Rebuilding after 15 years of storage

[PHOENIX-GER]

Electric go on...
passengerside nearly ready - just some minor things to do
Also Dakota Digital is mostly done on the device





the exchangeable lightbar make also progress



I dont know how it is in USA - here you have to use reflectors Trailer triangle, and Vehicle all shapes beside triangle. So we perform turntables one side triangle and the other side square

 

[PHOENIX-GER]

We had a lot of "Fun" yesterday during we finished the electronic shifting for Dakota and Compushift on the 4L80e Transmission and we noticed we had missed our wiring diagrams for the cab to go on there


Well an option was to drive home and pick them up or continue with other work...
We decide to go on with the exchangeable Lightbar


This is ready now to got a nice hot cinque bath, of course without the lamps
We will finish the wiring on that bar after having the cinque bath

For info - until now was the 4L80e swap easy and just drop in.
Any wiring for Dacota and Compushift is prepared and well explained.
You need to know electric basics but nothing special additional.
Let us see if all go ahead so easy with the rest of installation.

 

[PHOENIX-GER]

Really it dont look like we going forward - but we do.... still not ready inside but a lot of forward.
And every evening after the job is done again transfer all installations and changes to the wiring diagrams



We noticed we still need another Distribution board/relay unit for the Parklight where we will connect fog light, fog rear light, parking light from the trailer, position indicators, lighting of radio. As we dont want hook them all just on the original wiring of the parking light.
Thinking also about a solution for control lamp for the 4x4 and Terrain reduction. Lamp is already in the system integreated. Just thinking how i can get that information from the shifting.
Also for the Blacklights i need a safety system as it will not pass the roadregistration with original setup
We thinking in a safety switch which give the blacklight circuit free.
Just now it is disconnect as it is not allow for roadregistration

 

[PHOENIX-GER]

Still on the electric... a neverending story
Coming up by first missing the parkbrake switch.


found it later correct bagged but not in the place where it had to be stored...
Now i need to figure out on Dakota how it will work with the new cluster



the function should be given with it, as parkbrake is listed on the connectors
What about Fasten Belts - this have a buzzer also
Double Protection with Lamp and Buzzer?



another part which is not more in use with the 4L80e
I have seen also an expensive part
We have to check the HGM instructions for the kickdown-switch

meanwhile i have order the TÜV/Roadregistration-papers for the M1102 towing eye. Without this paper, which come with a registration number for the test is it not possible to got a roadregistration with that towing eye.
I have to sent the towing eye to the shop which will do the safety testing by an TÜV Engineer. It come back with a registration number, which is in Germany highly important for any road registration.
Unfortunately for the military hitch is this not available. No one done this before.
It is an expensive choice. This is the only one offer here in Germany, so he can make the price you have to accept. Complete will it be 865 Euro and i still must take the trailer to the TÜV-Engineer that he sign the new registered Towing eye on that trailer - again 100 Euro. It is cheaper not to stay original... that what the former owner done for the roadregistration was around 300 Euro.



he cutted the towing eye off and welded this one on it. Got roadregistration with that in NL but not in Germany
As it is missing the welding certification for that job. It must be done by a professional.



It is a complex and expensive measure to let test something on its strengthen for a roadregistration. As a rule, it is only worthwhile if, like this store, you want to generate sales revenue later on. There is no demand for the US Military trailer hitch as there are Nato-Hitch and Rockinger with Roadlicence avialable.



I need only to send the towing eye for the test



Problems will also be with the lights on the trailer. Not allow here in that way they are used on it. Our Truck was in 1995 one of the last which have an extra allow on red turning and brake lights in one unit.
So we already plan to go with the moveable lightbar, so this should not make a problem
The red round reflextors on the back are also not allow and must be covered in road use
Trailers have here triangle reflectors to identify immediatly this is a vehicle combination.

 

[PHOENIX-GER]

Finally we finished the cab-electric
Our additional wiring is bigger than the original one only as we dont want to destroy the original one.
Now the dashboard is filled completely with wiring.







about a weak battsystem of a lot of testing are the lights also a bit weak beside we not remove the covers
We have here some rules to follow in roadregistration:
Highbeam are allow only 4 in roadregistration.
So the inner two on the lightbar have a switch, the both on the outer positions work with highbeam of the headlamps
Rear fog light only allow if front foglight is on
The worklight in the rear will be on with the switch without ignitioncircle or lightcircle.







Next will be Dacota and Compushift connection, than we can go to the engine compartment wiring.

 

[PHOENIX-GER]

the moment where you noticed you missed to complete the wiring for the temperature gauge.
Dacota have also a temperature device but as this was build in before and the hole was cut in ...





for trailer is a different relay necessary
Also for the hazard lights needed it to complete with a red warn lamp which is here necessary to got road licence for a vehicle.
In the past we had used this old bosch-switch instead the original knob





Now we will use the original knob with the light in the middle console



Trailer turnlight control is also necessary for roadlicence, it is the lamp above the hazard control lamp

 

[PHOENIX-GER]

We struggled a bit with the Gen1 and Gen2 indicator lights
Dakota does not have this function in the cluster so we had to reset the lamps outside the cluster
Very helpful was many informations on this community in that case
Finally we got them connected



but as you can see the indicator light of Gen 1 is not as bright as Gen 2
i should not be worried about it as the original cluster shown the same fact


We picked the signal up directly on the Switch Connector of the cluster.
I am not sure if we have enough resistor on that bulbs - they have 1,2W
What about the original bulbs - i dont know what power they have and i dont find anywhere an information about it.

also checked fitting about the safety Switch for the Blacklights







This switch shall allow to switch between a wiring circle with blacklights and a wiring circle without blacklights.
As you know roadregistration dont allow blacklight in function. So i must prevent this during a drive on public roads.
The original toggle switches could be actuated accidentally, but this is no longer possible with the safety switch

 

[vanaisa]

Man, you really love switches Overall excellent job! Too bad, that Germany have all those restrictions and rules.

 

[PHOENIX-GER]

Man, you really love switches Overall excellent job! Too bad, that Germany have all those restrictions and rules.

Thanks. I try to beat their restrictions with their own rules

 

[PHOENIX-GER]

Dakota Cab wiring is finished
To calibrate all sensor need them to install - located in the engineenviroment does this wait until today for to do...





Compushift is also complete wired
Of missing sensors and engine running pop up different calibration errors which is in this status normal

Radio wiring also completed and noticed that our DAB Radio from 2018 which was in our former Volvo used for a year is gone after storage of 5 years... needless to say it was running as we pull it out, storage can destroy this is already a fact which is well known.
The former UKW Radio from the Truck which was installed 2014 working well. It have no DAB but instead a CD Volume. Maybe match already better to the Building of that truck and i do not need to find a place to patch the ugly dab-antenna
This radio is also equipped with free hand mobil phone advice. Thats our primary goal.
Beside this the DAB Radio is still avialable for just 150 Euro. So no big deal if we really want to use DAB.

We coudnt test the speakers as we didnt find the old windows antenna connection... we take it out with the windshield. So it must anywhere in our shop. Small parts like to leave us anywhere in the shop and enjoy our seaching





Rest in Peace

I guess only using the two speakers in the dashpad will not be nice
We used in the past behind the seats two additional bigger 3-way-speakers - dont know if this is the right translation, but i am sure you know what i mean
Also if it dont make a difference during a ride about the high noise cab-level will it be nice to have a good sound by parking anywhere.

After collecting all parts we need for the military trailer electric does we decide to go with a new connection box.
The civilian trailer electric box is filled up. We dont want to have two seperate boxes



this one will cover up both systems in one safety box



The new box we bought for the Chevy will be still in use for the M1102 Trailer Military Electric.
The Civilian trailer electric will come with the moveable lightbar we already build.

Dakota RTX Video
There is no crack on the cluster - it still wear its plastic protection

 

[PHOENIX-GER]

So finally the papers for roadregistration for the M1102 Trailer and the Nato-Hitch is arrived.
It was impossible to got roadregistration for the old US Hitch.
But the Nato-Hitch from Dixon Bates have an announcement that they be build by manufactor with european standard trailer hitch values.
That make it easier but not cheaper to got roadregistration.
Now i got all my papers towing eye 850 Euro and the Dixon Bates 680 Euro for roadregistration.
With this i need to go to the TÜV Office and let an engineer checking that all parts be correct mounted and that this are the parts listed in the papers.
Both towing eye as also the hitch got an indiviual testing stamp number on it.
The trailer come with his own us registration import papers


Dixon Bates


Registration number - seems to be stamped from a student... if we had given ever such results in our job we would be fired!









not the same but nearly similar











with the roadregistration can the trailer be towed with any fitting hitch and i can tow also with the natohitch any fitting towing eye.
In the past some got a roadregistration in oldtimerstatus for only towing original military traier with original military trailer hitch. But this is today not more allow.

Beside this we start on the elctric in the enginecompartment

 

[PHOENIX-GER]

Last post April 28th...
Well we was busy by moving our horses to a new rented area.
There we needed to build a dry paddock zone like we had at our old pasture.
We take all our material from the old to the new location.
It was 3,5 month hard working time (pick up all from the old location and build up again at the new location) - but now we are ready in our new location and we can go on with the Chevy.

Beside this i had also an accident with a deer with my Volvo.
It was my first deer which i kill on the road.
The repair was done in a shop as i have an insurance for that.
I got a Hybrid Toyota for that time. I thought hybrid should be a good choice for future, but it isnt.
About the fuel ratio i couldnt find an advantage as i my way to work is about countryroads and highway around 35 km one direction.
It was not cheaper to use the toyota than my old Volvo C30 Diesel... (until 50 km/h is electric on, about 50 km/h will be use the gasengine) which will last longer as any electric vehicle, now 17 years. Show me any elektric car which is driving still with his original engine/battery after 17 years... The fuel economy is great if you be able to hold back your foot on the gaspedal. You can reach 5,5 l /100 km. Unfortunaltey i am havent such a selfcontrol. This little Volvo have much power and make as much fun. So i deal with a fuel ratio from 7-8 l / 100 km. I know you measure it in a different way....

Yesterday we wanted start with much enthusiasm on the chevy but at least we done nothing as take the actual stand of the job.
The last we was on - ended up with a failure:
Dacota Digital dont shown the right gear by shifting.
We was not in the mood to figure that out yesterday, neither was it with the trailer electric which need to complete (new distribution box for civilian and military electric).
So we just take the status whats still to do, which failure to solve .... and giving us a weekend of any work

We also have in the shop now the Kryptonite Front-End for the GMC Sierra.
Looks great - but this also didnt find our mood to start with it.



Maybe we become old now that we really need a time-off

 

[1love]

We had a lot of "Fun" yesterday during we finished the electronic shifting for Dakota and Compushift on the 4L80e Transmission and we noticed we had missed our wiring diagrams for the cab to go on there

View attachment 917471
Well an option was to drive home and pick them up or continue with other work...
We decide to go on with the exchangeable Lightbar

View attachment 917470
This is ready now to got a nice hot cinque bath, of course without the lamps
We will finish the wiring on that bar after having the cinque bath

For info - until now was the 4L80e swap easy and just drop in.
Any wiring for Dacota and Compushift is prepared and well explained.
You need to know electric basics but nothing special additional.
Let us see if all go ahead so easy with the rest of installation.

Is that 4l80e shifter electronic or manual? Or a better question, do you still use the steering column to shift gears?

 

[PHOENIX-GER]

Is that 4l80e shifter electronic or manual? Or a better question, do you still use the steering column to shift gears?

We use compushift controller and lokar for the steering column shifting.
For more information we must check the shifting again. I dont note what was wrong as we stop working.
There was much frustration about that failure and the knowledge that we must stop on the chevy for the moving let me just close the door of the shop.
I just remember, shifting was smooth but it dont show the right gear by shifting on the dacota instrument.

Next weekend we should know more about that failure.

 

[1love]

We use compushift controller and lokar for the steering column shifting.
For more information we must check the shifting again. I dont note what was wrong as we stop working.
There was much frustration about that failure and the knowledge that we must stop on the chevy for the moving let me just close the door of the shop.
I just remember, shifting was smooth but it dont show the right gear by shifting on the dacota instrument.

Next weekend we should know more about that failure.

Looks amazing! Very nice. What model shifter did you go with? I'm in the process of getting my shifter installed.

 

[PHOENIX-GER]

Looks amazing! Very nice. What model shifter did you go with? I'm in the process of getting my shifter installed. View attachment 929908

We use the Lokar Column Cable Shift Linkeage Kit ACA-1804

Rebuilding after 15 years of storage

Job for next weekend is save Lokar arrived also some other essential needed parts arrived as o-rings... used the last one in store two weeks ago oilcooler-line (transmission), fittings and some new hose-clamps for the cooling system

www.steelsoldiers.com

Build was not without customizing

Rebuilding after 15 years of storage

Job for next weekend is save Lokar arrived also some other essential needed parts arrived as o-rings... used the last one in store two weeks ago oilcooler-line (transmission), fittings and some new hose-clamps for the cooling system

www.steelsoldiers.com

We had the same problems like most reviews told for squarebody. We want stay with the steering column shifting. Mentioned we rebuild the chevy as oldtimer investment. So here in Germany we need to stay original or use exchangeable parts by storing the original. Thats why the TH400, the original instruments like all other parts we had improved stay with us.

By the way last week we brought all metallscrap from the chevy (bolts screws, suspension...) to the scrapyard 300kg - we got 51 Euro for that renew the truck was 3 zeros and some Euros more behind the 51. In this costs are 25000 Euro for the new drive train. And we have still not finished that build. But big costs should not be waiting for us except the new registration. Maybe they want some extra tests about the new drivetrain before giving us roadlicence on that truck again.

 

[PHOENIX-GER]

FInally could solve the problem with the wrong gear on display.
It was not a failure it was just a missing programming in Dakota...



As we stopped three month ago was no more time to check if all steps was done.

Beside this i can become familiar on the fuel costs.
Today i refill my Volvo 70 l tank ~ 100 Euro
The Chevy have dualtanks and now 140 l
Refill one time Chevy ~ 200 Euro
The price for fuel is actually low with 1,55 Euro / liter - usually is around 1,65/liter



15 Euro Premium was carwash - 2-3 times a year is that ok and worth the money. It is a good washcenter at that fuelstation.

 

[PHOENIX-GER]

a new problem occur.... like usual
We cant shift clearly, the cable shifter seems to be a bit spongy.
there are only two position where you can adjust the cable.
We work now the third weekend on it with no result
Nothing we want stay with it.
We are thinking about throw away the cable shifting unit an use a custommade rod again.
The idea behind using the cableshifter was the faster way than use a custommade rod.... There is nothing to buy on the shelf

Meanwhile we had check the Compushift TCM.
The TCM was programmed from Compushift on our demands, so that it is just a plug and play installation. Nevertheless i have access with the HGM APP by Bluetooth on the System. Needless to say, I am completely overwhelmed with so many possibilities and therefore gladly accepted Compushift's offer of pre-programming









These are just a few screenshot, its impossible to display all options.

 

[1love]

Use this one! I just installed with great success!

 

[PHOENIX-GER]

We decide to go on with the trailer electric during wait for the universal shifting unit



We decided to enlarge the box to bring all wires in from military- and civilian electric




trailer blacklights