Thunder: a 2003 Tahoe build

[Tonyrodz]

started out trying to find the extent of the damage and started got the grinder and flap wheel out.
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Knocked out a bit then went to scrapers to remove a larger amount quicker. It was 1/4” deep in some places!

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Hand made some outer skin pieces also

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one of the Mount holes

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It's nice when you can do your own rust repair.

 

[outcast99]

I pretty much have to, no shop in town will touch it “it’s a liability” or some ****…

anyways, passenger side is done except for the finishing body work. This is a lot of work… I got a 6’x8’ fireproof blanket that I’ve been putting inside to protect my seats and stuff.






the pieces that were cut out. The one on top, I thought I got all the rust, but looking at the backside of the metal, I missed some so I got the rest in another sliver out.

 

[outcast99]

Still doing rust repair, slowly. In the Meantime I’m building my stereo system with 4 Skar EVL 12, Taramp MD8000.1, and a Taramp 800x4 for components

The box a Buddy designed and is building for me



My cousin insisted I need a custom bass knob so I chose Gizmo




Shipment 1, 50’ of Sky High oversize 1/0, some brass lugs and shrink tubing, 6 lug battery terminals, dual 1/0 amp inputs, and some waterproof grommets



I’m using Ogre 1/2” techflex on all my 1/0. This shows 2 out of the 4 new subs in. I had 2 used ones in a ported box and someone scooped that up with my old RP2000 amp for little more than I paid, so I’m buying 2 more new 12s so they all break in together.



Box builder sending updates. this is port wall and dividers going up. I like how he’s taking his time to router the ends

 

[outcast99]

Box walls going up



Meanwhile I also installed the torsion bar keys, chopped a coil off the back and I like it. It’s still fairly smooth, the back is noticeably higher but I figured once I add 150lbs of subs, sub box, amp and wiring… should be close to 800lbs to squat the back a bit more leaving it close to level

 

[outcast99]

Box is now done and installed with 4 Skar EVL12s

 

[Rocket Man]

Moving right along. Take that thing out in the desert over there and crank it up- you’ll hear it for miles.

You realize you probably won’t be able to keep any bondo attached though, right? Gonna punch it right off with those Skar’s.

 

[outcast99]

So the box sounds amazing, but I noticed the holes for the subs were cut out too large. Rather than bills another full baffle, the builder CNC’d up a piece of 9 ply maple and then made some recessed sub mounts.



Here it is at pick up, looks amazing



Used some Unicorn SPiT stain to make it stand out. Here is “Dragons Belly” and “Lavish Lovebirds” on the piece. I put a Skar sticker down first and stained over it, Peeling it after I was done.


That wasn’t enough gloss for me or protection so top coated with bar top epoxy. In the epoxy I mixed additional “Lavish Lovebirds” in for more flake. First later was good but the second coat made it pop.



So now I’m going to build a base for the box to bolt to, then it’ll be going back in.

 

[outcast99]

On the Tahoe side, I noticed some rust creeping in here n there, as well as clear coat peel. Already planned on repaint but I still have more body mods to do. Found a clean parts Tahoe so I scooped it up cheap.



Straight clean doors, hatch, and a front clip that will set me in a alternate direction.



So now I have a new plan.

Drop the back end more
Shave the green hatch off the wiper, wiper rest, and squirter (less rust)
Escalade d pillar covers
Throw the black doors on
Cat eye swap
SS bumper and grill
New headlights
TBSS wheels or something light like Cosmis
Reupholster front seat bottoms
Replace dash top
Debadge and remove moldings
Repaint rear quarters black
New license plates to say EVL HOE

 

[outcast99]

Progress pics. My doors had the delamination rust at the bottoms, the driver rear window wasn’t working, and the mirrors were bad so they got swapped also.

Here’s first fender on



Full clip on



Nicer doors on



All in all it was a fairly easy swap. I’m gonna throw a thick fender washer to space the bumper up some here soon to tighten that gap. I have new headlights, grill, and bumper cover coming.

Today, I will be demolding and debadging the black doors, putting my subs back in also

 

[outcast99]

Well I suck at replying…

Here’s the update! We moved into new home we are buying, 2017 stick built Hayden home so that’s been taking my time for the most part.



On the Tahoe, I’ve managed some stuff also though.



The led taillights decided to exit stage left thanks to the subs breaking the tabs. They might’ve been loose or something too though. All I know is when I pulled in my brother pointed it out.

Got the roll pan on, along with shaving the hatch of the wiper and wiper arm rest.



I needed time to do the rest of the roof, and start body work so I did the only thing a car guy seems feasible, bought another daily for my daily, to drive while my first daily is down.



2005 Sierra SLT. I took the push bumper, tool box, and running boards off for that clean look. Proceeded to raise the front a couple inches with the leveling kit, and take those cheap fake fender vents off also…