Builds BoltRipper's 2-year Overdue Build Thread

Overland Tailor

Boltripper
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952
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Birmingham, AL
Well, Almost 2 years later I figured I should start a build thread on my truck. Seems I just never have time to sit down and document the progress. Apologies in advance as I'm sure some things will be out of sequence, but I'll try my best to stay on track of when they were completed.

I purchased the truck from a small car dealer in Georgia.. She was a one owner truck originally from New Jersey, then went to Florida until it was sold at auction. I was a bit concerned about the few years in the Northeast, but the truck had no rust. Luckily it was a typical Northeast LC and was undercoated.

Truck had 81,000 miles when I drove it home and it was in unbelievable shape. Ran like a top on the test drive, no codes and has never had a light come on since I've owned it, but as you'll come to see I tend to replace things before they give me trouble (as my avatar signature states). Thats what working in aviation will do to you.

I paid more than most "mudders" would have, but I've seen too many $5K-$8K trucks that needed $10K of work to get them up to snuff. 1997, 3X Locked, Collectors Edition, 6M1, Super Clean Interior, Everything Worked, Dry - No leaks anywhere and 81,000 Miles.

$12K and I drove back to Birmingham AC blowing, cruise control set at 75... Smooth .......

Here she is when I got her home. 6/13/2013




And Here she is circa 2015



If your interested, stay tuned and I'll document the progress over the last 2-years ..... Hopefully it won't take me that long :)...

Thanks in advance,

-BR-
 
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jfz80

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Madison NC
Great looking rig. I'm sorry bout the 6m1 :p

Was following your efforts to reduce the fart can ems effect for a solution but think I found mine and it involves a sawzall :hillbilly:
 

Overland Tailor

Boltripper
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952
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Birmingham, AL
The first month I started the usual baselining -

Oil changed to Mobile 1 0W40 and Napa Platinum Oil Filter
MAF Cleaned
OEM Air Filter
Sea Foam to Fuel System
Flush and Fill Power Steering System with OEM Fluid
Yanked the Roof Rack - No Rust Found
New wipers
Front, Rear & Center Differential Fluid Changed to Amsoil
New OEM Front Pads

And My First MUD MOD - Passenger Side Shaky Mirror Fix....



 

Overland Tailor

Boltripper
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Messages
952
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Birmingham, AL
Great looking rig. I'm sorry bout the 6m1 :p

Was following your efforts to reduce the fart can ems effect for a solution but think I found mine and it involves a sawzall :hillbilly:
Well I was lucky enough to get an EMSP system that didn't (or at least hasn't) rusted or fell apart (yet)... Sound after my resonator mod, well its tolerable for me, but the :princess: says I sound like a old beat up pickup pulling into the neighborhood.
 

Overland Tailor

Boltripper
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952
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7/29/13 - 82,600 Miles

Installed George's LED's into all above head dome lights and some "Superbright" LED's in all other positions..




Then I did some 16" ProComp Wheels and Hankook Dynapro MT tires in 295/75R16

 
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Overland Tailor

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7/31/13 82,650 Miles

Started having some exhaust leaks due to the "Y" pipe finally giving up the ghost. I had an EMSP Exhaust already on order when I bought the truck and it was time...

This is what I removed and in retrospect I wish I would have kept the original muffler and resonator for a later date swap in...




And this is what I installed. New EMSP Single CAT system... New OEM O2 Sensors from -Onur- were added as well..















First impressions - Fit and finish A, Sound F.... Inline 6, what did I expect.....

So I started by adding a resonator..







Sound now was maybe a C-... I know, again, what did I expect......

So I decided to buy a TIG machine and start swapping in some larger resonators... Still that drrrroooonnnneeeee.... So finally I just installed a small muffler... What a fiasco... It was like i was :deadhorse:




View of ground clearance..



Sound quality was now a B- and I was done with it.. I figured it would fall apart in a year anyway..


-BR-
 

Overland Tailor

Boltripper
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952
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8/10/13 - 83,000 Miles


Started with the cooling system

OEM Radiator Hoses #1, #2 & #3
OEM Thermostat
OEM Radiator Cap

Used Constant Tension Clamps :





Completed the PHH Mod with Gates Green Stripe.

Removed the Rear Heater to ensure I'd never have a catastrophic failure of that system. Used The AJIK Kit to replace the hoses...

Rear Heater Components:




New Bypass Kit Installed:





The hole left from removing the rear heater:





Decided to weld in a cover plate rather than use the tar covered tape:




Primed, then painted:



Hopefully a lifetime repair:






Then it was time to Flush the cooling system and fill with Amsoil 50% and 50% Distilled Water



Flushing the system:



 

blkprj80

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Jun 20, 2012
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1,919
Location
Lafayette, CO
Bet them tires fit pretty tight! Just sayin'... 16's on a 17" rim could be difficult. :)

Nice build! I'm enjoying seeing your progress / history.
 

Overland Tailor

Boltripper
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952
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Birmingham, AL
8/13/13 - 83,200 miles

Started the PM on the Brakes. Did a pressure flush with Valvoline Synth DOT 3&4 Fluid.. Used about 2 quarts.

Next I replaced the Rear Rotors and Pads with OEM






I then wanted to cure the high pressure fuel spray when I remove the gas cap, so I replaced the Charcoal Canister with the VC120. I also replaced the canister and purge lines with Napa Fuel Line.



Replacement VC-120




Ended the day servicing the propeller shafts and degreasing the radiator fins using simple green and a pressure washer. Scan Gauge shows coolant temps at a Max temp of 206*.

-J-
 

Overland Tailor

Boltripper
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Messages
952
Location
Birmingham, AL
8/23/13 - 83,416

Received my CDL switch from Onur and completed the 7-PIN Mod




8/31/13 - 83,600 Miles

Replaced the fuel cap with OEM and added a Bottle of Redline Sl-1 Fuel System Cleaner to the tank. Ive used it religiously adding a bottle to the tank with each oil change.

http://www.amazon.com/Red-Line-60103-Complete-Cleaner/dp/B000CPI5Z0/ref=sr_1_1?ie=UTF8&qid=1430273089&sr=8-1&keywords=redline+fuel+system+cleaner

Also locked and unlocked the differentials on dirt to exercise the CDL and Lockers (Do this as well with every Oil Change Interval) and added some grease to the knuckles. Started getting the parts list together for the Front Axle Service..... Going to be expensive for the way I want to do it.



9/15/13 - 83,900 Miles

Replaced the Tie Rod Ends and Relay Rod Ends with OEM and replaced the stock steering dampener with OME SD#24

Set the toe-in at .125" and had great tracking and no floating at 80 mph. Centered the steering wheel while I was at it.. perfect after about 4 drive and adjust sessions.

-J-
 
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Overland Tailor

Boltripper
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Joined
Jun 24, 2012
Messages
952
Location
Birmingham, AL
9/16/13 83,900 Miles

Time for the Front ARB Bumper and Warn 9.5XP Winch.

Just Cleaning up the wiring with some tubing:



Winch Installed and bumper ready for fitting:



Lifting the ARB onto the Frame Rails:



Finished for now:



Next I installed the high performance Starter Cable and Grounding Cables.. I upgraded them a bit by adding some high temp and abrasion resistant sheathing.




While I was in there I replaced the EFI relay and Fusible Links with OEM.. Good insurance and no reason to keep the originals any longer.
 
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