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LCAC_Man #1027 LBZ Duramax Conversion
Author: LCAC_Man (Show all albums)

This album will cover the Duramax/Allison conversion(including dash cluster integration), installation of airbags to assist suspension, conversion of vacuum brakes to Hydroboost, replacement of Onan gas generator with a Onan/Cummins 5500LP, inverter/charger installation, dual roof a/c installation, and Bedroom reconfiguration that will add "pass-thru" storage.
Show Newest Photos First | Show Oldest Photos First461 Photos - Page : [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] [20] [21] [22] [23] [24] [25] [26] [27] [28] [29] [30] [31] [32] [33] [34] [35] [36] [37] [38] [39]

Power Safe SBS145F batteries, 145amp hours each, and 100lbs each. Made in the USA and typically used for higher end solar setups, they have a 10yr expected life.

Perfect use of the old air conditioning condenser mount location, just required a little beefing up to carry the extra weight. With these installed I can remove the heavy steel plates that were installed on the backside of the front bumpers to assist in handling.

Drivers side rear air bag lower mount, the tube structure is 1"x2"x1/8" and then plated both top and bottom with 1/8". Bottom plate is welded both inside and out. Gusset is 1/4" plate. The swing arm attachment is 3/8"x4" flatbar.

Access hole in the bottom plate allows you to install the air bag mounting hardware

Fabrication on all the rear air bag mounts is complete, I can reattach the shocks and install/plumb the airbags now.

Coat of paint and airbag installed, I'll wait until I compress the suspension to attach the bottom of the airbag.

Passenger front air bag upper mount in work, cleaning the under coating off was the worse part of this..

this is inside at the top of the wheel well and attaches to the top of the upper air bag mount spreading the load and reducing any transverse movement.

Fabrication complete on the passenger front. you can see the old upper shock mount behind the new structure, I was able to weld them together to further increase rigidity.

There were a lot of backside welds that you can't access, that's why I had to step it out a couple inches and use a combination of mechanical and welded joints.

Passenger front complete, new upper shock mount had to be made for relocation, lower is the factory mount re-positioned and reinforced.

Broke out my new hydraulic crimper and got busy; house batteries fully wired and connected...leads from the batteries to the inverter are 4/0 and were a SOB to route!
Show Newest Photos First | Show Oldest Photos First461 Photos - Page : [1] [2] [3] [4] [5] [6] [7] [8] [9] [10] [11] [12] [13] [14] [15] [16] [17] [18] [19] [20] [21] [22] [23] [24] [25] [26] [27] [28] [29] [30] [31] [32] [33] [34] [35] [36] [37] [38] [39]

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