1999 Dodge 2500 CTD Build AKA Han Solo

[Luckychase5]

Taking out the seats was about a half hour. Only 8 or 10 bolts in all and a quick disconnect of the airbag sensor. However the seats are heavy and come out as a whole unit, definitely needed a second pair of hands for that.
The cost wasn't bad at all, I think around 100$ for the doors, firewall, and under the floor matts. Definitely not Dynamat quality, but also not nearly Dynamat price.
I got it all from AMC. If I was going to do it again I would get a few more of the small sheets (PN 38-2819)
The big sheet for the floor was nice, but I actually turned it 180* to get it farther up on the firewall. It was a nice piece but the 'custom cut' isn't the best. (PN 55-9141)
In general whole project took me about three hours and I would definitely do it again, I would have some new snaps on had to hold on the door panels, and it people don't do this already, the claw end of a hammer helps a lot when removing the door panels.
Hope this helps!
Oh and I lit up my 20" Stealth light bar and holy crap! It easily lit up the street three blocks down. Here is the spot it put out about 50' away.

 

[EXP-T100]

The switch panel came out nice!

 

[Luckychase5]

The switch panel came out nice!

Thanks EXP! It's my first custom install making the backer plate and all so it means a lot. Cheers!

 

[takingatrip]

How did you route the wiring from the cab to the engine compartment?

 

[Luckychase5]

How did you route the wiring from the cab to the engine compartment?

I ran it through a plastic cover in the dash above and to the left of the steering column. I have rear air bags and that where that installer ran the wires for that so I just followed his lead.
And speaking if wiring I ran the wire for my back up and side lights and installed the switches for those as well. I got the sides and my Stealth bar all mounted and might have the rears done tomorrow if all goes well building my rear bumper. Here is a few pics
The chaos of wiring
here is the drill jig I made for mounting my front bar. There is about 3/4" between the light and my grill.

All mounted up

Grill closed.
I'm also in the middle of building my bed drawers so pics of that will fallow in a few days. So much to do! So little time!!

 

[Luckychase5]

Well today I got the bumper done, minus the swing out and installing my back up and license plate lights.


Here are the brackets I made. Simple 1/4" plate with 9/16 holes for three grade 8 bolts with grade 8 my lock nuts.


The arms are also made of 1/4" but 3x3 angle, just had to weld them on a cut to the right length.


Marked and ready for the cut-off wheel.


Here is type actual showing bumper. It's made if .120 wall 2x6" box. I cut these holes for the angle to slide into and be welded. The tension was enough to hold them quite well so lining them up was pretty easy.


Test fitting and tacking in place for final welds. And this is basically how it looks now, except for my zip tied on license plate and lights.



I welded it on the inside and outside of the box, hopefully strong enough to support me with the swing out totally loaded with 11 gallons of fuel.


And the final look. I'm waiting to paint it until I get the swing out, and all the holes drilled for lights.

Well there you go, hope you enjoy! Simple yet effective! I think about $60 in steel with some added cheap scrap and two cut-off wheels. Not bad for 3 hours work. Cheers!

 

[Luckychase5]

New brakes!!
So today I put on new calipers, pads and rotors today. As well as new brake fluid, passenger side unit bearing, abs sensor and U-joint. Here is some proof

Parts!!

All apart-ish

New rotos and bearing

Well I kept gloves on for about 10 minutes. Dirty hands!!

All new, so pretty!
And done! After a lot of brake pedal pumping

 

[Luckychase5]

Ahh and I also finished up wiring up all my lights, and switches!

Off

On!
Kinda fun, so now there are cheap harbor freight low profile lights on the back and sides, and a Baja Designs 20" Stealth bar on the front. I can't believe how bright that bar is! And only 20"! I can only imagine how bright the 50" once bars are. Crazy. Cheers! Hope you all enjoy all the work I've done in the last week or so. Now onto the bed system!

 

[Luckychase5]

We're off!

 

[EXP-T100]

Love the Landing light switch where did you pick them up? Good luck on your adventures!!, did you start a thread in the "In Progress Adventures" section? :beer:


Josh

 

[Luckychase5]

Otrattw.com for the switches. And not yet, soon when I have internet again. I'm sure we'll need a rest day from climbing soon

 

[Luckychase5]

Anybody know of a place I could potentially borrow a welder and drill in the Bozeman MT area? Ill be there next week. Thanks!!

 

[Luckychase5]

oh and here is the adventure thread!
http://www.expeditionportal.com/forum/threads/129855-The-Pegasus-Adventures

 

[Luckychase5]

Oh I finished my rear drawers before I left. Really like this slide set up, with 1" square steel tube in the drawers and skateboard bearings in the sides. The only thing needed for alignment and adjustment was a bunch of cheap washers. All built with 3/4 birch and a little maple

Here is the basic frame

And the drawers in place. The whole setup is 7.5" short of the full bed length to fit either my jerry cans or water cans.

And closed without the top deck
Pretty fun to build my second setup, hope to build a few more when I get back to a home base.

 

[Luckychase5]

Got some work done on my tear bumper today, just need to attach the toggle clamp, run the wires for my liscence plate light and paint! plates being tacked on
alignment of the arm going on

And final welds with my alignment wood holding everything in place
Hope to finish the rest tomorrow, but now it's time to cast some fly lines and hope to catch some dinner!