We were down to the wire. It was now just days before the start of the Ultimate Adventure, and the K5 Blazer's progress was still far behind schedule. What Fabworx Off Road had done so far was nothing short of a miracle. It wasn't exciting, it wasn't fun, it was painful. This was supposed to be a nice, easy collaboration of Fabworx and 4-Wheel & Off-Road's resources to craft a premudder that could drive nonstop across the country, wheel the hardest trails, climb the biggest sand dunes, and wallow in the biggest mudholes. But it turned out to be a thrashfest to make it be everything it needed to be without adding any of the extras. That meant no stereo for me on the drive out there (only 450 hp to listen to for hours on end), no speedometer (that's OK, I had a V1 radar detector), and no Specialty Top Co. top (now this one was going to hurt in the thunderstorms). We had made some good progress since we left off in last month's issue. The engine was back from the engine shop and assembled, the four-link was finished, and the front axle was slung in place. We'd have a rolling chassis as soon as we assembled the Center Line bead locks and mounted the BFGs. All that was left was to build the entire rollcage, the '88-'98 Chevy front clip update, mount the rear coilovers, add all the Auto Meter gauges and the rest of the interior, hook up the radiator, and...oh yeah, make sure it all works before we race for Idaho. No problem! We decided to finish the front end first. The engine had gone in already, and all that was left was to get on the front clip and mount the shocks. Light Racing had sent us some flared hole dies to try out, so we used some to add strength and rigidity to the new front radiator support mounts that we would have to weld to the frame. The flared hole dies are put on both sides of a drilled or punched hole, and via hydraulic pressure, crush the steel plate into what is commonly known as a dimple, thus the nickname "dimple dies."We decided to finish the front end first. The engine had gone in already, and all that was We had to make new mounts because we were using a radiator support off an '88-'98 Chevy, as per our fiberglass update kit requirements. Though the original radiator support placement is close to what is required, it's not close enough. Bryan McCully and Forrest Moore constructed the new frame mounts from flared 1/4-inch plate sides and 3/8-inch plate tops.We had to make new mounts because we were using a radiator support off an '88-'98 Chevy, a Energy Suspension supplied us with a urethane bushing kit to replace all the worn-out rubber. We actually raised the body 111/42 inches when we put the new bushings in, since the rubber body mounts were completely gone and the body was resting on the frame.Energy Suspension supplied us with a urethane bushing kit to replace all the worn-out rubb Once we had the '88-'98 radiator support mounted, we test fit our Flex-a-Lite Flex-a-fit Crossflow radiator on the support. We had taken measurements of a radiator from an '88-'98 truck and we had ordered accordingly. We were not worried about mounting because of the ultra-versatile mounting ability of the reservoirs' fluted rails. So that we didn't have to mess with a mechanical fan drive, we ordered dual electric fans as well.Once we had the '88-'98 radiator support mounted, we test fit our Flex-a-Lite Flex-a-fit C We test fit the Glassworks Unlimited front end to make sure everything lined up, and to get a spot for the new radiator support. The Glassworks front clip puts a prerunner '88-'98 front end on a '73-'87 Chevy/GMC...We test fit the Glassworks Unlimited front end to make sure everything lined up, and to ge ...You'll have to drill holes in the fiberglass, but the fenders will mount to the body tub and the radiator support. We used Autofab hood-pin kits....You'll have to drill holes in the fiberglass, but the fenders will mount to the body tu The new prerunner-style fenders not only updated our front end and grille to 1998, but also gave a 5 1/2-inch bulge and flare in the fender. It would be enough to cover the 39-inch Krawlers on the widened Dynatrac Pro Rock 60 frontend we had scavenged from last year's hammered U.A. yellow Chevy stepside.The new prerunner-style fenders not only updated our front end and grille to 1998, but als Though the previous owner had installed stainless braided brake lines, we didn't know what kind they were or how long they'd been on there...Though the previous owner had installed stainless braided brake lines, we didn't know what ...We felt it best to call up Russell and get some new 21- and 30-inch-long stainless braided Kevlar reinforced brake lines for the front and rear brakes....We felt it best to call up Russell and get some new 21- and 30-inch-long stainless brai All we had left to do in the front was mount the 14-inch Radflo 2.5 remote-reservoir shocks. Though we knew we'd use nowhere near 14 inches of travel, we had plans to later add a Deaver long-leaf pack to the front and utilize all 14 inches...All we had left to do in the front was mount the 14-inch Radflo 2.5 remote-reservoir shock ...The 1 1/2-inch 0.120-wall tube from Team Tube was used to fashion shock hoops and the engine crossmember. The lower shock mounts were made out of 3/8-inch plate....The 1 1/2-inch 0.120-wall tube from Team Tube was used to fashion shock hoops and the e With the front buttoned up, we started with the cage. Tubing was measured, cut, and notched with a holesaw fixture. Fabworx had ordered a variety of 1-, 1 1/4-, 1 1/2-, and 1 3/4-inch tubing from Team Tube to build the rollcage and suspension with.With the front buttoned up, we started with the cage. Tubing was measured, cut, and notche Bryan, Forrest, Brandon, and Dave went forth bending the tubing to the degrees specified and did some initial cutting and notching to start fitting things together. Adjustments usually have to be made (angle increased/decreased, tubing cut) so only tack welds are put to hold the tubing in place.Bryan, Forrest, Brandon, and Dave went forth bending the tubing to the degrees specified a The rollcage frame had been cut, bent, and tacked in place. Some of it will be pulled back apart while Forrest figures out how to mount the coilovers on the rollcage which doesn't attach to the frame yet. We'll cover that and the rest of the rollcage next time.The rollcage frame had been cut, bent, and tacked in place. Some of it will be pulled back Forrest made some plate mounts to attach the rollcage to the body. In the future (after the Ultimate Adventure) and when there is some more time, Fabworx will make mounts that bolt to the cage on the other side of the body and attach to the frame via a urethane bushing mount. (The body is mounted on Energy Suspension bushings and is therefore not hard-mounted to the frame, so we have to follow suit with the rollcage.)Forrest made some plate mounts to attach the rollcage to the body. In the future (after th We didn't skip all the extras, just most of them. After Justin Fenzel took the time to grind the fuel-tank guard clean, holes were drilled and flared to add some strength and style. It's still the stock piece, but now it's a little stronger and we could sell it on eBay to a bunch of bling-lovers for lots of money.We didn't skip all the extras, just most of them. After Justin Fenzel took the time to gri To get this truck rolling around the shop, we put together the new Center Line I.C.E (internal centering element) three-piece bead-lock and runflat wheels. You need to get the middle centering element in the tire first. We found it easiest to just stand on them and they easily fell into the 39-inch BFGoodrich Krawlers.To get this truck rolling around the shop, we put together the new Center Line I.C.E (inte The Center Line I.C.E. 17-inch wheels are the easiest bead locks we've ever assembled. All it took was a torque wrench and an Allen wrench, and we had each wheel together in under 12 minutes. You can replace the inner piece of the modular wheel to change lug pattern and variable offset. They weigh about 40 pounds each, and each one costs more than the BFG Krawler they're mounted in, but they are so worth it.The Center Line I.C.E. 17-inch wheels are the easiest bead locks we've ever assembled. All SOURCES Fabworx Off-Road www.fabworxoffroad.com Center Line Wheels N/A www.centerlinewheels.com Glassworks Unlimited www.glassworksunlimited.com RadFlo www.radflo.com Flex-A-Lite 8-00/-851-1610 www.flex-a-lite.com Energy Suspension 1131 Via Callejon San Clemente CA 92673 Russell 800-416-8628 www.russellperformance.com Dynatrac Light Racing www.lightracing.com Team Tube BFGoodrich Tires 877-788-8899 www.bfgoodrichtires.com By Jerrod Jones Enjoyed this Post? Subscribe to our RSS Feed, or use your favorite social media to recommend us to friends and colleagues!
