'82 Duramax Swap Pictures

Lonnie

Horsepower Addict
Here are a few pictures from today.

Test fitting intercooler
029.jpg


034.jpg


Heaterbox waiting firewall blockoff plate
036.jpg


Modified intercooler
047.jpg


049.jpg


Misc... please excuse the dust
048.jpg
 
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Lonnie

Horsepower Addict
Got my radiator today, this one did not look like it was run over by the brown truck. It fits with about 1/4" to spare. The lower hose is very close to my inner fender.

I now need the tabs & lower grommets to secure it properly.

Now I need fans....
Did I hear correctly that some of the new trucks have electric fans?
 

Leadfoot

Needs Bigger Tires!
Dec 27, 2006
904
31
28
48
Western MA
www.matpa.org
Wow, and I thought I was a neat freak when it came to my truck.

That is a sweet looking rig and should be a nice "whatever you want to do with it" ride. I know how tedius it is to go through a vehicle like that. I did not do a DMAX conversion but I turned a manual window and lock 350/TH350/slip yoke 205 with 10 bolt into a 350/700r4/250 fixed yoke with a Dana 60, and then into a frame off resto 454+/TH400/205(different style) and derivited the frame and painted everything inside and out, keyless entry, power window and door locks, cruise, and rewired the entire truck, etc. so I know how time consuming it can be (and you definitely added a level of complexity with the Duramax/Alli/dual climate setup).

My hat is off to you!
Good luck with the project and have fun enjoying it when complete. :cool:


I may have discussed my Duramax swap into my '82 Chevy Tk. with a few of you here & also asked a lot of questions (special thanks to Mike L. & Pat for all the tech advice).

Here is a link to some photos that I have taken so far. Please check back often as the motor is going back together & I'll have more photos up soon when the motor & cab finally come together.

http://www.lonniesperformance.com/82chevyduramax.htm

Lonnie
 

Lonnie

Horsepower Addict
Leadfoot,
Thanks for the kind words. Your truck looks really clean. Took my drivers test in my dads black '77. Brings back memories. PM me your phone # & I'll give you a call sometime. We may be able to trade some parts.

This project happened almost accidentally.

I have '78 truck that I was building & while looking for parts, I found some really nice stuff, that I did not need. I figured, I could always use the extra parts on my '82. Now, it took precedence over my '78, which is sitting n the corner of the garage, waiting its turn.

Here is the '78.
78pickupside.jpg


78pickupeng.jpg


Then 1 day I was looking on one of the "other" diesel sites (even though I didn't own a diesel vehicle). I thought, "A diesel would make this truck run pretty well"

Timeline from day 1 is:
The '82 was bought by me in '87 with a blown up 6.2.
In went a 350, with the diesel 4 speed OD manual trans, & it became my daily driver for the next few years. 3.73's replaced the 3.08's & I really enjoyed the truck.

In '89, after exploding the trans many times (the cluster gears do not like power shifts), I finally put in a TH400. Now it was reliable, but mileage sucked.

In '90, I added 35's with 7" lift.
Mileage still sucked, so I added an IROC Tuned Port EFI. Was definitely an attention getter then.

After about a year, I got tired of the motor & built a tall deck 427 with some race engine parts I had laying around. Now it was a monster, but getting single digit MPG & it pulled a trailer well.

Then I thought a 700R4 would help the mileage. Built one & installed it, but decided it needed more gear with the big tires. So I added 4.56's & drove it for the next 10 years (mainly in the winter or to haul stuff).

It got pretty rough & gas got expensive, so I basically retired it.

Before this build, it has seen 3 engine configurations, 6 transmissions, 5 rearends, 4 front axles & 2 transfer cases.

Seemed only natural to change everything again.
Now it is coming back from the dead & getting a diesel again, only with a few hundred more HP than the factory 6.2.
 
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SmokeShow

Well-known member
Nov 30, 2006
6,818
34
48
43
Lawrenceburg, KY
Obviously your 82 is prestine but what's wrong or left to do to the 78? It looks complete to me except the front end paint... speaking of, could we see some more detailed pics of that tilt front end? :D


Impressive. :beer
 

Lonnie

Horsepower Addict
The '78 is rather complete, I just wanted to put a big block in there before I finished it. The front end is brand new GM stuff from 12yrs ago, good parts from before the dies were worn out. The only thing left to finish before paint is the actuators for the tilt stuff & the fenders need capped where they are cut. Then I can paint the whole thing properly.

I wanted a ZZ502EFI, but the price on those is outrageous.

Have a 14 bolt rear for the back & found a brand new military D60 (4.56's)with posi for the front. Rears are all black urethane base & cleared to match the frame.

I just need more time....
 
Jun 28, 2007
3,259
0
0
NE Pa
Here are a few pictures from today.

Test fitting intercooler
029.jpg


034.jpg


Heaterbox waiting firewall blockoff plate
036.jpg


Modified intercooler
047.jpg


049.jpg


Misc... please excuse the dust
048.jpg

I remember a long time ago you asking me about how much the motor rocks because you were worried about the manifolds hitting the frame. Well from looking at the pics you should be more than fine;):D
 

Lonnie

Horsepower Addict
The only close part is the rear 3 bolt flange on the pass side. I have about 1.5" now. Ran into a dilemma as more height gave me floor clearance issues & less made the front frame crossmember closer to the front axle.

I managed to retain the stock d-max driveline angle & not cut the floor. Everything is tight but manageable. My only dislike is that I keep putting more junk under the hood & on the motor making it less visble. Unfortunately all that junk is necessary.
 

Lonnie

Horsepower Addict
I made a little bit of progress on the heater box this weekend.
Here are a few more pictures.

New firewall blockoff plate ready for paint.
011.jpg


Underdash photos of '05 heater box installed
014.jpg

015.jpg

Note how close trans is to floor... has over an inch to spare.
 
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SmokeShow

Well-known member
Nov 30, 2006
6,818
34
48
43
Lawrenceburg, KY
can't remember, is there a body lift or an trans tunnel modification to achieve that clearance??

Was that floor pan originally for a manual trans?


C-ya
 

Lonnie

Horsepower Addict
There is a small 1" body lift on it, but I may have to go a little more.

It is an automatic cab with no body modifications.
Going out of my way to do this swap without altering the body in any way, so I can make it look factory installed.

To anyone contemplating a swap in this type of truck... do not do the heater box mod like this.
It is far too much work to make fit. It would be way easier to keep the factory box & add a vacuum pump to work the controls.
I caused myself a lot of work just to get dual climate control & a smooth firewall.
 
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