[ForeverAlive91]

91 Dodge Dually Show Truck Build Thread

Hi everyone my name is Will, I'm only 18, and I'm reinventing my 91 cummins dually. This truck was my dads work truck since before i was born, and he worked it hard i tell you what. Now that he got a new truck awhile back i decided to take it and fix it up for myself. This truck has 273,000 miles on it which we all know is just a real good warm up for these trucks, and for being a work truck the body wasn't as bad as i thought it would be.

This is what the truck started out as.

The truck had an oil leak and a little fuel leak. My dad and i had to take the injection pump off and get it resealed which is where the fuel leak was coming from. It was the first injection pump i ever took off a truck so it was a long process. While that was off we were able to also fix the oil leak by putting a new gasket on the pushrod cover. The old one had about a 1/4 inch crack in it. I don't have any pictures from doing all the motor work though.

Now i have recently started on the body half of the project and at the moment have it all stripped down.

I also took out the dash so that i could paint it and so i could swap the doors on the truck.

Since 1. i hate fiberglass, 2. one of my fenders was broken, and 3. i like customizing vehicles, i got the great idea from a friend to put rear fenders from a 56 ford truck to cover the outer wheel.

Here is the fender up against the truck to get an idea of what it looks like. When it gets installed the box will be cut to match the fender and the fender will be welded in place.

The dash was the stock maroon color which was all faded, and that color won't work too well with the matte black that I'm painting the truck. So i decided to paint it a gloss black to match the gloss black interior of the truck.
Here is the dash with the stock color.

Here it is after i painted it.

Then i saw the other day a friend of mine, has a 97 dodge that got hit by the killer dowel pin which jogged my memory that i still had to buy a KDP kit. And so i did, and installed it the other day.
I made it easy on myself since i had the fenders off, i just when and took the whole core support off as well.

Then of course took the fan off and the timing gear cover and ten minutes later had the new bolt and washer installed.

Now with that taken care of its back to the body work, and the best part about that is i have a whole other truck sitting waiting to be stripped out.

My favorite part is the original grille in perfect condition.

Sitting next to the parts truck is the poor old girl waiting for parts.

The first part i have swapped between trucks was the steering wheel because the donor truck has half as many miles on it so most of the parts are nicer than the ones on my truck.
Here is my old steering wheel out.

And the new one in.

I'll be sure to keep ya'll informed as i keep getting more and more done on the truck.

 

[9297oldram]

Did you check the cover bolts on the inside, they can work loose also.

It would be a good time to adjust the valves while you can get to them easy.

Looks like that project will keep you busy for a while, keep up the good work.

 

[ForeverAlive91]

Ya they were good, and probably a dumb question but adjust the valves how, and yes it will keep me pretty busy but my goal is to have it done about around April hopefully.

 

[9297oldram]

Sounds like you better go to genosgarage.com and get you a factory service manual. It will be the best money you'll spend on your truck, between that and CF you'll find all you ever wanted to know about your truck and then some.

 

[ForeverAlive91]

Ya i have learned a good bit about it so far but would love to know every single little thing i can about it.

 

[ForeverAlive91]

A little update here:
Got the core support tore apart and cleaned up now i have to paint that.

I got all the body parts off the donor truck that i wanted:

Also got the heater box out of it to put in my truck, and took my old one out as well.
My truck:

New heater box, (took the top of to clean up the inside and get the heater core flushed)

Reason I had to put a new heater box in:

Then i started cutting out the passengers side of my bed so i can install the fender.

First time ever using a die grinder and pretty happy with the out come.

 

[Dazed&Confused]

Be interested to see how those fenders look finished. I would make mounting brackets so i could unbolt and remove them in case one ever gets hit though.

 

[ForeverAlive91]

Ya i might do that depends which ever i can get to work better.

 

[ForeverAlive91]

Another update here:
Got the box cut to resess the fender, now I just have to mount it. I also have to fill in from the bottom of the fender to the bottom of the box.

Also set the new seat in there to mock it up and figure the mounts and holes to drill.

Got the new heater box in.

And then got a few front end things painted.

 

[jawman]

nice job on the build. looks like you are actually getting it done, unlike a lot of projects that get torn down and never get put back together. got a few questions for you:
1' what kind of prep work are you doing before painting?
2' what paint are you using?
3' what kind of spray setup are you using"?

 

[Mosier Cattle Co.]

Like jawman said glad to see you getting this done. I will be following closely as come this spring i am going to do the same exact thing to my truck. Tear it all down and build it back up. Keep up the good work. I would also like to know what you are using for paint and how you are applying it.

 

[dB Zac]

There is not many of us 2wd duelers on here. Looks good

 

[ForeverAlive91]

Hey thanks for all the compliments and support guys, and ya my goal is to have this done by April hopefully. And as for the paint I am doing the standard cleaning, sanding, and wiping down with laquer thinner. and with these parts i kinda cheated and rattle canned them but all the other body parts are gonna be sprayed with real paint.
And db zac where did you get those rims?

 

[jawman]

so you want some nice 19.5 or 22.5 aluminum wheels. there is a really nice d350 that is flat black that has 19.5's on it. really looks nice. I will see if I can find a picture if you want to see it

 

[Crispell]

LOVE those rear fenders. way cool!!!

 

[Taquache]

Sweet project! Its nice to see younger kids taking interest in projects like this. :thumbsup:

Any reason in particular you want to go with flat black?

I think that truck would look sweet in color, especially with the custom fenders. That way they dot just disappear into the bedsides

 

[ForeverAlive91]

Jawman: ya if you can find that picture that would be awesome.
Crispell: hey thanks man im gonna like them so much more than the original ones especially since they are metal.
Taquache:ya ive been loving this project because i have been raised around fixing old cars and trucks since i was born. The reason I'm going with flat black is because i have seen a few trucks the same color and i liked the look. i also figured it would complete a hotrod type feel since im puttin 56 ford fenders on the back, and later on when i get better at pinstriping im gonna go around the truck and put a bunch of red striping on her.

 

[peckens]

I have the same seats. I cut and welded the factory mounts. I also took the rear facing cup holders and modified them so they could be used in the front. If you are tall I would make your own floor brackets and use <1" square steel

 

[jawman]

I think the one I am thinking of is Crispell's. maybe we can get him to do some picture whoring

 

[ram09]

And db zac where did you get those rims?

DITTO! I've got a white D350 Ext-cab and I'm wondering the same thing