Part 3: Final Assembly and First Flex Test

Project SilverDuty: 2001-2010 Chevy 2500 SAS Build Overview

In Part 1, I removed the factory IFS and prepped the frame for this GMT800 Chevy 2500 solid axle swap. In Part 2, I built and installed the main Chevy SAS kit components, including the frame plates, coil buckets, transmission crossmember, radius arms, and panhard bar.

Part 3 covers the remaining mechanical work needed to get the truck back on its tires and moving under its own power. That includes converting the Super Duty Dana 60 wheel pattern, welding the front differential, installing the steering, replacing the ball joints, connecting the brakes and front driveshaft, and completing the first suspension flex test.
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