Sal's K2500 Dana 60 Solid Axle Swap

strikk · Apr 29, 2022

Working on the intercooler. The core is mounted the bottom of the radiator support. The hood latch support was cut and will be fab’d up to mount to the intercooler. Piping for the drivers side was cut from generic polished aluminum tube and mandrel tube bends.

I also used a 4” x 9” k&n air intake element and a 4” elbow to finish up my intake. I’m not a fan of the blue but it’s what they had at the time

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strikk · Apr 29, 2022

The radiator was put together with a bunch of random coolant hose. Lower is 1.5” out of the block to 1.5” big block Chevy radiator, Cummins top port is 1.75” necked down to 1.5” with a coolant filter for now. I’m not sure what’s going to come out of the block so I’d like to try to keep the new radiator clean

strikk · Jul 22, 2022

Some more slow progress on the build. Mostly been collecting parts for a big push later on in the summer.

Finished up the intercooler piping, trimmed the battery tray a bit to fit. Finished up hydroboost and power steering lines with a small cooler mounted up front.

Picked up a 6.5 turbo diesel exhaust and some assortment of pipe to make a 3” downpipe and 4” exhaust out the back.

strikk · Jul 22, 2022

Started measuring for driveshafts and came up with this graphic. I’ve been shopping around for a driveline company to get me some custom shafts

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strikk · Sep 6, 2022

Worked through fitting the factory dual battery setup around my intercooler setup. The driver side took a bit of slicing and dicing to get the 3” tubing through the middle of it.

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BNielsen · Sep 6, 2022

Where'd you get the 6.5L exhaust from? The exhaust on my K3500 is cobbled together and I'd love to install a whole new system once I do the HX35 swap.
Also interesting routing on the intercooler, I may have to steal that since I want to retain a factory battery layout once I do my swap; only I'm torn between an LB7 swap or building up the 5.9L Cummins I got from a buddy.

strikk · Sep 6, 2022

For the exhaust I went with Summit Racing over Diamond Eye simply because summit had it in stock
SUM-680061 - https://www.summitracing.com/parts/sum-680061

i’m working on a custom down pipe made from 3”, I picked up 2x U bends that should have more than enough material to find it’s way to the oe exhaust location where the 4” will be. We’ll see how this all comes out, huge learning curve for me.

DonYukon · Sep 6, 2022

strikk said:
Started measuring for driveshafts and came up with this graphic. I’ve been shopping around for a driveline company to get me some custom shafts

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For custom shafts I was lucky and got mine locally. but there is a company TomWoods they do a awesome job but they are pricy.

b454rat · Sep 7, 2022

Highangledriveline. If he’s still around, been behind years…

strikk · Sep 7, 2022

DonYukon said:
For custom shafts I was lucky and got mine locally. but there is a company TomWoods they do a awesome job but they are pricy.

I was looking forward to doing business with Tom Woods as their reputation precedes them, unfortunately for me my rear drive shaft length is too long for their tooling. I had an excellent conversation with their rep over the phone, they were truly interested in the project and educated me further on what I would be looking for in a builder at the length I need. I will be purchasing the front driveshaft through them in the future, but thats low on the list of priority.

Thank you @b454rat for the recommendation, i'll give them a call!

Sal's K2500 Dana 60 Solid Axle Swap

strikk

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strikk

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strikk

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strikk

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strikk

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BNielsen

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strikk

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DonYukon

Dont stop until it sounds expensive

b454rat

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strikk

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