1996 GMC K3500 Dually Build

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93M6Formula

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As if I don't already have too many projects, i'm starting another...
Hope you like to read because I like to type lol.

I was needing a crewcab again and after looking at a bunch of 99-00 CCSB trucks that were way overpriced and absolutely shot and GMT800 trucks being through the roof, I pretty much gave up until this came along. I've never owned a dually but i've always wanted one and this one fit the bill for being a GMC, 95+, a crewcab, and cheap. Wasn't totally wanting a big project but I figured i'd be searching forever and probably overpaying for something that isn't what I really wanted. This being cheap enough, it's pretty much a blank canvas to build the exact truck I need.

My 95 K2500 is my main tow/work rig right now and the poor thing is just getting so rusty and being an extended cab, it just isn't worth fixing now with a family being started. Makes me a little sad because I absolutely love the truck and how it looks so my idea with the dually is to recreate my 95 in dually crewcab form, color, drivetrain and all.

Now for the intro to the dually. It's a 96 SLE with a Vortec 454 and 4L80E and 163K rough miles. Very nicely optioned which made me happy, pretty much only missing leather. Has rear defog, overhead console, power seats, etc. The motor is bad which didn't matter because i'm building a 6.5 for it. I have tons of donors for parts laying around so the swap will be easy.

The truck is honestly pretty rough unfortunately... It was a farm truck and lived on gravel roads so it has rust and dents but not totally roached where it can't be fixed. Frame is solid for the most part, just minor pitting on the rear half although i'm going to replace the rear spring hangers. Floors seem solid so far, just going to need full rockers and cab corners. Doors, fenders, and the entire box is shot but I found a good box and I have everything but rear doors laying around.

This will be a complete frame-off/nut and bolt build that will cost me too much money but i'm all in... The final product plan is a Burgundy/Silver two-tone CCLB dually with burgundy interior, fresh 4L80E, fresh built 6.5 similar to the one in my current 95. I eventually want a slide in camper for it so my wife and I can travel a little as well. This will take awhile so I probably won't update regularly but I hope to have the truck of my dreams within two years.

The day I picked it up.
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93M6Formula

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This is about where I stopped for now. I started gutting the front end also but didn't take pics. Right now i'm waiting for my new garage to be built so I can bring this home from the farm and really go to town. Plan is to bring just the cab on the rolling chassis since that's basically all i'm using anyway. Probably going to start on the patch panel stuff first, then strip the chassis and get that all done.

I did get my rockers and cab corners from mill supply the other day.

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And here's my super mint dually bed I picked up friday. Came from the PNW and was a real good price so I was happy about that.

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Eskimomann209

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Last but not least, I picked up a set of 99-00 GMT800 2500 knuckles. This will allow me to do a GMT800 brake upgrade using all stock parts.

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Really tell me more.
What’s all needed just the knuckles out?
Obs upper n lower arms work?
Then the dually wheel adapter bolts right on?
I have a 93k3500 I’d be interested in doing this to.
 

93M6Formula

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Really tell me more.
What’s all needed just the knuckles out?
Obs upper n lower arms work?
Then the dually wheel adapter bolts right on?
I have a 93k3500 I’d be interested in doing this to.
Has to be 99-00 GMT800 2500 4x4 knuckles because the stock GMT400 tierods bolts right in. 01+ GM changed the taper so you would have to ream the hole to fit GMT400 tierods. The only modification needed for these knuckles is reaming out the upper balljoint hole to fit the GMT400 upper balljoint. You can then use 8 lug GMT800 lower controls arms, brake calipers, and rotors and 99-07 GMT800 half ton 4x4 brake hoses. Basically all plug and play with the right combination of parts and only modifying the upper hole. I am going to look into using GMT800 half ton UCAs though, I noticed they are the same width as 8 lug GMT400 UCAs so they may be able to be used. However I kinda want to keep the 400 upper balljoints, I feel like they are better.
 

Supercharged111

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Has to be 99-00 GMT800 2500 4x4 knuckles because the stock GMT400 tierods bolts right in. 01+ GM changed the taper so you would have to ream the hole to fit GMT400 tierods. The only modification needed for these knuckles is reaming out the upper balljoint hole to fit the GMT400 upper balljoint. You can then use 8 lug GMT800 lower controls arms, brake calipers, and rotors and 99-07 GMT800 half ton 4x4 brake hoses. Basically all plug and play with the right combination of parts and only modifying the upper hole. I am going to look into using GMT800 half ton UCAs though, I noticed they are the same width as 8 lug GMT400 UCAs so they may be able to be used. However I kinda want to keep the 400 upper balljoints, I feel like they are better.

What sort of 8 lug 800 stuff was available 99-00? The 400 was still going in that time frame.
 
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