www.3500HD.com

General Category => Intros - 3500 HD History => Member Projects => Topic started by: fabman72 on October 01, 2011, 07:01:43 PM

Title: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: fabman72 on October 01, 2011, 07:01:43 PM
Hi guys .I have a Hd3500 15,000 gvw and im putting in a 5.9 cummins and a 9 speed eaton trans and a Kodiak rearend and a rear air ride from a Freightliner ambulance i'm also going to put the front springs and front shackles from the kodiak under the front and am going to make up a air ride setup for it also i also raised the rear 5" to match up with the front springs from the Kodiak the truck will have the larger 8 lug aluminum wheels from the kodiak i just need to buy a set of adapters for the front and later i will be changing out the solid front axle to a dana 60 or 70 anyhow thats a start i will have a few pictures shortly.wish me luck!!!
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: ED-NY on October 01, 2011, 07:40:14 PM
fabman72

Welcome to the forum..sounds like you have your work cut out. I'm sure the pictures will be coming!

Ed
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: fabman72 on October 01, 2011, 08:28:33 PM
Thanks Ed here is some of the things i have done it is getting close to being done
(http://i1135.photobucket.com/albums/m636/fabman72/springcomp.jpg)
Spring comparison
(http://i1135.photobucket.com/albums/m636/fabman72/cutsprings.jpg)
Kodiak springs cut
(http://i1135.photobucket.com/albums/m636/fabman72/redrilledaxle.jpg)
Re-drilled axle for new springs
(http://i1135.photobucket.com/albums/m636/fabman72/uboltcomp.jpg)
U-bolt Comparison
(http://i1135.photobucket.com/albums/m636/fabman72/rearend.jpg)
Kodiak rearend mounted with air ride
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: Raymo on October 02, 2011, 02:03:59 PM
I'm officially jealous  8)

At least I get to live my dreams of air ride vicariously through your build  ;D
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: fabman72 on October 02, 2011, 08:17:56 PM
I will try to not let you down !! here is some more pictures
(http://i1135.photobucket.com/albums/m636/fabman72/bag.jpg)
(http://i1135.photobucket.com/albums/m636/fabman72/bagpad.jpg)
Front spring pad

(http://i1135.photobucket.com/albums/m636/fabman72/smallpanhardbar.jpg)
Old small panhard bar

(http://i1135.photobucket.com/albums/m636/fabman72/heavypanhardbar.jpg)
(http://i1135.photobucket.com/albums/m636/fabman72/heavypanhardbars.jpg)
New panhard bar

The reason i cut out the front cross member was because i had to keep the motor as low as i could to get the 9 speed under the cab.


Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: Raymo on October 02, 2011, 10:31:14 PM
I was wondering how you were gonna fit all that trans under there  :D

What's the shackle get-up behind the bag mount on the front? For the swaybar?

Bags on the front make me nervous, but it looks like you've put a lot of thought into your setup  8)
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: fabman72 on October 02, 2011, 11:56:48 PM
Thats the sway bar brackets that you see in the picture. here is some more.

(http://i1135.photobucket.com/albums/m636/fabman72/truckframe.jpg)
(http://i1135.photobucket.com/albums/m636/fabman72/truckframe2.jpg)
Frame after the rearend is mounted.

(http://i1135.photobucket.com/albums/m636/fabman72/installedsprings.jpg)
Front axle almost done

(http://i1135.photobucket.com/albums/m636/fabman72/specialmadewheeladapters.jpg)
new wheel adapters made

(http://i1135.photobucket.com/albums/m636/fabman72/motormounts.jpg)

(http://i1135.photobucket.com/albums/m636/fabman72/drivermount.jpg)
Motor mounts

Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: fabman72 on October 04, 2011, 04:43:07 AM
Here is some more pictures
(http://i1135.photobucket.com/albums/m636/fabman72/9speed.jpg)

(http://i1135.photobucket.com/albums/m636/fabman72/P1010087-1.jpg)
Downpipe made

(http://i1135.photobucket.com/albums/m636/fabman72/compspace-1.jpg)
Dodge AC compressor

(http://i1135.photobucket.com/albums/m636/fabman72/P1010095-1.jpg)
Stack tube

(http://i1135.photobucket.com/albums/m636/fabman72/P1010093-1.jpg)
Air tanks

(http://i1135.photobucket.com/albums/m636/fabman72/P1010096-1.jpg)
New adapted front driveshaft

(http://i1135.photobucket.com/albums/m636/fabman72/cabup-1.jpg)
(http://i1135.photobucket.com/albums/m636/fabman72/transclearance.jpg)
(http://i1135.photobucket.com/albums/m636/fabman72/moto_0348.jpg)
(http://i1135.photobucket.com/albums/m636/fabman72/cabdown.jpg)
Checking cab clearance



Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: fabman72 on October 04, 2011, 05:02:44 AM
Ok now on to the clutch pedal setup it is a cable setup.What i did was take a pedal from a kodiak and mount it into the HD and bolts wright in except for the mounting in the firewall i cut the cable bracket from the kodiak and mounted in the firewall here is some pictures.

(http://i1135.photobucket.com/albums/m636/fabman72/clutchpedals-1.jpg)

(http://i1135.photobucket.com/albums/m636/fabman72/clutchpedal-1.jpg)
Left is kodiak right is HD

(http://i1135.photobucket.com/albums/m636/fabman72/clutchmaster-1.jpg)

(http://i1135.photobucket.com/albums/m636/fabman72/cableclutch-1.jpg)
Firewall mounting
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: Raymo on October 04, 2011, 10:14:46 AM
 ;D
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: fabman72 on October 05, 2011, 02:01:24 PM
This is close to where i am at the moment
(http://i1135.photobucket.com/albums/m636/fabman72/moto_0294.jpg)

(http://i1135.photobucket.com/albums/m636/fabman72/moto_0293.jpg)

(http://i1135.photobucket.com/albums/m636/fabman72/moto_0296.jpg)
The stacks are just setting on it thats why they look crooked

I am now hooking up the hydraulics for the bed and steering and the wiring and Intrer-cooler.
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: someotherguy on October 05, 2011, 04:26:15 PM
This thing is nuts.  I love it.  It's a Baby Kodiak.  ;D

Whatcha gonna do for side steps?

And actually, I thought about it a second, and it kind of begs the question.  Why not take a Kodiak/Topkick, pull the Cat diesel, install the Cummins, and then retrofit a regular front clip (with HD filler or whatever else may be necessary) to replace the fiberglass tilt hood?

Richard
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: Raymo on October 05, 2011, 08:15:32 PM
This thing is nuts.  I love it.  It's a Baby Kodiak.  ;D

Whatcha gonna do for side steps?

And actually, I thought about it a second, and it kind of begs the question.  Why not take a Kodiak/Topkick, pull the Cat diesel, install the Cummins, and then retrofit a regular front clip (with HD filler or whatever else may be necessary) to replace the fiberglass tilt hood?

Richard

I wondered that too, then realized he's a lot like me, and that would be too easy  ;D

It really reminds me of when my truck sat about the same height, I can appreciate how big this thing is in real life!
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: fabman72 on October 05, 2011, 08:59:41 PM
Yes i agree I do take the hard way a lot.This is kind of my reason for the build. I started moving sheds with a 95 HD with a 14' bed that i built and had the rear part of it extend 6' more in order to slide under the sheds anyhow with this truck I had the wonderful 454 and let me tell you when hauling a shed that's 12' wide and 24' long the motor did not like it about 3-4 mpg loaded and i always had problems with it over heating as long as i was not hauling sheds it never did overheat and the thing just didn't turn very sharp always had to pull up and back just to get into yards.so i decided to move up to a Kodiak .and loved the way it turns on a dime almost like a zero-turn.My biggest problem with it is the weight of it .It weighs 15,000 lbs. and most of the weight is in the front. If the front end sinks in a yard just a little I'm done ,but my problem with it is I just about wore the thing out.I am hoping to keep this truck around 10,000lbs and eventually have locking rear ends front and  back.I have learned alot from building the rollback beds on the first two trucks and am going to make this one even better. (Also i have a life saving story with my first HD. I wonder if i should start a new post for it or add it to this one.)
 Whatcha gonna do for side steps?
I have a set of saddle tanks that i am going to cut down for it.
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: KODIAK on October 06, 2011, 03:39:04 PM
where did you buy your wheel adapters ? 
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: fabman72 on October 06, 2011, 04:39:25 PM
I looked all over and no one made anything for the HD so I had a machine shop make them for me.It was around 600.00 for the pair.
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: KODIAK on October 06, 2011, 11:08:48 PM
Thank you for the info  i would like to get some made  for the  HD that would adapt to the big 6 hole19.5 pattern  the one that is on the 4500 /5500 GMC  also what size rear is that & what ratio  And your HD is lookin good
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: fabman72 on February 16, 2012, 10:08:05 PM
Well I just drove the truck on  its maiden voyage and all i can say is I'm loving it!!!! .The 9 speed is a little tricky to get used to but i am getting the hang of it.I have no speedometer  or tach but i am thinking I may not need 9th gear unless i travel the salt flats it feels like 55 at 1000 rpm. I will try to get some pictures in a day or too. Soon i will be hooking it up on vegetable oil.I ran my Kodiak on the stuff for over 100,000 miles and saved a few dollars over the years. I am one happy camper!!!!
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: someotherguy on February 17, 2012, 09:14:34 AM
Well come on with it...you know what we want...more pics!  How about video! ;D

Really cool project.

Richard
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: fabman72 on March 01, 2012, 08:31:24 PM
(http://i1135.photobucket.com/albums/m636/fabman72/moto_0505-1.jpg)
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: rockmanben on March 01, 2012, 08:39:40 PM
Sweet, hows it run and perform?
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: fabman72 on March 04, 2012, 03:20:05 AM
It runs way better than the old 6.5 ,the ride is a little more harsh than i would like i am going to ad ping tanks to it and see if the ride is any better but i really think it was worth all the work i cant wait to get the bed made for it know!
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: Rayjon237 on September 08, 2012, 01:32:12 AM
any update,  like the air ride,  just wondering how the bed turned out???
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: fabman72 on January 22, 2013, 06:41:02 AM
Sorry i haven't been around much but i will have some more pictures soon and will try to video shifting the truck here is a few pictures of the truck  (http://i1135.photobucket.com/albums/m636/fabman72/dogshelter_zps3336ff28.jpg) (http://i1135.photobucket.com/albums/m636/fabman72/unloading_zps61ada33f.jpg)
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: KODIAK on January 23, 2013, 10:21:42 AM
Looks nice HD,S  AT  WORK  like it lets all  post pics  of  HD,S  working  or HD @ WORK
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: someotherguy on January 23, 2013, 12:57:32 PM
That's not an HD.  That's a mini-Topkick!  And it kicks ass! :D

Richard
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: fabman72 on March 11, 2013, 06:36:10 PM
Well i scored a transfer case from a 4x4 HD from the other side of the U.S. to bad they already got rid of the front axle.
(http://i1135.photobucket.com/albums/m636/fabman72/transfer_zpsc9e9df82.jpg)
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: AZTimT on March 11, 2016, 11:51:10 PM
What was the final curb weight of this rig? You mentioned a target of 10,000 lbs, I am curious how close to that it is?
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: fabman72 on March 12, 2016, 11:10:40 PM
it ended up being 11,300 with me in it
Title: Re: 99 GMC 3500HD 5.9 Cummins 9 speed
Post by: AZTimT on March 13, 2016, 12:57:06 AM
Still not bad, that's a good two tons less to haul around empty than the larger trucks and a one of a kind rig. :)