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Another 2 door Tahoe for me

ak diesel driver said:
That yellowish stuff on the axle some kind of corrosion inhibitor? If you find another of those cupholders I'd be up for one.
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I bought a few off Ebay. They're kind of pricey now.

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Today I made brackets to adapt an AD244 alternator to the truck. To make it easier I did the work on a mockup engine rather than on the truck - made it a ton easier to see what was needed. The top bracket was the easy part, I just needed to make a simple offset strap.

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The bottom bracket to put the bolt in double shear was the trickier one. To figure out the bracket I took 3 strips of thin cardboard and cut a bolt hole in the end. I then installed those on the 3 bolts/studs I planned to use. I positioned them to where they made a triangle and taped them together. This was my template for making the bracket out of steel. I had a remnant of 1/4” steel plate laying around that was just big enough so I used that. This worked out well.

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All installed, even with a belt. I used the existing 6PK2565 belt I had used on the dually and it was a perfect fit without the vacuum pump. I swapped the correct size pulley on the alternator so it will read correctly. BTW, this alternator is rated 145 amps, which isn’t a ton over the stock 105 amps, but low RPM will be significantly higher than the stock CS130 alternator.

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I will be blasting and painting all of the accessory brackets for installation later.
 
Good decision on the painting. I had my brackets powder coated and it cracked and fell off. I have been blasting and painting as time allows. I just finished my third bracket which was the alternator bracket. I put it back on yesterday.

I dont know much about powder coat except that when it fails, it fails in a big way.
 
Yes that has been my experience. Most shops quit blasting in our area mostly due to EPA and the labor cost. I do small parts for work. And the big shops have to send all blasting out. We tried doing etching but rework was causing a big problem for us. Of course powder age and quality play into it also, but I am an amateur anyway.
 
Today I picked up some sheet metal for the Tahoe. I need to change the silver to the correct color, but the green should match correctly. Pretty much no rust, and what little rust there is will be an easy touch-up. The green isn’t in perfect condition, but I’m hoping I can touch it up with a scuff and some new clear coat and have it match the rest of the body close enough.

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I rebuilt a heater box for this. I put all new heater core and evaporator in it. I also put new blend doors in it (I bought some before they were discontinued). I also tested the actuators to make sure the motors functioned and then put new gears in from blenddoor.com.

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Yesterday I got the cargo doors swapped out on this thing. I bought pins and bushings from Cunningham Machine. Really good stuff. I also bought their pin removal tool - that works great on the lower pins, but is useless on the upper pins. I thought about making my own tool for the uppers, but didn’t feel like investing the time, so I used the grinder, then hammer/punch technique. Pain in the ass, but it’s done. So nice for the unsightly rusty doors to be gone. Not sure if I want to reinstall the Tahoe badge or not. Still thinking on that.

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I also dropped the block and crank for the truck off to the machine shop. I’m slowly making things happen…..
 
n8in8or said:
Yesterday I got the cargo doors swapped out on this thing. I bought pins and bushings from Cunningham Machine. Really good stuff. I also bought their pin removal tool - that works great on the lower pins, but is useless on the upper pins. I thought about making my own tool for the uppers, but didn’t feel like investing the time, so I used the grinder, then hammer/punch technique. Pain in the ass, but it’s done. So nice for the unsightly rusty doors to be gone. Not sure if I want to reinstall the Tahoe badge or not. Still thinking on that.

View attachment 99506

I also dropped the block and crank for the truck off to the machine shop. I’m slowly making things happen…..
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Looks nice
 
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