Build Stevo's '95 4BTRunner

[StevoJonesFJ60]

One thing for sure to check when getting a new axle is the lug spacing. Turns out Chevy/GMC went to a 8x180 spacing in 2011. This means that the axle flanges are different too from older model trucks. There isn't much information on this so I will continue to post any other changes I find.
In the meantime, I needed to swap it back to an 8x170 pattern. Easiest way is adapters, but tacking on 4" to an already wider axle was a no-go.

One of the main reasons why I wanted to run a 14 bolt in the first place, other than the 3rd pinion bearing, was the fact that they are super easy to work on and can be chopped down to run "two short shafts". This would shorten the axle down 6", allow me to bring a single spare, and allow me to run adapters, to keep the same axle width.

I got to make good use of the metal chop saw I picked up. Hands down one of the best purchases I have made. It chops through steel like butter, no heat buildup and clean edge ready to weld up. Made quick work of that axle tube.

Clamped back up and ready to weld.

Welded up!

Since I had an extra "long shaft" I decided to make a trail spare. Probably wouldn't last under some significant abuse but I imagine it would at least allow me to limp off a trail.

 

[StevoJonesFJ60]

Like everyone else, I love snagging some deals at auctions. I found some tig cups up for sale managed to snag 546 tig cups for the grand total of $50.

Those got put to use on the remainder of the manifold install. First day on site it was pouring rain so had to move operations to inside.

But the next day was beautiful so the install was moved outside.

Installation complete, all that was left was to order to flex lines to the tanks.

 

[StevoJonesFJ60]

Back on the rear axle:
I wanted to make sure that there wouldn't be an issue with the chopped section so I added some additional beef.
Small top truss.

Rear span truss, tied into the new diff cover.

Dumped the Gov-Loc and swapped it for a grizzly locker.

Gears and locker back in.

All buttoned up and painted.

Still need to add on the spring mounts and anti-wrap brackets but those will be "field-fit" when I get the old one pulled.

 

[StevoJonesFJ60]

That brings us to the last major change. I was not thrilled with the first iteration of the front bumper. I had a bunch of 4" tubing left over from that steam install so I decided to see how a new round tube bumper would look. Little CAD mockup.

No going back from here:

Liking it so far.

Added in some plating.

Welded, cleaned up, painted, and installed.

 

[StevoJonesFJ60]

Stay tuned for the next few things on my to-do list:

• Going to be resealing my T-case and installing a T-case brake
• Shortening front driveshaft
• Installing new rear axle
  • New shocks
  • Lengthen rear driveshaft
  • New brake lines
• Engine bay work
  • Filter box
  • lower thermostat hose swap
  • redo inner fenders
  • seal up a bit on the sides to cut down some noise
• Redo front shock mounts - going with hoops for a cleaner look
• Potentially sourcing a new front axle (05+ SD)
• Compound turbos might be in the mix too or maybe twincharging

 

[GLTHFJ60]

Love the updates. The front bumper tubes remind me of two stroke mufflers for some reason, lol.

 

[D21FJ60]

Love the updates. The front bumper tubes remind me of two stroke mufflers for some reason, lol.

Bottom of Darth Vaders mask IMO

 

[StevoJonesFJ60]

Been a busy summer so its time for some updates, the truck has been a blast to drive. Still haven't maxed out the fuel but other things have been adjusted.

I shortened the front driveshaft so I can use 4WD again. Unfortunately there aren't too many places out by me to hit trails.

Had a buddy come to town for a few days so we took the weekend to pull the rear axle.
Out with the old...

And in with the new!

Swapped out the lift blocks for some bigger ones to get rid of the "squat" it had. Looks a lot better, and it just makes it through the garage.

That's with a quarter tank of fuel, so i probably won't let it get any lower than that. I do plan on redoing the front suspension a bit when I swap in the 05+ SD60. So i will hopefully be able to drop the whole truck 2-3" for a little lower stance.

I also installed the new T-case brake, which works great.

 

[StevoJonesFJ60]

Most of the summer has been spent with clients, lots of installs and too much travel. But hey gotta make money somehow.

One trip was up to a client in NJ. They are opening this weekend so its been a mad dash for them to get everything in and production underway.
They have a really sweet setup, with a 500 gallon mash tun stripping still, a 250 gallon finishing still with a whiskey column, two retorts, and a gin basket.

Client #2 is down in "Mis-sippy". Huge equipment, much larger then a typical startup. 2680 gallon mash tun, 1340 gallon still. I went down for an install trip, but the only equipment on site was a bobcat and a telehandler, so not much was stood up.

They also had not taken into account how tall the boiler was before framing out the "boiler room".

Fortunately the contractors recommended going to a 10' garage door into the distillery vs the 8' on the plans. The largest piece of equipment just barely fit with .5" to spare.

And the last client was up in upstate NY. Spent a few days teaching him how to make vodka and gin.

 

[StevoJonesFJ60]

On my list of things to do was to get a working fuel gauge. I swapped out the sender, and put an adapter to make the stock gauge work.
While the tank was down I swapped out my fuel filler hose for something a little nicer that flowed better. Its all about making improvements to the project at this point.
I was able to get a first estimate of my fuel consumption, and even though 80% of my driving is just me flooring it around, I have been getting about 17.5mpg. Not bad for a 6500# truck. I can't wait to see what the number will grow to as I take it further and floor it less.

Back when I did the frame swap I must have created a ground fault on the dash light circuit somewhere, so I never could get my dash lights to work without just frying fuses. So to have a little more confidence driving at night I will be adding some other gauges. Plus I was never 100% confident in the stock ones.

I have an uncracked dash that I will be swapping in so I will drill a hole in that to get the new gauges located. I will be tackling this as the weather cools down. But here it is about where I think the gauges will go.

I also installed a panhard bar to help with the street driving. It would start to get a bit squirrely as I got above 65mph.
Much nicer with the panhard, and I made it removable so I can easily jump out and disconnect it.

 

[GLTHFJ60]

Time for some bigger tires!

 

[StevoJonesFJ60]

Time for some bigger tires!

In due time, lol. I think some 40's would be nice to have in the future, but for now the 37's have been pretty nice.
I definitely wouldn't be getting them before I drop the lift a bit. I like to be able to pull it into the garage for working on it.

 

[StevoJonesFJ60]

It's been a while so time for some updates!

During the cooler months I was hoping to get some things accomplished, first of all was some additional sound deadening to help with the street/driving noise. It was just too loud to have a conversation in the truck. Fortunately some deadening and new carpet fixed that issue!

New carpet was pre formed for the floor and went in great, of couse I forgot to take a picture of it in place

The truck also had a slight bit of squat to it that I wanted to level out so I got some facebook marketplace ford springs and modified my pack. Worked out perfect to drop the ride height down, and moved the axle back a couple inches to better center the axle in the fender well.

 

[StevoJonesFJ60]

In getting the truck on the road I had thrown together the suspension and wasn't thrilled how it looked every time I saw it. I also wanted to open up the passenger side for future growth i.e. turbo #2.

Previous arrangement:

Chopped out:

New Hoop:

New inner fender:

Plenty of room for turbo #2:

 

[StevoJonesFJ60]

Driver side was way too ugly, had so much going on.

I also had the unfortunate side effect of slamming the axle into the frame with a big bump. Fortunately no steering arm contact, but I still wanted to bring that inboard to get rid of the double cardon steering shaft assembly. So I had to chop the top for recessing the box in and the bottom for steering arm swing.

Added braces inside and out to strengthen everything up and made the notch for the axle as well.

Fully plated:

Fully braced and box and shock hoop installed.

I also made a new motor mount for the engine and frame side, as the old one was right where I notched for the axle.

Truck now can get bounced without any contact issues. Rides fantastic and the steering is a lot nicer with a standard shaft vs the DC setup. I also have adjustability in the shocks, and with the 14" Bilsteins on it now I have them set to 6" bump 8" droop. When I get some time to flex test it out I might adjust that to 5"/9" I just need to chop the panhard down to be reinstalled, it made a big difference at high speeds, I had the truck up to 74MPH with no issues at all on the highway.