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Square Body Cummins Swap Part 1 (Boxing and Prepping the Frame) 

ChucksCustoms
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Welcome to Chucks Customs! In our first episode we're gonna kick things off by attempting a slightly controversial engine swap. Cramming a 12 valve Cummins and Allison 545 transmission into a 1/2 ton, 2wd, 1978 GMC Sierra. A lot of people say it cant be done, and they might be right... but we're gonna find out the hard way as we attempt the impossible, right here on Chucks Customs!
In this episode we're focusing on getting the frame ready to accept 1,400 pounds of american cast iron! First I have to clean the 40 year old dirt and oil off of the frame, then I can focus on removing anything that might be in the way (brake lines, wires, exhaust, etc.). Then I'll be using plate steel to box and stiffen the frame, removing and making crossmembers, and installing the new motor mounts.
Materials used in this video include:
-1/8 inch plate steel
-1/4 inch plate steel
-1 1/4 inch schedule 80 steel pipe
-And a gratuitous amount of .030 flux cored welding wire
Music
Song: Electric Youth
Available on ampletunes.com
I am not affiliated with or sponsored by Ampletunes.com
However I do give credit where it is due. Thanks to the guys at Ampletunes.com for creating free/ royalty free music for creators to use without having to worry about copyright infringement. Super easy website to use and the selection is great! Thanks Ampletunes!

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26 сен 2018

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Комментарии : 88   
@thereelangler2391
@thereelangler2391 5 лет назад
Every Chevy 305 is clapped out from the factory. It was a standard option.
@ChucksCustoms
@ChucksCustoms 5 лет назад
Lol very true
@imonaroll9502
@imonaroll9502 Год назад
Sweet. It’s great that you show the real dirty work with the tear down. ❤
@joelbookhagen6654
@joelbookhagen6654 5 лет назад
Excited to see you continue this project buddy, can't wait to see it finished
@tjs_welding_and_fabrication
Reminds me of my 85 k10. Frame cracked in half both left and right side frame horns from plowing snow. Pulled engine clamped and welded frame with a steering box plate and boxed the horns where the dual front shocks mounted all the way back to the trans crossmember. Was back out plowing the next day. Good times. Nice work.
@josechairez3285
@josechairez3285 Год назад
Hey Chucks,I’m enjoy what you do on this Chevy o sierra saludos desde Yuma Az
@ttngarage
@ttngarage 4 года назад
AWESOME VIDEO! Very clear and comprehensive explanation of every part of the process! Loved every bit! ;)
@ChucksCustoms
@ChucksCustoms 4 года назад
Thank you! Glad you liked it!!
@christianjulian4800
@christianjulian4800 5 лет назад
Was an awesome! Video I've been wanting to do this to my 84 cucv for a while and haven't had the balls to dive into the project.. your vids are definitely going to help my dream come true man!
@ChucksCustoms
@ChucksCustoms 5 лет назад
That's incredible! Thank you, so much! And I'm glad I could help!
@MrMpala69conv
@MrMpala69conv 5 лет назад
Great video!!! Your giving me ideas on my blazer swap.
@mikeymcknight9524
@mikeymcknight9524 5 лет назад
Great video. I'm about to do a 12v swap on my 86 m1009 cucv. It has a tired 6.2 turbo diesel but it's just not enough. Thanks for the informative videos
@ChucksCustoms
@ChucksCustoms 5 лет назад
Sounds like a good build! And it was my pleasure 👍
@charlesstevenson5141
@charlesstevenson5141 4 года назад
I have a 97' 6.5 dually that I have been wanting to swap during a full frame off restoration but I agree with Chuck that you can't hardly find any info on the swap so you have to take what little tid bits of info you can get and piece it together. About 2 years ago I atarted collecting all the data I could and have a binder dedicated to pictures, diagrams, parts lists, procedures etc.to ease the process before actually getting started.
@TheTexasVet
@TheTexasVet 5 лет назад
Subscribed! Loving the Channel along with all of the great videos. I started out of order but wanted to start over with episode one. Keep up the awesome work!
@ChucksCustoms
@ChucksCustoms 5 лет назад
Thanks for the support!
@johnbehneman1546
@johnbehneman1546 Год назад
GREAT VIDEO CHUCK!!!! GREAT IDEA ON BOXING THE FRAME. ANYBODY CAN DO THAT. I LOVE YOUR PROJECT!!! GREAT VIDEO AND THANKS FOR SHARING. I LEARNED SO MUCH.
@diazmike427
@diazmike427 4 года назад
Nice work! Doing the same with my 1/2 ford
@chrishester3738
@chrishester3738 5 лет назад
Love this project! Thanks for sharing the vids. I'm on the hunt for a second gen cummins to drop in my 1970 Winniebago and, while the platform isn't the same, these videos will come in handy with some of the roadblocks I'll be facing too. Good job, keep up the fun!
@ChucksCustoms
@ChucksCustoms 5 лет назад
Thanks! That sounds like one badass project! Keep me posted on the progress once you get started, I'd love to see how it turns out!
@chrishester3738
@chrishester3738 5 лет назад
@@ChucksCustoms Will do! I know I have my hands full but it'll be a fun project. Looking forward to seeing your truck on the street! Going to be badass, that's for sure!
@ChucksCustoms
@ChucksCustoms 5 лет назад
I really appreciate it! Hopefully a new video will be coming soon!
@nellyfarnsworth7381
@nellyfarnsworth7381 4 года назад
Surprise, Surprise, surprise. The Winnebago is built on a DODGE one ton frame. Same frame as the first year dodge cummins pickup????????
@imonaroll9502
@imonaroll9502 Год назад
Might want to box the front. Some chevys would crack right around the steering box.
@sandvillage1242
@sandvillage1242 3 года назад
That's exactly what I want to do with my square body!
@EricRyanSound
@EricRyanSound 4 года назад
"This is chuck's customs... that's not gonna stop us from tryin'! *look*" lmao
@ChucksCustoms
@ChucksCustoms 4 года назад
😂
@chevyzillav8monster870
@chevyzillav8monster870 5 лет назад
Thank You for this video. Helping me out alot. God Bless
@ChucksCustoms
@ChucksCustoms 5 лет назад
My pleasure! Glad I could help!
@gagewarneka9244
@gagewarneka9244 3 года назад
I got a 78 c15 too but im looking to drop a lbz duramax in it is it worth boxing the frame or looking for a 1 ton frame?
@Domi-83
@Domi-83 3 года назад
you remind me of myself when i am working on my 35yo bmw e30 wearing ripped jeans. How come they never appeared anymore in other vids? Looks epic.
@Aliceswonderclam
@Aliceswonderclam 3 года назад
Great video, terrible welds lol.
@truckman63
@truckman63 5 лет назад
You know what's even sadder is that nobody supports a 2wd version. Heaven forbid we dont drop another grand into something that will never be used. But good luck on your build man I really can't wait to see how this turns out.
@ChucksCustoms
@ChucksCustoms 5 лет назад
I appreciate it man!
@loganspargo9222
@loganspargo9222 5 лет назад
Better to have it and not need it than need it and not have it is my view but I live in the desert with lose sand everywhere you can get stuck easy if your not careful I guess it depends on where you live but I have been all around the country and if you want to go places that aren't paved your better off with a 4x4 there is use for them everywhere
@ChucksCustoms
@ChucksCustoms 5 лет назад
I would love to have 4x4 but this was all I could afford at the time. Plus it's a matter of concept to see if I could do it lol but I do plan on doing a 4x4 conversion down the road! Should make for a few good episodes 👍
@truckman63
@truckman63 5 лет назад
@@loganspargo9222 The truck im planning on doing a diesel swap in is going to be a highway truck i have no need to take it offroad after all its a 70 f250 id rather not bang it up off roading through the woods
@durawins
@durawins 4 года назад
Holy cow you found a rusty one to revive
@ZerokillerOppel1
@ZerokillerOppel1 4 года назад
6:27...Pakistani Truck Channel style bro!!😉😅 But that's how you get the job done!!
@so-flamotorsports7491
@so-flamotorsports7491 3 года назад
Not bad for flux core really lol . Cool build
@ChucksCustoms
@ChucksCustoms 3 года назад
Thanks!
@zebwhelchel4393
@zebwhelchel4393 3 года назад
I wanna do this with me 1965 k10, but with a 4bt Cummins, 400 more pounds of engine might not end well for the smaller axles
@ChucksCustoms
@ChucksCustoms 3 года назад
Good call! Lol that truck would be sick!! 😎
@mxcatkiller
@mxcatkiller 4 года назад
Only? 20k views, and 344 likes??? Guess not much building goin on these days. Very nice! I’m fixin to start a project my self!
@ChucksCustoms
@ChucksCustoms 4 года назад
Not as of lately lol but I'm hoping to get back into the shop very soon! What kind of project are you working on?
@mxcatkiller
@mxcatkiller 4 года назад
ChucksCustoms I was meaning other people not building as much, I’m sure most are paying a shop to do the work. I have some body jobs to do. I have to get some space cleared and cleaned up in the shop before I get started on anything 😂😂
@jessiej3991
@jessiej3991 5 лет назад
Hey Chuck got any plans for that Predator engine on that table behind you? Maybe you could build a mad max themed go-cart for us or a trike or something along those lines? Just thought I would throw some ideas around for another custom build from you
@ChucksCustoms
@ChucksCustoms 5 лет назад
I've got pretty big plans for it! I cant tell you exactly what, but it involves something I've never seen attempted before. If it works it should make pretty big power! Should be starting that project in a few months. That's for the suggestions!!
@bensproul4836
@bensproul4836 3 года назад
Thinking of 12v + nv4500 swapping my 05 crown Vic police interceptor haha
@ChucksCustoms
@ChucksCustoms 3 года назад
That would be sick! Lol
@javynlandscaping2677
@javynlandscaping2677 4 года назад
So if I'm installing a cummins into an 87 R30 1 ton.... I don't need to reinforce the frame....?
@ChucksCustoms
@ChucksCustoms 4 года назад
I wouldn't think so. You probably could if you REALLY wanted to have a bullet proof rig lol but I don't see why it would be necessary.
@TheRossillini
@TheRossillini 2 года назад
At that point you don’t think it would’ve been wise to pull the bed and cab?
@ix_d3monzz_xi135
@ix_d3monzz_xi135 4 года назад
Got a 87 454 SM465 gmc high Sierra last week , debating on doing this with it , mine is 4x4 so maybe it wouldn’t be as bad , what’s your thoughts on doing this
@ChucksCustoms
@ChucksCustoms 4 года назад
If you're going to do it, 4x4 is definitely the way to go. You have a lot more room to work with because the 4x4 has the straight axle instead of the bulky crossmembers like mine. I would definitely say youd have a badass swap on your hands if you decide to do it! 👍
@ix_d3monzz_xi135
@ix_d3monzz_xi135 4 года назад
Yes sir thanks!
@nellyfarnsworth7381
@nellyfarnsworth7381 4 года назад
@@ChucksCustoms 1. Sell it 2. Go buy a DODGE pickup 3. Will be cheaper than conversion. 4. Only need conversion of the mind. 5. Be Happy 😊 6. I have a low mileage 3500 DODGE CUMMINS/AISIN for sale. AISIN transmission is better than Allison. Aisin is made by the world's largest transmission manufacturer. Also has factory CUMMINS/ AISIN exhaust brake. I towed my huge R.V. fifth wheel UP the Rockie Mountains on CRUISE CONTROL. USED CRUISE Control & exhaust brake on the down slope side. All without touching a pedal. If you want to tow with the big dogs, buy a CUMMINS/AISIN.
@ChucksCustoms
@ChucksCustoms 4 года назад
I already AM happy man! that's why I did the swap lol I simply dont like dodge pickups, just not my thing. No hate to guys who do like them, but I prefer old school GM. And I promise you, the swap really was way cheaper than buying a dodge cummins. How much are you asking for yours? I'm not much for towing, but it sounds like a badass rig you've got on your hands
@morgansword
@morgansword 4 года назад
There is not enough room for negative comments on a 305 chev engine but this is not what this is about... that said did one in a highboy ford and just curious as to what your struggle was. Maybe the body being in the way all the way but then how are you to know where to stop with everything.. curious is key
@MrLobsta21
@MrLobsta21 5 лет назад
Woo hoo first comment on this viral sensation!
@MrClarkisgod
@MrClarkisgod 3 года назад
Tattoos, low fade, web belt.... US Marine stationed currently or recently in California?
@EricRyanSound
@EricRyanSound 4 года назад
15k views!? Damn dude Im sending you some music! lol
@ChucksCustoms
@ChucksCustoms 4 года назад
I'm just as surprised as you are! Lmao
@K5junkie
@K5junkie 5 лет назад
Rob Bonney Fabrication sells a frame boxing kit for 67-87 Chevy. Excellent choice for DIY. Check em out on eBay
@ChucksCustoms
@ChucksCustoms 5 лет назад
I'll have to remember that for the next one! Thanks for the tip!
@TheTexasVet
@TheTexasVet 5 лет назад
K5junkie Do you know if they make one for a ‘66 Model C10?
@PeterHatch-mx7zc
@PeterHatch-mx7zc 4 года назад
Can you whistle no cant sing to LOL. LIKE THE video welder better weld if it's a 220 volt is the pan front or rear sump aa for trans better with a 47 rh .or a 48re. 47 cheaper non electronic it 3speed with over drive and lock up converter. Do your killer Dial pin why you've got the engine on the ground any questions call me the 545 trans one to one Ratio your 1st 2 years are gonna be too low for the weight of the vehicle just trying to help out mate.done a lot of them
@grimwulf7173
@grimwulf7173 Год назад
Ok correct me if I’m wrong but the Gen 1 and Gen 2 Cummins only had 400 to 500 lb of tq. A 454 had that much and they where in 1/2 ton trucks.
@frankdaiello2449
@frankdaiello2449 Год назад
The difference is a 454 probably gets 8mpg unloaded lol… also, the diesel can make that torque at 1400rpm vs 4500rpm
@grimwulf7173
@grimwulf7173 Год назад
@@frankdaiello2449 I’m not disputing that a Cummins is a great engine I was asking why box the frame if that frame wood handle the talk of a 454 which was the same as a GEN one or Gen 2 Cummings?
@ChucksCustoms
@ChucksCustoms Год назад
I boxed the frame just to be safe for now, but I also intend to tune the engine much higher in the future, so this saves me the trouble down the road 👍🏻
@grimwulf7173
@grimwulf7173 Год назад
@@ChucksCustoms aww ok very cool
@arlenewolf5260
@arlenewolf5260 4 года назад
If you want a project, I would like a Cummins R2.8 in my like new 1987 S10 Blazer 62K original miles.
@ChucksCustoms
@ChucksCustoms 4 года назад
Now that would be a badass project!!
@arlenewolf5260
@arlenewolf5260 4 года назад
@@ChucksCustoms Does that mean you might be willing to do it for me? The Blazer looks almost like it never left the showroom when you look under the hood. The interior looks like it was never sat in. It was senior citizen owned and garage kept and still is (i'm getting up there). Original paint. It does have a small crease on the pass side front wheel opening, the power door locks need repair and there are some vacuum issues (the AC only blows cold under the dash and there is no vacuum to the 4WD booster behind the battery probably just a bad vacuum switch). The factory 2.8 V6 gas engine in it is toooooooo slow, the wife's 4 cyl Hyundai is like a race car compared to it. The Factory V6 is just a 135HP slug with no torque. It is like having a New Chevy 3500 dually with a Vega 4 cyl engine.
@ChucksCustoms
@ChucksCustoms 4 года назад
@@arlenewolf5260 I would love the opportunity to try! But right now it would be difficult to say yes in my current situation. I'm getting ready to move up to Michigan so I'll be out of commission for a little while as far as projects go. But if youd be willing to foot the bill for parts (and of course some labor) I'd be more than happy to try once I'm settled in my new place!
@arlenewolf5260
@arlenewolf5260 4 года назад
@@ChucksCustoms Keep my email this may happen. The Blazer is a garage queen and just sits there for now.
@ChucksCustoms
@ChucksCustoms 4 года назад
@@arlenewolf5260 awesome! Are you on instagram? If you are add me @chuckscustoms and we can direct message there. Otherwise I'll just try to catch you on here again when the time comes 👍
@theadamfangue
@theadamfangue 5 лет назад
I’m about to start the same swap in my 87, it’s an old military truck came with the Oldsmobile 6.2 diesel, but it’s time for some more power. What size metal did you use to box the frame in with? If you don’t mind me asking. I’m working on researching as much as I can when I stumbled on your channel and immediately hit that subscribe button!
@ChucksCustoms
@ChucksCustoms 5 лет назад
I appreciate it! To box the frame I used 1/8" sheet steel. You should he able to find it at your local machine shop/ metal supplier. If you measure your frame height (typically 6 inches on these trucks) they should be able to cut it into strips for you. It saved me a ton of time and made it a lot easier to transport and move around the shop
@ChucksCustoms
@ChucksCustoms 5 лет назад
I've always loved those military squarebodys! Such beautiful trucks. Keep me posted on the build, I'd love to see how it turns out!
@theadamfangue
@theadamfangue 5 лет назад
I sure will, hopefully I’ll be starting the build soon.
@JEDS_GAMING04
@JEDS_GAMING04 4 года назад
With the square body's basically all the frames were the same from the duallys to the single rear wheels
@shawnsutube
@shawnsutube 3 года назад
That’s wrong, the K30 frames are different.
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