some of you have asked for pictures of progress in the past, so i thought i would put up a few. I made an aluminum adapter to adapt the t-case out of an F-550 with a 7.3 and Auto, its a nv271. I had the output shaft threads moved back so that the lock nut would seat against the speedometer reluctor and resplined the output shaft to 31 spline to fit the transfer case, the shaft work was done by performance cyrogenics in california. If anyone is interested in the aluminum adapter i can make them for a reasonable price. The picture of the whole truck is from when it was still 2wd, it now sits a couple feet higher. The picture of the twins is old, i will try to put a couple more up when i get the setup done.

 

The front axle started life in the rear of a 76 dodge motorhome. It is a Dana 70HD with 4.56 gears, an open carrier, and 35 spline axles. I lengthened the passenger side tube by making a tube that was 4 inch OD and pressed inside of the factory tube. I bought Dana 70 factory kingpin inner knuckles and bored them out to 4 inch and welded them on the tubes. on the driver side i had to trim the third member a bit and welded a spring perch in after preheating the housing with the torch. the inner and outer axles are 35 spline 4340 cromoly factory length for the 77-79 ford dana 60's. The outer knuckles are from SOLID axle, and the steering arms and kingpin caps i milled from 8620 steel. the spindles are for a 78 f350 dana 60, the hubs, rotors, and calipers are from 97 f350 dana 60. i had to make my own caliper brackets to fit the newer style calipers to the kingpin knuckles out of .375 plate and 1.75 square solid stock. the lockouts are mile marker 35 spline supreme hubs. the tie rod is the factory 2wd tie rod shortened 7 inches or so.

 

Nice, another pix of the engine compartment if you can , I really want to see how the 466 fit, here is a link to mine,

1995 3500hd crew cab with 5.9 cummins

Pm or email me if you want info on doing air ride in the rear, one more thing add the 3 leaf pack for the front, mine weighed 4600lbs on the front, the two leaf packs are overloaded on a stock crew cab, makes a big difference in how they ride.

 

I looked for suitable tires and wheels for several months to fill the gap created by the straight axle conversion from the 2wd drob beam. I ended up finding a set of 14.50r20 michelins that are about 44 inches tall and on 8x6.5 rims. I made adapters for the rear out of steel pipe 5"ID x9" OD and 2.5 inches thick to go from 10x7.25 to the 8x6.5 to fit the wheels. to lift the rear and keep towing manners i bought another HD frame off a 96 and stacked it under the original frame. the truck now sits pretty much level. I am using the frame plates off the spare frame to build the front bumper. i have also been working on installing 07 and newer chevy headlights, and using part of the 95 gmc grille to make room for the Peterbilt intercooler and chevy C50 radiator as well as 4, 12" electric fans. i think it sits WAY too high, but it looks really funny on 33" tires, or 37" tires, and i really cant cut the 3" body lift down or drop the suspension and still keep acceptable clearance between the 466 and dana 70 and bellhousing mounts and cab.

 

Here is a link with the spring info,

front springs,

Stock crew cab HD's were overweight on the front springs, you can usually just add the helper as long as your springs arn't wasted too bad,

There are very few of these trucks in crew cab, there are a couple guys on 3500hd.com and all our trucks are different,

A few things we learned beside the springs

Wiring harness, if the color codes don't match look at the p30 van chassis,
Radiator support, radiator and Shroud are HD specific,
Stock carpet kits don't fit real well trans tunnel was fabricated,

I am sure there is a lot more but these caused me issues on my swap..

Good luck they are great trucks overbuilt frame wise,

 

thanks for the reply. i used an overload spring from the rear of a 99 k3500 and it seems to be about right as far as length and taper, but thank you for the link on the springs. as far as the cab and wiring harness goes, i started with a standard cab, and swapped the 99 k3500 7.4 gas cab on to the HD frame, then swapped the standard cab and diesel wiring over to the crew, but still have a bit of splicing for the stereo and interior lights and such. Do you have a good source on wiring diagrams for the p30 and the normal truck chassis? I have found a few on the Autozone site, which should be enough to get me through most of the wiring headache. i have ditched all of the factory radiator, core support and etc, but thanks for the info.
i got a carpet kit from jcwhitney as this is a standard k3500 cab and it seems to fit perfectly. i will get more pics of the engine compartment next week when i get home. I cut the water pump down and converted everything to serpentine to use the 6.5 accessories and for the tach to work off of the alternator, which helps the engine fit much better.

 

Used Mitchell on demand at a friends shop for the wiring,

Btw when you are taking pix can you get one of where you did the spring pearch on the dana 70,

 

Looks killer. Have you fired up the twin turbos yet? I am in the works now and want to do twins

 

Thanks! I fired it up and drove it last weekend. It runs REALLY good and drives pretty nice. It is a lot quieter than the 12 valve cummins. I installed 5" exhaust from the turbo back with a small straight through muffler to cut the drone, but it is seriously rather quiet. I think the twins reduce the exhaust noise a bit. I will be home in a couple weeks and try to post pictures of the turbo and exhaust set up. i havent had a chance to get it done enough to pull a trailer and see how hot the EGT's get and how much boost it produces. as it is, it has a serious amount of torque, far more than the 12 valve cummins and with far less smoke. The twin turbo set-up with piping and all cost me less than $700.

 

Nice!!!! I can't wait to see it. Keeper posted!