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This is a community for planning and discussing offroad adventures. All makes and models of offroad vehicles are welcome! Multi-day expedition-style trips are our main focus, but there are plenty of day runs, clinics, and tech-days as well.

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  #1  
Old 09-14-2012
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PMA4x4 PMA4x4 is offline
(Rob or Ramjet) (KC0DBH/DBG)
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Location: Apache Junction, AZ
Vehicle: The Mule 91 Suburban
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Cool Project MULE - Expedition build on a 1991 1500 4x4 Suburban
Some of you knew we were looking for a new expedition rig. Well, after a few months of searching and research. we narrowed it down to a 2002-04 Jeep Grand Cherokee but with not having any luck finding the trim package we wanted Bridget start thinking bigger. she knew i owned a Suburban in a previous life. So last weekend we checked on out so she could see one in person ans BAM! less then a week later we fall into this. Some how we think this may have been meant to be.


1991 Chevrolet Suburban Silverado 1500 4x4

Engine: 5.7 Liter/350 Cubic Inch FI TBI
Miles: 113,000
Transmission: 700R4
GM 10 bolt front and rear 3.42 gears
New engine 45K ago from a dealership
Newer BFG 32x11.50x15 All Terrains with 95% tread.
AC works both front and rear A/C!
Interior is in excellent condition with just two cracks on the top dash
Drivers side rear door has a bit of a scrape dent from a tree
Power windows actually go up and down in a timely manner!
Every thing is pretty much stock like the radio and what not.

The seller was the second owner and has receipts and manuals and maintenance paper trail from the original owner day one!

Goal:
TBI upgrade >DONE<
Transgo towing shift kit
Tru-Cool LPD Tranny cooler with fan and thermal switch >DONE<
30K GVW inline transmission cooler >DONE<
Sealed snorkel system using a Donaldson cyclonic air cleaner.
4" lift TC HD springs front
4" lift in rear is still back n forth on either a shackle flip or plain springs.
4.56 gears
Manual hubs >DONE<
315/75-16 BFG ATs
American Racing AR23 16x8 8 lug wheels
Upgrade rear to GM 14 bolt Full Floater
ARB front and rear
On board air
Dual AGM DC batteries (separate from the starter battery)
Custom front bumper (going to reproduce a Warn Trans4mer with brush guards) >DONE<
Custom sliders (main idea is from badmix sliders mounts)
Custom rear bumper (in prototype stage)
Custom full length roof rack >DONE<
Ladder and tool mounts on driver side barn door
Spare tire and tool mount on Passenger side barn door
Steering gearbox frame reinforcement plates
Steering brace from ORD
Steering cooler >DONE<
Toughbook LT Mount
GPS, CB, HAM
Other misc electronics.
Custom interior cabinets and drawer systems
Captured cargo net on ceiling.

If you go here this will give you an idea of what I am going to be doing. I even got some ideas from these guys. Expeditions 7 build: building a vehicle to go around the world















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Last edited by PMA4x4; 1 Week Ago at 09:24 AM.
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  #2  
Old 09-14-2012
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J.R. J.R. is offline
(J.R.) (KE7JRW)
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Default Re: Project MULE - Expedition build on a 1991 1500 4x4 Suburban
You sure will be able to put a whoooole lot of cr....ummm STUFF in there! Expedition gear! Thats the words I was looking for.
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Old 09-14-2012
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PMA4x4 PMA4x4 is offline
(Rob or Ramjet) (KC0DBH/DBG)
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Default Re: Project MULE - Expedition build on a 1991 1500 4x4 Suburban
167 Cubic Feet YEAH!
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Old 09-14-2012
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Default Re: Project MULE - Expedition build on a 1991 1500 4x4 Suburban
I had a 91 Full-size Chevy Blazer. I LOVED that truck. I regret everyday that I got rid of it. They are easy and fun to work on, and plenty of room for a tall guy like me. Congrats!
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Old 09-14-2012
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Chevy Re: Project MULE - Expedition build on a 1991 1500 4x4 Suburban
I can't find pictures of it right now, but we used to wheel a '73 burb back in the day. George bought it used and rebuilt the suspension and did a bunch of cool upgrades to the interior. I LOVED that truck! The only reason we sold it is I started classes at ASU and it was hard to park... =( Sometimes I really miss that thing, talk about room to sleep inside, and the thing was a freeking tank, it would go anywhere!
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Old 09-14-2012
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(Rob or Ramjet) (KC0DBH/DBG)
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Default Re: Project MULE - Expedition build on a 1991 1500 4x4 Suburban
I had a 76 with a 400 SB in it with fulltime 4wd, ugh drove that down to texas and lived out of it for a summer.
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Old 09-14-2012
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Default Re: Project MULE - Expedition build on a 1991 1500 4x4 Suburban
The other one I had in high school had a 400 too, but it had checkered red & white seats. :0
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Old 09-14-2012
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PMA4x4 PMA4x4 is offline
(Rob or Ramjet) (KC0DBH/DBG)
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Vehicle: The Mule 91 Suburban
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Default Re: Project MULE - Expedition build on a 1991 1500 4x4 Suburban
Depending on how things go down. Almost immediately it will get 4.10 gears maybe a ARB in the rear and move the limited slip up front. a 4" lift and some Powerplant upgrades
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Old 09-14-2012
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Default Re: Project MULE - Expedition build on a 1991 1500 4x4 Suburban
Ours was a 350 w/4 on the floor (granny gear like no other), locking hubs. G installed a Rancho 4" suspension lift. It was pretty stiff on the trail, but it was so looong, that you couldn't really feel it much, either that or I can't remember that far back...
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Old 09-14-2012
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PMA4x4 PMA4x4 is offline
(Rob or Ramjet) (KC0DBH/DBG)
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Vehicle: The Mule 91 Suburban
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Default Re: Project MULE - Expedition build on a 1991 1500 4x4 Suburban
Yeah Rancho WAS the big dog back then. I am going with a 4" Tuff country HD springs up front and a Shackle reversal in the rear and getting some Bilstein 5125 series shocks and all greasable suspension. I want it to ride smooth.
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