasons. The most important reason is that the ball joints and torsion bars won't hold up to the extra weight or torque of the big cummins. There is somewhere between 500-600 lbs weight difference between the two. Sure, they'd last for a little while, but I'm too hard on my truck to rely on an already weak design from GM.

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Here's a pic of the GM alternator and A/C compressor setup with the brackets I used.

 

So...the front shocks and right rear shock are hung. I would have both of the rear shocks hung if I hadn't lost one of the brackets...I know it's somewhere around here...


I re-did the transmission crossmember. I used a piece of 2x4 square tubing and cut the ends to make a flat surface to bolt to the frame.



I also got the rear disks on, but am having some trouble getting them hooked up. Somehow, I was thinking I could use hard lines to hook the calipers up, and after getting extremely frusterated, I realized that they were designed for the front...I got some front lines, banjo bolts, and washers, only to find that the banjo bolts they sold me were the wrong ones...and the parts stores are closed...GO FIGURE!!





I had planned on some pics of the front shocks, and I also have the rear bumper built...but my camera batteries died. I'll try to get them up within the next few days. OH YEAH!! And MY BOGGERS!!! I only have 2 of them (the other 2 rims are on backorder) so I'm going to put them on the rear, and probably run the 39.5x15 TSL's I have on the front until my other two come in.

 

SWEET! Its really nice to see your progress! I cant wait to get started on my conversion. Cant wait to see some video of how your truck runs when its all done!


Awesome Job!

 

Very nice