Tink's - S10 / K5 Hybrid Project

[Tink]

The Goal: To have a S10/K5 Hybrid that appears as if it came from the factory that way (except for a lift and big tires, of course ).



The Reason: In the summer of 2003, the frame of the Baja buckled on the jack; the entire frame was pretty much rotted and rusted away from years of wheeling and life in the NY road salt. In addition to the frame, the brake lines and fuel lines were also suspect. The truck was no longer safe to drive on the road and the search for a donor frame began. A 1976 K5 was found shortly after. It was driven and wheeled for a few years before being taken off the road to begin the Hybrid Project.



Thoughts: Often, S10/K5 Hybrids do not have the wheels centered in the S10 wheel wells and some show the K5 frame rails under the front of the body/bumper. Usually, the distributor keeps the cab back. The cab could be moved forward by making a huge body lift so that the firewall would essentially be above the distributor, but this would cause typical body-lift gaps. The front axle could also be moved back about 2" instead.



Plan: However, my plan is to move the engine & transmission forward ~ 2 in order to achieve better wheel placement. The bed will be mounted first with the rear tires centered in the wheel wells. The rear of the K5's frame kicks up, so a small body lift will need to be fabricated to level out the box and therefore the cab will also have a body lift. The existing HEI set-up may be changed to a remote coil mount distributor if possible for added clearance. Further measurements will be done to determine how far forward the engine and transmission will need to be moved forward. (the engine cross member on a K5 frame bolts on) Next the cab will be installed. Since the S10's wheel base is ~ 1 in longer, the axles will then be moved if needed. Hopefully, the final result will be centered wheels, little frame to body gap and no appearance of the frame from the front of the vehicle. To keep the truck appearing factory, the gauge cluster will be switched to one out of an older S10 (86 to 88), so it will have a mechanical speedometer to mate up to the 76's cable speedo. Everything will be rewired using a painless kit.



The Questionable Things:
Dependent on how far forward the engine needs to be moved, should the rear driveshaft just be lengthened OR should the THM350 be swapped out for a 700R4 and adapter to mate to the NP203 (this will add ~ 2 in)?

Headers - will there be clearance issues and V8 swap headers be needed?

Steering column - will the S10 column work?

Tires - how large and wide will fit?

[Tink]

The Body: 1989 S10 Baja package - all body parts except for cab itself have been replaced. The front and rear baja tube bumpers are new and the roll bars are in good shape. Frame is shot.

S10 Frame cancer:




The Donor Chassis/Running Gear: 1976 Chevrolet K5 Cheyenne - Low-mileage Jasper-rebuilt 350, THM350, unadulterated NP203 Full time 4wd transfer case, Dana 44 Front, GM Corporate 12 bolt rear. Frame is in good shape, body is shot (I know it doesn't look like it in the picture above, but it is amazing how much bondo is in it).

K5 Body cancer:

[Tink]

Table of Measurements from both trucks:



These measurements were taken with stock rims, the S10 Baja on 235s and the K5 on 31s.

[1993blazerlt]

the s-10 steering column should work if you use a steering shaft out of a newr k-5. The 76 would have a splines on the end of the steering shaft where as the s-10 on would not. This swap has been done before i have seen pics on www.CK5.com of it

[<-~Jo~->]

so will it have solid front axle ? that will be awesome

[Tink]

Thanks 1993blazerlt for the steering column tip... I'll definitely check out that site too...

Originally Posted by <-~Jo~->

so will it have solid front axle ? that will be awesome

Yup, it will have the Dana 44 solid front axle. I would like to run at least 35s, but I have heard that 35s are really the limit of the D44, so I'm planning to upgrade to Yukon chromoly shafts (inners and outers) to increase strength.

[1993blazerlt]

the D44 can run larger than a 35 with no problem, it just depends on how bad you actuall beat on it. Running a tire like that you should also think about regearing or just find a set of 3/4 ton axles for cheap because they come with better gears anyways

i have pics here of mine i just put a 4 inch lift on and it is sitting on 35's
http://www.cardomain.com/ride/2206366

[Tink]

Updates:

Bought the wiring harness for this thing... 18-circuit harnesses with GM (column mounted) ignition switch plugs and a GM (column mounted) turn signal switch plug.



Decided to forgo the 700R4 for time and $ reasons and run the TH350 for a while...

The 76 is running great with the Holley Truck Avenger Carb, shifting smoothly, plenty of pep even with 3.08s and 33s.

Parts left to purchase:

New S10 core support
Bushwacker cut-out flares
New radiator (looking for something that will fit into the S10 core support in order to conserve space)
Electric fans

[Maxx]

check out http://www.v8s10.com and http://www.s10v8.com
A corvette one off rad would do nice i think.
As for steering shaft late 80's or early 90's F-150. Used in v-8 conversions on S10's. Just cut down. I don't know exactly how it would work for your application.
Headers for the v-8 s-10 swap on both sites listed.

[Maxx]

Check out http://www.v8s10.com and http://www.s10v8.com
a corvette one-off rad i think would be of good use