This poor old truck has been chugging along admirably for quite some time now. I took it out of storage after a few years, put fresh gas in it, and drove it for a while. I changed the oil recently and have been driving it daily for a few months now. The 250 CID straight six engine has been reliable, though under powered for a 3/4 ton truck. It has done well. I recently went to change the brakes in the front and ran into issues, so I just slapped new pads on a ruined rotor and went about my life. I've been limping this thing along for many years now, and that's about to change.

I got a new job recently as a maintenance engineer, and am working much over time to get caught up financially. I don't have much free time for projects anymore, but I will have enough money to just knock out a bunch of things. This truck is still going to be a daily driver and a work horse, but I plan to give it a break. I went to look at some vehicles recently and found a nice van. It's a massive people carrier with a wheel chair lift, and I plan to buy it and build a camper inside of it. I'll start by just using it as a new daily driver so I can get the old truck off the road and into the shop. It needs a ton of work.

New brakes, all four wheels

New brake lines all around

New wheel bearings all around

New brake caliper, passenger front

Drum brake rebuild

New shocks, all 4

Tie rod ends

Steering box

Power steering pump

New steering linkages

New horn

Replace new temporary wiring with marine grade

LED headlight upgrade

Towing kit installed

Winch installed

New bumpers

Body work

Paint

Undercoating/paint

New seat

New dash

New dash cover

New inner door panels

Upgraded alternator/dual alternators

Second battery(Winch and such)

Raspberry Pi touchscreen interface

Custom cruise control

New engine

New transmission

New rear axle

New tires

Finish rewiring truck

New starter

Interior insulation(currently bare steel)

New speakers and stereo amplifier

Reasonable sub woofer(single 8 to 10 inch sub, under seat)

Upgrade to locking rear differential

I expect the full rebuild to come in around $15,000 to $25,000. This is a ton of money just to rebuild a crusty old work truck, but there is a good reason for it: This is a test platform for a much bigger project. The goal is to make a sustainable work truck that I can use for the rest of my life. The truck is one of the easiest vehicles out there to get parts for and repair. Servicing this thing is so simple it's weird. I'll happily pay the extra gas to run it, to save a few thousand on all the stupid little repairs of more modern cars I can't do myself.

The engine is the biggest upgrade the truck will see. I plan to order a rebuilt 292 CID straight six, and build it up with marine grade and racing parts for reliability. That engine is known for torque and reliability. It's not the most efficient option, but it is the simplest. The end goal is to produce, purify, and compress my own biogas to run this truck Having a large, simple, carbureted engine will make that simple. I was going to go with a diesel engine, but producing one's own biodiesel is not feasible for me at the moment. Eventually, I will get through all the biogas testing, then replace the gas tanks with fuel bottles and produce my own fuel for the truck. I may be able to run it on compressed natural gas, which can be bought, if needed. The truck could run on biogas most of the time, CNG when needed, and gasoline in an emergency or when a long trip is needed. Modern engines are too complex for my taste, so I will be going the old school route. I expect the engine build to cost at east $5,000, which I can have set aside in a few weeks of saving. I could upgrade to fuel injection and a turbo for more towing power and fun, but then it is no longer sustainable, unless the computer could be tuned for biogas. That may be an option worth exploring in the future.

The transmission is the next big item, at around $3,000 or so in parts. The truck has a TH400 3 speed auto trans in it now, but I want a 5 or 6 speed manual. I prefer standard shift for the efficiency and precise control. The current 250 straight six engine screams at highway speeds, and tops out at 90mph wide open. It sounds like it is going to explode. I'd like to be able to cruise on the highway at a reasonable RPM range, and have control over the gearbox for things like towing and pulling equipment out of stupid places. I haven't decided on the exact transmission yet, but am leaning towards the Tremec T5, I believe it's called. I want a fairly simple installation, and something that will bolt up to standard GM engines and mounts. I have considered a 700R4 auto trans with a locking torque converter, but I really want the simplicity and control of a standard.

The final big item is a new 14 bolt GM rear end with a locking differential. This truck is horrid on anything aside from dry pavement. I've been stuck on wet gravel multiple times already. That gets old real fast. I do add weight to the bed in winter. I may just rebuild the original rear end if it's in good shape. It looked great when I pulled the diff cover to replace the gasket, but I want a professional to tear it apart and check. I may also change the gear ratio once I get the torque numbers off the new engine. If that engine puts out enough torque, I may change the ratio towards lower RPM cruising, instead of low speed torque. This truck will tow from time to time, but not always.

The truck will be getting a custom bed camper at some point, but the new van would eliminate an immediate need if I get it. I decided to buy a new daily driver as quickly as I could to get the truck off the road and into the shop. Once it's mechanically sound, I'll take the new(used) vehicle to the shop for full inspection and any repairs, upgrades, and maintenance it might need. The poor old truck is about to get the care it needs. I bought it as a dumb kid, and now have the skills, knowledge, and funds to finally treat it right.