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DriftinBlzr
09-03-09, 07:27 AM
I thought I would start a project thread on my Blazer. I won't have very frequent updates as I seem to be busy with everything else in life except the Blazer. But I'll try to update the thread as much as I can.

I asked my wife what she thought I should name the project and she came up with "Project What the Hell" for a couple reasons. 1) When it's done, that's what most poeple will say when they see it. 2) Every time I go to work on something on the vehicle, something screws up and I want to scream, "What the hell?!"

My Blazer is a 2002 two door, 2WD, with the 5-speed. I has the Z85 suspension, 8.5" rear end, G80 posi, and GU6 3.43:1 gearing. It doesn't have cruise, power door locks or power windows or a rear window wiper. Pretty stripped down model.

The plans are to lower it, turbo it, and make it into a more race oriented, semi-Xtreme clone.

Here's how it looked most of the time I've owned it.
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN1997.jpg

I removed the roof rack and plugged the holes and I also removed the chrome trim around the headlights and the chrome bar across the grill. (I kind of have a hatred toward chrome. I'm not totally against it but try to keep it to a minimal amount.)

I then totalled my WRX in July and got a check from the insurance company and bought an expensive pile of stuff. I bought a marine intake, Zoom replacement clutch, QA1 coilovers w/ 550lb/in springs, 3" lowering blocks and a HP Tuner.

While walking through Summit Racing looking for trans fluid, they had some clearance tables out and I just happened to find some goodies. I picked up a set of returned clear markers for $20. Not bad I thought, until I came across a pair of 25mm Eibach wheel spacers for $25 (they retail at $202!)
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2756.jpg

I got a repop of an Xtreme grill from eBay for cheap. Even not painted, the new grill looks much better. The marker lights had small fitment issues but nothing a couple files and time couldn't fix. Now the front of the truck looks more complete. I still need to get the grill color matched though.
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2759.jpg

With my new coil overs and 550lb/in springs with the spring seat at 4.25 turns from the bottom, the vehicle was still at stock ride height. I wanted a 3" drop so I started looking for another set of softer rate coils. I got a great deal on a set of new 250-350lb/in coils and set them at 1/6 turns from the bottom.

I tried installing the 3" angled blocks from Belltech but the driveshaft was pushed all the way into the trans and I still couldn't get the locating pins to line up between the axle pads and the blocks. So back to Summit and I got some 2" DJM blocks for $20 less. After I get home and read the instructions (I know, who does that?) and DJM suggests getting block plates due to the narrow axle pads in the late S-series vehicles. Not wanting to run back to Summit or spend any more $$ I decided that making my own would not be hard. I found some 1/8" SS plate and made my own. After that I finally got the rear lowered.

Thanks to the wise people at GM but they decided that a 4x4 stance would be great for a 4x2 vehicle. So after a bunch of $$ and several trips to Summit Racing, I got Project WTH lowered. It's not as low as I wanted but it's close and I ran out of $$ to make it any lower this year. I think final measurements were 2.5" in front and 2.125" in the rear.
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2772.jpg

I also couldn't help myself and threw on the adapters and 2 of my Firehawk rims. The 275/40-17 Goodyear racing tires with shaved tread really demostrates that I need to go a little lower to make it look right.
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2773.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2775.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2776.jpg
The front rim/tire sits close to flush with the fender...
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2778.jpg
But the rear rim/tire isn't as flush. I plan on getting 1.25" spacers, instead of 1", for the rear to fix that.
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2777.jpg
I also turned the front wheel lock to lock to check for rubbing and I have at least 0.5" clearance to the nearest point.

That's about all the updates I'll have for a while. I still need to get my marine intake installed but I have to make the fuel injector wiring harness and all the fun stuff yet.

Later, Doug

'94 Big Blaze
09-03-09, 07:57 AM
cool stuff, check out http://www.dts2.net/turbos-10/ for your turbo needs.

spideyjected
09-03-09, 09:10 AM
This truck looks familiar! Nice ride!

DriftinBlzr
09-03-09, 09:11 AM
http://www.dts2.net/turbos-10/ for your turbo needs.

Looks like a nice site but pricey for a 4.3L turbo kit.:eek: I figure with some good bargain hunting I can build a complete system with intercooler for about $1,500 and that includes the marine intake and HP Tuner that I've already bought.

Later, Doug

12sws27
09-03-09, 06:33 PM
Cool! I new project to watch!. I like the wheels except for the red on the center caps. I got a 2dr Jimmy. Wanna trade trans and rear ends? :D

DriftinBlzr
09-04-09, 07:28 AM
I like the wheels except for the red on the center caps.Wanna trade trans and rear ends?

I'm going to try to strip the red around the center cap. I don't want to mess with the emblem as there are only around 26 sets of these exact rims in existance.

Oh, I'll swap you trans and rear ends only if you have a TKO 5-speed or T56 and a 8.5" 4x4 disk rearend. ;)

Later, Doug

12sws27
09-04-09, 04:42 PM
I'm going to try to strip the red around the center cap. I don't want to mess with the emblem as there are only around 26 sets of these exact rims in existance.

Oh, I'll swap you trans and rear ends only if you have a TKO 5-speed or T56 and a 8.5" 4x4 disk rearend. ;)

Later, Doug
What! You mean you don't want my 4l60E and 7.5/7.65?! That's what Camaros got. ;)

If I ever find a 4.3 short bed reg cab or Blazer/Jimmy with a 5 speed at a real bargain price I might start over again. My Jimmy would be so much more fun to drive if it were a manual.

DriftinBlzr
09-13-09, 09:08 PM
I lowered the Blazer a couple weeks ago. After driving it around, the back end seemed a little more bouncy than normal. I went to take measurements yesterday for some 3-link calculations and found the cause of the bumpy ride.

Right side bump stop had about 1/8" gap.
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2788.jpg

Left side bump stop was pretty much touching.
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2789.jpg

Apparently I forgot that I needed to cut down the bump stops after adding the 2" blocks. It looked like it had plenty of clearance when the suspension was at full droop. :grumpy_12

I popped the snubbers out and cut them at the 2nd groove from the bottom which shortened them about 2.5".
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2792.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2794.jpg

Installed back on the frame...
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2795.jpg

At ride height...
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2796.jpg
I was able to jump up and down on the rear bumper and actually had some suspension travel. Moral of the story, check bump stop clearance after lowering your vehicle. :rolleyes:

Later, Doug

DriftinBlzr
10-11-09, 10:07 PM
Update #1

I went to a swap meet about a month ago and picked up a few things. I got the light pigtails for the secondary lights in my turn signals. I got a Hurst shift lever for $5 and I picked out a new, still in EDP '95-97 OEM Blazer/Jimmy rear bumper for $20.

Three weeks ago, I went to a new Pull-A-Part location and picked up a pair of rear bumper extensions, a pair of rear bumper brackets, license plate light assembly for a '95-97 Blazer/Jimmy. I also picked up a fold down license plate bracket for a mid-80's full size Chevy car. All of this stuff for a few cents over $40.

The reason for the fold down plate bracket is that I want to fab some kind of hidden hitch and have it stick through a hole in the bumper behind the plate when I want to tow something.

Here's what I've done so far. I shaved all the un-needed holes in the license plate area and drilled two new ones for the license plate bracket. Two 8mm nuts were welded to the backside of the bumper for the license plate bracket bolts. The plugs were welded all the way around on the outside and tackwelded for extra reinforcement from the back and then smoothed on the front with a flapdisk and angle grinder. Excuse the splatter as I'm using flux-core wire. I still need to cut the top of the bumper and shave the rest of the holes for the plastic step, and shorten the bumper extensions.
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2807.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2800.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2801.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2804.jpg

The plan is to make a step shaver, without making the rear into a bubble butt like the ECC or other companies step shavers do. When I'm done it'll hopefully look like this...
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/109large2001_chevrolet_trailblazerr.jpg


I also got word from my painter that my headlight trim rings, Xtreme grill and airdam are done being colormatched. I got the 2 left side bumper brackets and have the upper right bracket on order. I think I'll be making the lower right hand because I having trouble finding a used one.

The back of the airdam's foglight holes have been cut so that I can eventually run brake ducts from them. My buddy said it'd be easier and look better to cut them before painting than after. I also hardly ever used the foglights on my WRX so I really wasn't bothered by not buying and wiring up new ones for the Blazer.
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/SSPX0055.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/Airdam.jpg

DriftinBlzr
10-11-09, 10:15 PM
Update #2

I also when back to Pull-A-Part last weekend and grabbed a fuel injector harness from a '00 Dodge Caravan with the 3.3L V6. The reason...some 2000+ Chrysler vehicles use the same EV6 connectors that the Mercury Marine intake uses. I cut the connector on the main harness side so it will be easier to splice into the Blazer harness. It cost me less than $10 compared to the $30 for 6 EV6 pigtails from eBay.

Here's a pic of my wiring mess. So far the hardest part of it has been figuring out how to pull the pins out of the connectors. Hint: A set of precision screwdrivers works wonders.
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2798.jpg

While I was messing with the marine intake, I also cut and filed the plate that is riveted to the throttle blade on a spare TB. A pair of tin snips and some files are all that is needed. The TB will be installed with the marine intake.
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2813.jpg

I also cut a spare A/C compressor/steering pump bracket in half becuase I want to ditch the A/C system. Here are the pics of the bracket after I was done with it.
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2811.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2812.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2809.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2810.jpg

I still need to get weld a nut on the bottom of the Hurst shift lever mentioned in the first update and buy a shift knob and that will be finished.

Later, Doug

hero dave
10-11-09, 11:19 PM
it's looking rather nice! love the wheels! need to update the pictures, looks like ALOT of air between the fender and the tire!!

DriftinBlzr
10-12-09, 08:00 AM
need to update the pictures, looks like ALOT of air between the fender and the tire!!

Nothing has changed since the pics were took so I have no reason to update them.

Yes there is a lot of space between the tire and fender and that's with the truck lowered a little over 2" all the way around. I'd like to drop it another 2" F/R but that's $$ becuase I'm going to either have to get Belltech 2102 spindles or a set of SD arms for the front.

Later, Doug

TreasonAgainstCaesar
10-12-09, 05:51 PM
I like this project.

What size rims are those? The side view made me think you should have something bigger, but the 3/4 view made them look dead-on right size.

hero dave
10-12-09, 06:00 PM
I can understand the $$$ thing..... mine is a 4" drop and it looks the part. my freind has one of your year s10 and it 4" ft and 5" back. the tires are equal with the fender. his drop cost way more than mine. but mine is 1st gen.

DriftinBlzr
10-12-09, 08:19 PM
What size rims are those?

The rims are 17x9.5" with some shaved 275/40-17 Goodyear Eagle Gs-C's tires.

Later, Doug

hero dave
10-12-09, 09:19 PM
i'll ask him next friday what his tire size is and the wheel size too. I work the weekend so thats the best I can do w/o waking up his family.

DriftinBlzr
10-18-09, 02:18 PM
Got my front end installed. My buddy and I also installed the DIY ghetto lip. I thought the $20 for the garage door seal, 3M emblem tape, and some auto trim screws would be worth it to keep from scrapping the bottom of the airdam.

Oh the carnage!!
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2833.jpg

Looking better...
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2836.jpg

Finished...
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2837.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2838.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2839.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2840.jpg

I have fixed the left headlight.

Later, Doug

droopy89
10-18-09, 02:32 PM
headlight looks out of alignment

jgx421
10-18-09, 02:37 PM
Sweet looking project...I like those Firehawk rims..

DriftinBlzr
01-24-10, 01:20 PM
A small update....

I know I haven't posted an update in a while but I haven't had anything significant to report.

Since my last post, I've acquired a non-A/C heater box, motor and fan. I've used my A/C about 6 times in 5 years and now it's lost all pressure and it's cheaper to ditch the system than keep it. Plus I'll trim some weight from the truck by doing so.

About a month ago I picked up a pair of 275/40-17 Dunlop SP9000 tires for free. They are in really good condition with at least 75% of tread left.
http://www.lotus-cars.eu/images/modifs/dunlopSP9000.jpg

Last weekend I also grabbed a 2.25 turn lock-to-lock steering box from a '91 Camaro from the junkyard. From what I've read the internal steering stops may give me a slightly bigger turning radius but with 275mm wide tires up front it will provide an extra margin of safety (http://www.blazerforum.com/forum/showthread.php?p=289014#) for rubbing.

I also finished my shifter project. I picked up a used Hurst shift lever, got a replacement knob through Summit and used a combination of shock spacer, and washers to make it work with the stock shifter and boot.
I have roughly $20 in it. It's slightly taller than stock but it works well with my elbow on the center console. I know my welds look like crap but they've held up so far and are hidden.
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2816.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2907.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2904.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2903.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2819.jpg
http://img.photobucket.com/albums/v39/Streetfighterkz/Blazer/DSCN2821.jpg

Later, Doug