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Discussion Starter #1
I bought my 6.5 in April 2016, and I have been working on it ever since. I'm not trying to build extra power on this one, just trying to make it as reliable as I can. Sorry for the lack of pictures, my camera battery is dead and I don't take many pictures of my vehicles (I'll try to get some more pictures tomorrow).

Things the previous owner had done (pretty shortly before I bought it):

-New IP, injectors, glow plugs
-Transmission rebuilt by a reputable local shop with an HD torque converter and shift kit (don't know what brand).

Things I have done so far:

-Skyjacker Hydro 7000 shocks
-New OPS (AC Delco)
-FFM removed and replaced with Racor 245R2 (with a kinda redneck mount which I made from rebar and a lawnmower blade)
-Plasti-dipped front grill and front bumper
-Wire brushed and painted rear diff, leaf springs, and much of frame.
-New waterpump and radiator cap recently (old wp sprung a pretty gnarly leak).
-New tie rods
-Touching up paint
-Exhaust: When I bought the truck, it had a hole in the stock muffler. I started by making a 3'' straight side dump with a square tip made from scrapyard steel, ran that for about a year, but I got tired of it, so I bought some never used 3 1/2'' exhaust components from the scrapyard. $12 and a long day of welding later, I had a 3'' to 3 1/2'' exhaust (first couple feet are still 3'') which exits in the stock location but has a 45 turnaround tip. Surprisingly quiet in the cab with no drone whatsoever. I've gotten many compliments on how it sounds, even from Dodge and Ford guys, the turbo whistle is absolutely ridiculous.
-Repainted many components on the truck, such as the wiper arms
-New batteries, terminals, and I also had to replace one of the ground straps.
-Procomp Xtreme MT2 tires in 265/75/16

Things I'm doing soon (I've already bought most of these parts):

-New fuel tank, fuel and return lines, and lift pump
-OPS relay mod
-GMC logo mudflaps (already installed front ones)
-Balljoints
-Custom bumper: I'm almost done building it, and actually had it mounted for a while, but I still need to weld on the top piece.
-Remove trim
-Rockerguard
-Fix all body rust and dents

Thing I want to do at some point:

-Fluidampr
-Braided oil cooler lines
-Intake (probably make my own with an aFe element)
-Custom headlights and taillights
-New windshield
-Will definitely think of more things
 

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Discussion Starter #2
More pictures... The batteries and fan shroud are removed because I am working on the engine right now. The truck has 340xxx kilometers on it (211xxx miles).
 

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respect the DB4 5722....
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decent truck, good one to hold onto, the old mechanical injected survivors are few and far between....

nice to see you are focusing on the safety side of things repairing the suspension/steering before the blingy stuff, you have a nice stance going on... as for your harmonic balancer, the fluidamper is somewhat over-kill, alright if you are rich, but not totally needed by any means, as long as the one you have is not separated, or you buy a new decent quality one from rock auto, they do not make a huge difference, only the hole in your pocket from the cost...LOL...

the better upgrade is the oil cooler lines, at which point you should also pick up a fresh cooler (the aluminum is known to corrode, and leak at the fittings after installing new lines), so it doesnt fail a week after you install the new lines...:thumb::thumb:... anyways have fun and diesel on, we are subb'd....J&J

also post script, love your gun control sticker with the maple leaf....
 

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Discussion Starter #4 (Edited)
decent truck, good one to hold onto, the old mechanical injected survivors are few and far between....

nice to see you are focusing on the safety side of things repairing the suspension/steering before the blingy stuff, you have a nice stance going on... as for your harmonic balancer, the fluidamper is somewhat over-kill, alright if you are rich, but not totally needed by any means, as long as the one you have is not separated, or you buy a new decent quality one from rock auto, they do not make a huge difference, only the hole in your pocket from the cost...LOL...

the better upgrade is the oil cooler lines, at which point you should also pick up a fresh cooler (the aluminum is known to corrode, and leak at the fittings after installing new lines), so it doesnt fail a week after you install the new lines...:thumb::thumb:... anyways have fun and diesel on, we are subb'd....J&J

also post script, love your gun control sticker with the maple leaf....
Thanks! The oil cooler/lines are a higher priority than the Fluidampr, which if I do get one, will be in a while. The current balancer and pulley are fine anyway. The only modification to the truck's stance is a few cranks on the torsion bars from a previous owner. I want to install a leveling kit in it at some point. The "No Compromise" gun control sticker is from the NFA (Canada's equivalent to the NRA). I cleaned the engine bay today, just a quick wipe down to make it more presentable for y'all. And yes, I am going to replace that plywood:eek: on my fuel filter bracket with aluminum and paint the top of my grill.:rolleyes: I'll do that stuff this weekend, probably.
 

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Discussion Starter #5
I'm getting set up to do my OPS relay mod this weekend, going to buy parts tomorrow and do the mod on Sunday, if the weather is okay. I read in the OPS relay thread that on '92-'94 trucks, the power for the pump has to come from the power block, instead of being able to tie into the orange wire the way that it can be on '95 trucks. What I'm wondering is which of the posts under the cover would be the safest to draw the LP's power from? Can I just use any always hot source of 12v power, or does it have to be a certain one of the posts?
 

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respect the DB4 5722....
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The posts are all the same on the OBD1 trucks. The closest to the passenger side should be a battery feed, and all the others are differing loads, with fusible links....J&J.
 

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Discussion Starter #7
Started my OPS relay mod, but realized I forgot to buy an inline fuse, and I ran out of solder. I'll buy those tomorrow, and have it done by Tuesday hopefully. Since I couldn't do any more on the OPS relay today, I installed my rear mudflaps. I bought them last summer, but somehow never got around to installing them.
 

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Discussion Starter #8
OPS relay mod done and working great. Had a bit of trouble getting a good connection between the OPS plug and OPS, caused gauge to max out without truck running, but I got it to work after some messing with it. I know there's other wiring diagrams of this mod, but I made my own anyway of how I did it. Anyway, next up is new fuel tank and lines, then balljoints probably.
 

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Discussion Starter #9
Finished installing my new fuel tank today. Old one leaked at the seam and would drip if I filled it above half full. Also replaced the fuel lines with rubber hose, as the steel line were rusty. Replaced the nuts and bolts on the strap while I was at it too. Deleted the sock, decided to go with an inline filter instead for easier maintenance. Replacing the tank was not the funnest job I've ever done (having a gravel driveway makes it even worse), so I'm glad its done. I used a motorcycle jack to remove the old tank and position the new one, I find that works the best.
 

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can you get a pic of your front bumper? i'm working on one also and would like some fresh ideas. maybe i'll start a new custom bumper thread.
 

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Discussion Starter #11
can you get a pic of your front bumper? i'm working on one also and would like some fresh ideas. maybe i'll start a new custom bumper thread.
Here is my custom bumper. It has cost me around $50 so far, since I am using scrap steel. I still need to weld on the top piece, prep and paint all unpainted surfaces, clean up all the edges, and mount it. I had it mounted without the top piece for a while last fall, and it looked good, but mounting it is difficult because it is heavy and awkward. I built the bumper and bumper mounts separately, then welded them together.
 

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looks good.
 

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Discussion Starter #13
Haven't done much on my truck lately, as I am daily driving it right now, but my Lubrication Specialist oil cooler lines came in the mail today, so I'll install them next oil change. I also ordered new rear shock mounts (both sides), but they have not arrived yet. Painted the diff cover and a few things under the hood blue, I'm planning to paint my leaf springs and rear brake drums (when I get new ones) blue as well. I got all my trim off, and right now I'm just pulling dents and prepping surfaces for rockerguarding everything below where my trim was. I'm going to have to weld in new metal in 2 places, but that's no big deal. I'm thinking about painting the whole truck black and maybe bedlinering the box this summer, as well as putting in new rear leaf spring mounts.
 

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Discussion Starter #14 (Edited)
Bedlinered box with cheap diy bedliner (actually somewhat tough), installed front bumper, which still is not quite done yet (needs top piece and another coat of paint), painted rear bumper, ordered new headlights, Plasti dipped GMC logo, got boost and pyrometer gauges, installed garden edging fender flares, I don't like the look either, but the law is the law :thumbsdow, painted one tow mirror (will do both), installed my new rear shock mounts, installing oil cooler lines next oil change (will be due next month). Ordered a few maintenance parts, I'm planning to start dailying a different truck at the end of the summer, so that I can do more on my 6.5 (have lots planned). Planning on ordering better lift pump next. Looking back at my first post, I realized that my truck could be close to having everything that I said I wanted to have done on it done by the end of this summer. Oh well, I've come up with a few more thing I want to do on it.
 

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Discussion Starter #16
Well I'm finally getting back to working on the 6.5. I was busy working on my Sonoma for the last 2 months, but I finally finished it for now, so now I'm driving that and working on the 6.5 again. I had been dailying the 6.5 all year until earlier this month, and aside from the fuel tank, it never missed a beat. Getting set up for paint, gonna bedliner the whole truck, led headlights, new rear brakes, and new leaf spring hangers, better lift pump, thats what I have planned to do for this spring. Currently just doing rough body work. Body rust is not too bad, Sonoma was much, much worse. Here is how the Sonoma turned out after being my evening/weekend project for 2 months. Before pic didnt do justice lol, the body rust on the Sonoma was BAD. Painted it with thinned Rustoleum, project cost me under $500 for everything I did.
 

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Discussion Starter #17
Got the bumper finished, and got started doing bodywork and some work on the frame, I'm considering buying a flatdeck 1 ton this summer and selling this truck though. I'd build a flatdeck for this truck, but I want something with lower mileage, and good condition flatdeck trucks are dirt cheap where I live. Not 100% sure if I want to sell the 6.5 though.
 

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