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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
 
I got the replacement front doors painted this weekend. Initially the plan was to just do the bottom color change from silver to sandalwood and then just spiff up the emerald green….. but after seeing how well the bodywork and paint on the bottom of the doors turned out yesterday, I decided it would be a disservice to not also do the same to the top part of the doors - there were some dents and deep scratches that would have still been there with my initial plan, plus I wasn’t sure how well I could have cleaned up the fading at the top, so doing a fully bodywork and respray situation seemed like the best path to an outcome I’d be happy with. They turned out pretty well, though if the damn paint gun hadn’t started shooting blobs of paint sporadically, they would have turned out quite well, so that’s disappointing. Even so, they will be a nice improvement to the truck as a whole and one step closer to removing the rust from it.

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