Everything WRONG with my Cummins powered Squarebody Suburban!

12,000 miles on the clock and there are still some things not right with the Burb. In todays episode we got through what I got right, but what I missed the mark with
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[@Mr.Thermistor7228]

Yesssss the sun visor on the burb is my absolute favorite as well!! Always loved when old burbs rock the sun visor

[@brianhamilton9392]

love the old burb. I am looking for another 86-90 suburban when i replace my jeep. Unfortunetly im my parts hard to find one thats not rusted out badly. I get the cummins swap, very cool, but i'd prefer a gas motor. I did recently find one running on propane. Can't wait to get back into the squarebody life. I has an 86 back 20 years ago and regret ever selling it.

[@JeffAdairKTM530]

Thank you brother for inspiring me to keep learning

[@kyles6634]

Thank you for the ck-in video. I'm taking your recommendations on my 89 burb build. Appreciate all your time invested in sharing knowledge!

[@MerricksGarage]

of course! Thats the whole drive of the channel. Get these trucks built and running!

[@JOMaMa..]

Cool you’re out of SB.I’m a mechanic in Ojai its nice watching a local whose made it.

[@ryannance9673]

Cheeeew ojai loc born and raised

[@cjjenson8212]

I'm exact opposite. My dad taught me to drive in a 1969 3 door suburban. Went from that to an 85 box body. My first experience driving a small car was my brother's 1980 Toyota stock mini truck. I just remember being scared to death people were going to drive over me. Now days I have a just barely over street legal to still pass CJ7. Still can't drive sports cars all these years later Beautiful truck!

[@jasonmorgan7373]

Pretty freakin cool man love it gettin ready to take 2 of my pops dream trucks and make the vision he had real lol a Cummins swapped k20 with factory manual trans but will upgrade the transmission to the nv4500 and if I don’t like the 5th gear I’ll go with the 6spd . It’s awesome to see you go from your driveway to a full blown shop congrats on that.

[@carlsandvik2893]

This burb has continued to get better and better. As someone who's ridden in it, watched it wheel in Death Valley, and been around for some of the "before vs. after" comparisons on improvements lately, it's just an awesome rig! The sound deadening and door hinge improvement made a huge difference! Keep doing great work James!

[@MerricksGarage]

thanks homey! Having AC has been a game changer!

[@Mogachaffe]

I like the Ford obs shock tower. Did the same on my 70 blazer

[@scottsimpson2265]

How are you doing love the video. I have a 1999 Chevy suburban barn doors. I love the thing paid two grand runs like a champ.

[@robertedwards7749]

I just found your channel and have watched one other video before this one and moving to your Burb build set. I just bought a 1985 GMC Suburban and I am so excited to begin working on it. I bought the Chassis manual, still looking for the Body shop manual. There are so many things swimming around in my head about what needs to be done and what i would like to do. The one thing you mentioned was a sway bar and bags that I had not thought about but I think would be a good idea. This vehicle will be my home while I travel around the US. I sure would like to talk with you. I am watching your full series once I leave this comment. I look forward to what you have to say and figure out a few more things that I might have to consider doing. I was thinking of having an 1999 - 2006 LS engine converted to a carburetor to get rid of all computer trash. Its a manual trans now but i want to go to an auto since I haven't driven a manual in over 4 decades as well as it being easier to travel for me. Hope to hear from you.

[@MerricksGarage]

I do actually offer build consulting for this exact reason. Gives us an hour to dig into your build, get targets and projects lined up. Where you should spend your money and time and any other build questions we can come up with . www.merricksgarage.com/build-consulting

[@colebertils7359]

Easily the best square body Suburban build on the ‘tubes! Makes me miss my cherry ‘91 6.2 powered noise maker. Had a dealer installed Banks Sidewinder turbo. The seats in those rigs are so comfortable too. Great job on all the hard work!

[@MerricksGarage]

thanks homey!

[@MRALL4FUN]

Love the BURB BUILD SIR!!

[@MerricksGarage]

Thanks man!

[@tonyvickers8659]

Another great video.

[@MerricksGarage]

Glad you enjoyed it

[@jeffrey36rich]

Ive been drooling over this rig since i found your channel. Im a big fan of this year sub. Ive wondered how much this rig cost to build,Id to find one but there is none to find with these improvements. Great job with this build.

[@MerricksGarage]

Thanks man. It’s got about $100k in parts alone

[@easyjerryl69]

Its a very cool suburban ! I have 3 of them, And I want to do different things to each one, 2 4x4 and 1 2wd

[@brianbiro9094]

All those shifters reminds me of my 1963 MERCEDES-BENZ UNIMOG 404S 💥🙂👊👍👍✌🇺🇸

[@jeremysmith3556]

a trick I found when swapping between my tube doors and real doors is to use an engine lift to hold up the door instead of two more people lolol

[@gearhead6493]

Love this rig. I have a 89 that I’m messing with. Do you happen to have a link to your headlight and the parking lights?

[@jamescason7783]

Well I'm working on getting a 3/4 or 1 ton truck and our 99 K1500 Z71 suburban up and running again. We have a lot of work to do😂

[@christophersanders5007]

I know what you mean by feeling like a BOSS riding around in a lifted square body. I feel the same way every time I get behind the wheel of my square body crew cab 4X4 with 10" lift and 38" tires. If you take out the doubler in your Burb then I guess that means dealing with drive shafts again. I have the same set of shocks you have. My truck gets a bit bouncy on rough streets and trails, but I just deal with.

[@MerricksGarage]

Yea driveshaft would prob go back to what it was lol!

[@michaelgiorsetti9385]

You Honestly have inspired me too Cummins swap my square body suburban.. I’ve been really think about it for a while but after I saw you do it I’m definitely going to be doing that please do more updates with the Burb thank you 🙏

[@MerricksGarage]

I have a ton of videos on the build up on my channel already. Check them out!

[@michaelgiorsetti9385]

@@MerricksGarage well actually already have checked them all out every video on the burb I have seen I appreciate the videos on the burb just keep up the videos man I love them

[@michaelgiorsetti9385]

@@MerricksGarage oh heyy I have a video idea 💡 you should do a video on how much the burb build cost that would be interesting and entertaining I think. A lot of people do it and on there channel and it topically does well not mention I have not seen a video like that about a Cummins swapped suburban

[@mrb0985]

@@michaelgiorsetti9385 he has, 70k in parts

[@mrb0985]

probably more now

[@christophersanders5007]

Do you ever get hassled by the law for the lift on your square bodies in California? I lived in Mission Viejo, CA back in the 70's and 80's, and the Orange County Sheriffs would hassle me all the time about a 1978 K30 I had that only had 6" of lift with 35" tires back then. That is why I will not set one tire tread over into California state line with my 10" lifted square body I have now.

[@MerricksGarage]

no, the only place I have been pulled over for the lift was in Montana when I was supposed to have mudflaps

[@itsmemaaaark]

70s and 80s huh. Interesting. I almost never get bothered with my truck. 6" lift and 37s. I use to be paranoid of my dark tinted windows if anything.

[@tyhunter8058]

Hey Merrick, really love the build. I have a 1989 Chevy crew cab dually with the centurion package. I’ve done Cummins, g56 swap. And a 4wd conversion. I’ve started working on getting the interior figured out. And I just don’t know a thing about a/c systems. How to get it to turn on, if there’s any vacuum lines that need to be ran etc. I’ve got all new components for it but I was wondering if you could do a more in depth video just on how to do all that?

[@MerricksGarage]

sure. It isn't as difficult as I thought it would be. The biggest issue is a vacuum source as the diesel doesn't make much vacuum. I installed a ford vacuum pump. But yea, a video would be helpful... Ill add it to the list!

[@MRALL4FUN]

I’d say keep the paint job exactly as it is Sir

[@highoctain113]

I ordered my lift, so I should be good to go on my build over the winter... The only real factor I haven't quite figured out is the second fuel tank.... I will be keeping my oe fuel system ( the diesel system but upgraded ) but I am trying to figure out a second tank for alternate fuels. Once the motor is warmed up, you can run whatever you want through the 12 valve, used motor oil, used fryer oil, ect., without needing to make it " bio diesel ". There are a few items I plan on doing a little different, but you have built just about the same as I have collected parts for. Maybe we can meet at some event once I get off my lazy azs and get this done.

[@MerricksGarage]

a separate tank for biodiesel sounds pretty cool.

[@darrinstone49]

What gears did you install? I have several gen 2 Dodge cummins with the 3.54 gears, lockers ect & love that gear combo with both my NV & 47RE... granted both have compounds but good mpg empty & loaded towing. I'm putting Allison's in the 85 Crewcab & 88 six door... prob step up to 37in tires. Bumping your axle gears would allow you to use your existing gears better & adding a K27. Later on you can add a larger one to give you amazing towing ability while keeping your egt's below 1300. Love my exhaust brake... 5in inline. Ever though about 4 linking & 11in rolling bags? Drop to load/unload as well as lower softer ride on the freeway... side winds don't push you around & way better aerodynamics. Want to open the wheel well openings by sectioning the openings so 35-37in tires fit better & looks like factory... possibly raise them slightly as well. Did you have any space issues with the exhaust & the front driveshaft? Love the fact you kept your stock AC system... it's my plan also. How much firewall clearance do you have? I'm going to stick with a mechanical fan even if it means welding in a slightly deeper firewall blister. You know how much room if any is inside? Figure just squaring off the top & sides would prob do it? Did you offset your engine to the drivers side any? 2wd steering box & crossover correct? Thanks Again!

[@MerricksGarage]

this is running 4.10 gearing and 38's and it is just about in its sweet spot.

[@gilhernandez605]

I think you need to start showing the Blazer some love.

[@MerricksGarage]

I agree, it has been getting some work off screen though. I found some cracks in the frame I am fixing and adding the big brake kit to it right now. Rubicon at the end of this month so....

[@johnjankowski1615]

awesome build!!! I have a 2000 Ford Excursion with a 12 valve swap and a ZF6 manual transmission and was thinking of a putting a detroit or yukon grizzly in the rear. Is your rear locker tolerable when towing or do you wish you went selectable.

[@MerricksGarage]

the locker in the rear works great. It is noticeable sometimes and can make a hell of a noise when it engages or releases. I usually get a funny look from my passenger when that happens, but I would do it again yes.

[@blackbeard308]

I bought rancho Blazer front springs I had Wrangler Jeep springs cut the eyelets off and made my own leaf spring packs for my 98 Chevy experimented with them and it rode smooth as hell love Merricks garage 🇺🇸🦾

[@MerricksGarage]

Right on

[@_Justinriceism_]

This is one truck I actually like the patina look on. Normally I can't stand it.

[@ArcAngelFA]

Where did you get your headlights and fog/turn lights? Yours looks very cool. I have a 89 K5 and i would love to start upgrading them to LED.

[@MerricksGarage]

the small LED are from KC.

[@delapeace805]

Do you have a video on the rugged radio

[@MerricksGarage]

Not yet…

[@danielalamo2075]

I love what you have done to your suburban! I personally love the 67-72 body style. We have a few, all 3/4 ton including a blazer and suburban (we like the tailgate and hatch for visibility). I was wondering what gear ratio you run in the differentials. . My 69 came stock with 456 gears and a Detroit locker. The rear end is a HO72. And I currently run 35 or 36 inch tires. Unfortunately all are not running. I have been driving a 2004 gmc Sierra 2500hd 4x4 with a duramax. Surprisingly the duramax tows about as well as my 69 with the 454 I put in (454 was built a little above stock by a local builder back in 91). My duramax gets average 17 mpg, my 69 is about 10 mpg. So I'm kind of in the TR4050.

[@MerricksGarage]

I am running 4.10 gears with the transmission and 38" tires. Considering regearing to 3.73

[@JayCrash450]

⁠@@MerricksGarageYour gearing is going to the opposite direction of mine. I’m running 4.88’s on 37”s (‘91 v3500 crew has a 12 valve/nv4500 and a gear vendors). Either way you go, I see you probably trying that rpm down to about 1800rpm @ 70mph….she’ll just buzz down the Highway!

[@trashbandit2449]

I recall you had a brief clip somewhere of the frame reinforcements, I believe on the suburban. It wasn't a plate, it was on the inside of the frame... where can I find a video of that?

[@MerricksGarage]

Good question. I need to dig that segment out and have it be a standalone video.

[@trashbandit2449]

@@MerricksGarage please do, I'd really look forward to that. The more detail the better

[@hirthirthirt1693]

You americans got the nicest motors - BIG V8's!!! Where comes the fascination for Diesels from???

[@MerricksGarage]

Diesels are great for torque and power. Great for towing. While a built diesel can be freaking amazing there is nothing quite like a howling V8

[@xpslinger8171]

You did an incredible job building your burb. I’m about halfway through doing a 24 valve swap into my 85 long box. Lots of work as you know, but it’s gonna be worth it.

[@paulgutierrez4505]

What about the body bushings and do you have a body lift? You didn't speak about these two things...

[@MerricksGarage]

The poly bushings were to replace the old worn out bushings. They are pretty necessary on most builds especially those with higher mileage like the burb. The ones on my dually look really good, but that only has 100k on it. the body spacers were necessary for ample firewall and exhaust clearance. I wasn't excited about using them, but they really made a difference fitting it all together somewhat easily!

[@peterhatch1583]

I still have that 1993 2500 4x4 surberbon set up for a cummins ! Free to you???

[@thomasmadden7580]

After your experience doing the 6bt burb, would you ever build a 4bt blazer? Or do you think the weight difference of the ls would offset any the performance gains?

[@MerricksGarage]

Yea power loss not worth it and it’s not as balanced as the 6 is. Despite the reputation, at cruise the 6 is sewing machine smooth

[@lilllamaboi]

How did you navigate the California smog/registration? I have a 91 cummins burb and im looking to move to cali, just curious how you did it

[@MerricksGarage]

This was a registered diesel vin before the swap

[@True_Knight]

I recently went with a full PSC kit on my CUCV. Now I’m having issues with the steering being slow and stiff. They sent me a bigger flow control fitting but it didn’t really help. I’m thinking the hydroboost is restricting the flow needed for having a ram assist. Did you have any issues with this?

[@MerricksGarage]

something else is going on. You still have the diesel? You may need a larger pulley on the pump.... It sounds like you have something binding. That is the challenge with Hydro assist, it can hide issues and problems as it can just power through them. Try and run the steering manually without the ending running.

[@TheNorteysur]

Beauty truck ❤chevy love

[@MerricksGarage]

I love it

[@samsara2024]

Great video! I have the oportunity to buy a square body from 1987 here in Spain for 8000 dollars. 6.2 Diesel. 105.000 km what do you think? :)

[@PeterHatch-mx7zc]

Its a credit to you on this build tryed to give away "free " 1993 2500 4x4 surberbon set up for cummins ! No luck so started to finish 12 valve 47 rh any way thks for your videos

[@gfamily8406]

I'm curious about your transmission choice. I was in need of a transmission for my 6bt and know of a tremec 4050 rotting away in mexico but when I asked my local transmission shops they said it wouldn't hold up.

[@MerricksGarage]

Yea they were available in South America and Mexico in HD trucks for GM and Ford

[@gfamily8406]

@Merricks Garage Yes I found a Dodge Ram 4000 in Tijuana for $1,500.00 with a bad motor(Hemi 5.7L). I called Silver Sport Transmissions but they told me it wouldn't work as a replacement for my broken Nv5600. Idk why if they sell kits for Nv4500.

[@patrickturner270]

Here's the most important question. How many cupholders?? ;)

[@calholli]

I would leave the doubler, and just put higher geared DIFF's with lockers on both. It would be well worth the upgrade, and your setup after that would be ready for anything. When the lower gears are useful is pulling heavy loads, or tractor pulling something big out of the mud.

[@dixiemae5042]

The rig is awesome … if ya don’t want it I’ll take it gladly off your hands 👍🏻👍🏻

[@MerricksGarage]

did you watch the video? ha ha ha!

[@dixiemae5042]

@@MerricksGarage I mean you could’ve changed your mind … lol

[@richardgreen1142]

What would be your thoughts on the 203/205 with an auto?

[@MerricksGarage]

I mean if you really need the gears I would be looking at the magnum box over a doubler

[@richardgreen1142]

@@MerricksGarage I too am doing a 12valve swap and am gonna use the 47re trans. Thing is I can’t find a dodge 205 and I have a new (rebuilt) Chevy 205 and have a good 203. It will be going into a 86 crew cab 3+3. I’ll look into the mag box. Thanks.

[@chickenfoundation9323]

Do you know how much it fully weighs?

[@MerricksGarage]

right around 8150 lbs. She's a big girl

[@alexalejandre5053]

How much have you invested in the burb its awesome, im guessing more than 50k, beautiful truck 😁👍🏼

[@MerricksGarage]

double that and you are getting close. Its all the little things that add up. Condenser for AC, stereo, driveshafts, window tinting, sound deadener.....

[@alexalejandre5053]

@@MerricksGarage 👀woow awesome 👍🏼👍🏼 bad ass truck are you planning on painting it it looks cool like that but personally i think a good paint job will do better justice for that bad ass truck

[@danielcortes3478]

How you smog it

[@MerricksGarage]

it doesn't need smog. Its titled as a diesel

[@jackaiello3599]

How did you register in Cali ?

[@MerricksGarage]

It’s a diesel title

[@redneck305xD]

Just curious what sort of fuel mileage are you getting?

[@MerricksGarage]

12-14 but I still need to do some work on the fueling

[@redneck305xD]

@@MerricksGarage I’m sure you’ll make a video about it lol love your content and thanks for the reply.

[@calholli]

I just think it would be a disservice to drop the doubler. lol.. You gotta leave it in, just for the bragging rights.

[@MerricksGarage]

ha ha. Well it isn't high on my list as it is working. But next time I have to replace the clutch it is probably coming out. I will leave the shifter farm in place though to look like I have 748 speeds!

[@calholli]

@@MerricksGarage Those new Broncos' manuals have a 7 speed gear box. Which is actually just a typical 5 speed with the 6th being a LOW gear: Like the ZF 6speeds in the SuperDuty's.. but the Bronco has a 7th "C" gear, which is even lower, for "crawl gear" -- which almost acts as a doubler, built right into the transmission, because it's so low. Very cool design.

[@cottonmouthdre]

Bro like Iron Man for square body. Aka Tony Stark

[@marcelhenry7243]

Does it smog?

[@witcher71]

Pre '98 model year in California doesn't require diesel automotive smog. Once you notify the DMV that you've "Changed mode of population" (Gas to Diesel), they will send you to the Smog referee for an inspection. If you pass then you will be given a tag to attach to the firewall and new registration with the correct acronym for a diesel engine. After that, it's legit and no more Smog inspection. California has a lot of stupid requirements but this one is one of very few cool ones.

[@marcelhenry7243]

@@witcher71 thanks for that info I always thought it had to have been a diesel truck to begin with yo be exempt

[@jameshall4385]

That is such an awesome rig. Guys would give their left nut for a sweet burban.

[@MerricksGarage]

well it cost me a lot of sweat and blood!

[@brianbiro9094]

💥💥💥💥1'st time viewer WOW .....FUCKING AWESOME TRUCK MAN 💥💥💥💥🙂👊👍👍✌🇺🇸

[@MerricksGarage]

Thanks man. Wish you were more excited

[@danielcortes3478]

I want to put a Cummins on my truck

[@mkperez7465]

How often do you get pulled over by the "tax collectors" in Cali?

[@MerricksGarage]

Hasn’t happened once. In either truck

[@mkperez7465]

@@MerricksGarage crazy, I got pulled over 4 times living in Monterey for like a year and half lol all of them were modified exhaust and modified vehicle stops. All I had was a straight piped evo with texas plates. lulz.