The Slow Build
So the build has begun. This build is going to be slow and take place in three phases. As funds allow steps will be completed and I will update this thread. I will also try to report back and answer questions as to long term durability and after install issues. So if you are interested then read along.
PHASE 1: Reliability.
Now my Power Wagon isnt that old. But I wanted to address some issues that are known before the present their ugly heads and leave me on the side of the road or trail. I will also be taking care of some common upgrades as well, things that improve overall performance or just generally make things nice.
[x] K&N Drop In Filter
[x] Magnaflow 18" w/deleted resonator
[x] Line-X bed
[x] Weathertech floor liners
[x] Sonnax Line pressure booster
[ ] 180* Thermostat
[ ] Dynatrac or PP ball joints
[x] Synergy Steering Brace
[x] Bilstien 5100 Steering Stabalizer
[ ] Spyntec Hub Conversion
X - Completed
So as we all know the 2500-3500 trucks tend to get steering wander and have a habit of tearing up steering boxes when lifted. So that is one of the issues I am addressing, as well as the crappy factory ball joints (bad design, to be discussed later). I want a truck with a front end that will last 250k miles with nothing more than regular maintenance, even when lifted.
PHASE 2: Lift and tires
[ ] Synergy 3" with arms and bypass shocks
[ ] All Steering linkage addressed
[ ] 37" Toyo Open Country M/T
[ ] 5.13 Gears(?)
[ ] 55 gallon fuel tank (Titan maybe?)
PHASE 3: Bumpers, Lights, Finish up
[ ] Front Bumper
[ ] Rear winch mount bumper
[ ] lighting
[ ] Rock Rails (functional)
[ ] On Board Air
[ ] Additional skid plating if neccassary
Now like I said this will not be quick, I plan to spead this out over about 3 years as funding allows. But I will continue to update with any little additions or issues I run into too.
Synergy Steering Brace and Bilstein SS
Well lets start with the Bilstein
Wasnt that quick! Seriously, remove the 4 x 15mm skid plate bolts and remove the plate. Remove the two bolts holding the steering stabilizer. On the axle side it is a 15mm bolt with an 18mm nut and on the tie rod you just remove the 18 mm nut, take the old one out and do the whole thing in reverse.
Synergy Steering steering brace.
Ok, first things first, its not quite a direct bolt in. Everything lines up, but it was designed for a truck without the smart bar. The smart bar cause some trouble.
So I rotated the smart bar about 50* and that will get you close, the pic above shows where you still have issues. I ended up taking a grinder and removing about 1/4" of material from the non-used ear. A little touch here and there with the grinder and it fits!
Now pull it back down and install the spindle for the steering pinion, put the whole support back up and install the support bearing.
Now your steering bax shaft is mounted in double shear and should give you no problems. Take it for a spin and make sure everything works, drive it to work and re-torque everything after about 100 miles.
MagnaFlow 18" and resonator delete
Ok, no pics...sorry, but its just a muffler. If you really dont know what it looks like you need to trade in your PW for a Prius!!
So I wanted the PW to sound more like a truck, a 2500 shouldnt be able to sneak up on a group of chanting monks without being noticed!
I have had it on for about 500 miles so far. Here is what I think. I love it!
I didnt want it to be to loud (i'm not 16 anymore). It sounds great, nice low grumble at idle, makes some noise when you step on it and fairly mild while cruising. Now I dont have the highly calibrated but dyno that some of you claim (I want the imperial data proving it!), but I really havent noticed any gains or losses in power or mpg. Maybe a little more oomph (and that is a highly technical word) at lower RPM but overall I got it for the sound and am happy with it. Combined with the K&N drop in and conservative driving I am getting 16-16.5mpg on the highway and about 12mpg around town all hand calculated.
Downside: With the resonator removed I will occasionally hit a certain gear/speed/rpm and get a really annoying drone. So far just a burp of the throttle has always taken care of it.
Looks like you have a good plan, and the title seems fitting, with rubber that big you won't be moving that fast, so I got a chuckle out of 'slow build'. I'm glad to see you starting with reliability, too many of us, myself included, go right for the power without thinking about the long term.
Great Thread, great thread. What is this muffler you speak of?? Naw, just kidding. Anyway, looks great. It's probably a good idea to have a plan like yours. I read and think ' I want that', ooh I want that. But you have a plan.
I know what most everything is/does you have listed, except for the line pressure booster. Not to sound dumb or anything, but what does it do? I don't think I've heard of it before.
Thanks, and keep up the good work.
Cabin filter mod done today. Got the filter and door in the mail today and took about 10 min with a sharp knife trimming the door opening. Very easy mod and only cost $30! Now my cabin air is HEPA filtered.
Well, I guess slow was the right word! Anyways, the Spyntec hubs have been ordered! Hopefully in the next few weeks I will be able to update with some pics and reviews once I get them on.
I havent been completley lazy in the in the mean time. I decided I simply dont like chrome.
I bedlined the grill and bumpers.
PlastiDip for the wheels is in the garage once the weather gets better and I have time!
What year is your truck ? What is the part number of the sonnex line pressure booster you used ? I called one of their dealers today and the guy on the phone couldnt even tell me what part number I needed cause they said they didnt even know what transmission is in my 2012 PW , thats alittle scary.
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