Offroad Trailblazers and Envoys

4Crawlin Build Thread

G80, GU6, GT4, GT5, WTF? This section is for gearing and driveline stuff.

by chevycrew » Sat Apr 02, 2011 8:05 pm

This is an un-official build thread so we can discuss as it goes. It will start out slow, but eventually all hell is going to break loose.

Keep in mind, this is a hobby, I work full time, and have a daughter that was born on 3-28-11...

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4-1-11
Purchased an 02 Trailblazer LT 4x4, Indigo metallic with Grey cloth interior, 130k.
Serviced, replaced wipers, and drove 500 miles home.

4-2-11
Repaired drivers front of roof rack (front screw was pulled through rack)
Installed cabin air filters
Replaced serpentine belt
Last edited by chevycrew on Sun Apr 03, 2011 5:33 pm, edited 1 time in total.
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by chevycrew » Sat Apr 02, 2011 10:51 pm

Guess I can give some insight to what the plan is.

Here is what I have gathered so far:

NP231
Box 4 Rocks Doubler
NP241 with SYE
Dana 60 front with 4.56's and locker
10.5" 14 bolt rear with 4.56's and locker, factory disc brakes
CV driveshafts front and rear
1” Body Lift pucks
Steering gear box (drilled and tapped)
Hydro assist ram and lines
2” wheel spacers (set of 4)
42x15x15 swampers on beadlocks.
10,000lb winch
Yellow top optima
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by chevycrew » Sun Apr 03, 2011 1:37 am

Just to show Im serious:

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Pucks: ^^^

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231 t-case: ^^^

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241 t-case: ^^^

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Boxs 4 Rocks Doubler kit: ^^^

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Dana 60 and Drive shafts: ^^^

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Steering gearbox: ^^^

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Ram, Pitman arm, hoses: ^^^

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42s on beadlocks: ^^^
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by SteveTB03 » Sun Apr 03, 2011 2:24 am

Nice parts you got there so far.

What's the steering box out of? And are putting on a SYE on the t case at all?

EDIT: Nevermind I'm pretty sure your going to be using the 241OR for the last t case as it has a fixed yoke and no need for a SYE like the 231 needs.
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by chevycrew » Sun Apr 03, 2011 2:50 am

The steering gear is a spare from my crew cab, fits 88-98 chevy trucks. Pitman arm is a 4" drop for a 78-79 ford.

Im using the 231 case up front, turned into a doubler. Rear case will be the 241C, it has a JB conversions SYE kit installed from my last build.


Its going to be close, I may have to be creative with rear t-case to fuel tank clearance.
Last edited by chevycrew on Sun Apr 03, 2011 6:03 pm, edited 1 time in total.
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by SteveTB03 » Sun Apr 03, 2011 3:23 am

Ooh I thought it was the 241OR like in the jks.

How much are you going to lift it suspension wise?
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by chevycrew » Sun Apr 03, 2011 3:57 am

Not sure exactly on lift, but enough to fit my 42s. Its looking like around 12" though.
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by dirty anton » Sun Apr 03, 2011 9:32 am

:shock: :drool3:
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by DmccartneyFF2TB » Sun Apr 03, 2011 9:45 am

My hero..... Pumped to see this happen
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BDS,ROUGH COUNTRY,
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33" Procomp M/T X MARK SPACERS.
Only Blue lifted 2002 Trailblazer in WMASS.
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by Rob93 » Sun Apr 03, 2011 10:45 am

Why wheel spacers on full width axles?
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by chevycrew » Sun Apr 03, 2011 11:31 am

My 42's are on 15" wheels, they wont clear the dual piston calipers on the front, or the rear.

It will also give me more stability, and the tires wont be as likely to rub on suspension components.

My other tires, I have 37's on 17's (H2 wheels with 5.5" backspace), and 40's on 17's with 4.5" backspace. No matter what I run, the spacers will be a plus.
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by HARDTRAILZ » Sun Apr 03, 2011 12:21 pm

I like it. Was planning the start for myself. Swapping some good parts from other build to keep then sell leftovers to buy other parts. Will giv you a call soon about suspension thoughts.
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by chevycrew » Sun Apr 03, 2011 2:33 pm

I really havent been under it enough to figure out suspension yet. Im hoping this week.

For now Im going to start on my bumpers, sliders, winch, and body lift.
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by chevycrew » Sun Apr 03, 2011 5:42 pm

Well I dove into this thing today.

4-3-11
Front and rear bumper covers off.
Front and rear bumpers off.
Mudflaps removed.
Inner fenders (in front of front tires) trimmed.
Measured for dual cases... going to be a very tight fit against the tank, may have to slide it back a little.
Poked around a little about suspension setup.


Ive noticed some other things that will need to be addressed:

Behind the rear tire, there is a section of body that drops down, looks like an empty box. (It needs to go)
Rear hitch hangs way to low.
On the front fenders, where the bumper cover attaches needs trimmed off.
Exhuast behind rear axle is a joke.

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by chevycrew » Sun Apr 03, 2011 6:34 pm

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Some shots of me pulling it apart. Some have crap lighting due to the snow in the backbround.

Note the shot of the rear hitch flipped...
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by The Roadie » Sun Apr 03, 2011 7:22 pm

You're discovering in three days stuff that took some of us five years to get around to. Cool!

But I always said (back when most of these were bought new for $30-35K, and everybody still had loans and used them as their DD) that REAL builds and SAS projects were going to happen when they could be bought used for $5K and not needed for everyday transportation, by folks who already owned welders and it wouldn't be their first build. :cheers:

The resonator (we call it the trash can) is indeed laughable, and one of the first things I dented in on rocks and ripped off.
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by chevycrew » Sun Apr 03, 2011 7:33 pm

How did you know what I paid? :o
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by Trail X » Sun Apr 03, 2011 10:55 pm

Don't forget to put something in your plans to protect that radiator. It hangs down pretty far, and with the IFS subframe gone, you're not going to have much to bolt a skidplate to.

Even though I'll probably never do an SAS, I can't wait to follow the build. You work rather fast compared to our normal crowd. :salut:
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by chevycrew » Sun Apr 03, 2011 11:05 pm

Most likely Im going to run leaf springs. That will have some spring hangers that drop about 6" down from the bottom of the frame. Ill run a crossmember betwen the two, then cut out the factory tube crossmember for winch placement.

That should be plenty to protect the radiator.



But thanks! And keep the ideas coming, you guys have way more experience with these rigs than I do.
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by Diacom » Sun Apr 03, 2011 11:41 pm

For front coils, is it the upper coil basket or the link arm mounts that would create the most trouble? Though I'm more like JD, I doubt I would ever do a SAS, i'd end up buying a Jeep if it comes to that, I am interested in the build.

Beings your plan is to have this easily duplicated, and possibly a kit, I would think a bold in upper coil mount would be a solution, unless there is a problem with clearances. I jig and tubing bender would easily reproduce a kit once created as long as it was something that worked.

Keep up the good work.
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