Crawlorado2It’s getting down to the wire for Kevin Stearns and the Pacific Fabrication crew with a little over a week to finish up the build up before they hit the road for the secret start point of the 2015 Ultimate Adventure. If you haven’t heard how this build came together to represent BDS Suspension on #ua2015 check out the UA Winner! article along with finding out more about the plans at Crawlorado build plans and Update #1.

With less than 2 months to complete the transformation (all the while managing the shop’s day to day business), the crew at Pacific Fabrication set out to tear down their shop truck, a timid looking beige 2011 Chevy Colorado with a healthy 5.3L V8 under the hood. In the last update we hit on the steering mods, front suspension, and axle upgrades. In this update we’re hitting on their progress to fabricate front and rear bumpers, buttoning up the suspension, t-case and driveline install, and prepping for future mods that are getting started.

With most of the front suspension buttoned up, and the JKS prototype swaybar getting installed. The attention turned to the rear where the Dynatrac ProRock 60 went into position using a new perches and a simple spring over conversion to net enough lift to level the stance and fit 37” Pitbulls. Matching the front a pair of Fox 2.5 remote resi shocks were added.

Behind the stout factory 5.3L V8 and automatic transmission we turned to our friends at Off Road Design for a transfer case. These guys make some trick products and thought a custom pink/purple Magnum Box was just the ticket for the build. Following that South Bay Driveline got wind of the Magnum and sent a set of powder blue/pink driveshafts to send power to the front and rear ProRock 60s with 4.88 gears.

For bumpers the team at Pacific Fabrication fabled up a front and rear set to maximize clearance, offer addition protection and to mount up the Warn Zeon 10.5S winch and an assortment of Vision X LED lights. Time is running short as the team wraps up the build adding a roof rack, rock sliders, install and wire up the winch, lights and other accessories before they hit the road for the start of the 2015 Ultimate Adventure representing BDS Suspension.

Stay tuned for updates as this build comes together gets painted and graphics in the next week. We’ll be posting on the BDS Blog and watch for daily updates on Facebook and Instagram as we hit the trails for the 1000+ mile Ultimate Adventure June 27-July 4, 2015. #ua2015

Crawlorado2Long days and long nights, neglecting family and friends and banished to the fab shop as he slaves away on his latest project build. While those may or may not be the words from Kevin Stearns of Pacific Fabrication, I’m sure that sentiment has crossed the crew’s mind as they overhaul this year’s Ultimate Adventure entry to represent BDS Suspension. If you haven’t heard how this build came together check out the UA Winner! article and find out more about the plans at Crawlorado build plans.

With less than 2 months to complete the transformation (all the while managing the shop’s day to day business), the crew at Pacific Fabrication set out to tear down their shop truck, a timid looking beige 2011 Chevy Colorado with a healthy 5.3L V8 under the hood. The stock suspension, steering, axles and bumpers were pulled to prep for the new components. From there measurements were taken and calls were made to get new parts coming to the Gilroy, CA based fab shop. Fast forward a few sleepless weeks and we have our first update on the build progress with a little under a month to go before this rig hits the road for the secret start point of the 2015 Ultimate Adventure. The first order of business on the buildup was converting the torsion bar independent front suspension (IFS) over to a more reliable and adaptable solid front axle. With strength and reliability the goal an order was placed from our friends at Dynatrac for a set of JK spec’d ProRock 60s with 4.88 gears and Detroit lockers. These axles are slightly wider than the Colorado’s stock track width, but should work nicely for our plan to adapt JK steering and suspension under this Colorado. Some of you may be asking why the move to JK parts? Well the JK is a similar size, weight and has unparalleled aftermarket support making it easy to source parts for the build and easy to find replacements in a pinch if we run into any issues on the trail.

In keeping with the JK theme the JK spec’d axles are being installed using a BDS 4-link front long arm designed for a JK that took a few mods to fit the Colorado framerails. The upper and lower arms are built from 1.75”x.250-wall tubing with 1.25” forged flex ends for plenty of strength and up to 30 degrees of misalignment. Rather than converting to coilover an upper coil bucket and shock mount are being used to allow the use BDS JK coil springs paired with Fox 2.5 shocks with the remote resi and DSC adjuster to adjust the compression/rebound on the fly. To compensate for weight of the Colorado and allow us to dial in the ride height and bump stop positioning, a set of JKS ACOS Pros are being installed with the coils. With the suspension install moving right along what steering is being mocked up.

For steering the factory rack-and-pinion would not have cut it for our planned use. Instead a PSC steering box designed for a JK was sourced and is being fitted to the Colorado’s framerail. Once plumbed it will have the added benefit of hydraulic ram assist to make easy work turning the 37” Pitbulls aired down in the rocks.  Heavy duty linkage was installed to connect the steering box to the front axle. Also added was a JKS sector shaft brace to reinforce the box and add a track bar mount to control lateral axle positioning.

Along with these mods other parts are beginning to arrive for the build like LED lighting from Vision X, a magnum box from Offroad Design, 37” Pitbull rockers radials, a Warn Zeon winch, Factor 55 flatlink and a few upgrades for the stock 5.3L V8. Stay tuned for updates as this build comes together on the BDS Blog and watch for daily updates on Facebook and Instagram as we hit the trails for the 1000+ mile Ultimate Adventure June 27-July 4, 2015. #ua2015

Crawlorado

Project Crawlorado, dreamt up by the guys are Pacific Fabrication and BDS Suspension. If you haven’t read how the project came to be, head back and read the last article, 2015 UA vehicle winner.  The plan Pacific Fabrication is getting started on the tear down and will be overhauling the 2011 Chevy Colorado 4WD over the next few months leading up to the Ultimate Adventure this summer. The midsize truck has a full-size 5.3L V8 putting out 300hp/320tq stock. Pacific Fabrication specializes in GM-powertrain upgrades so this truck is sure to be a screamer. The stock engine and tranny will be backed up by a Off-Road Design Magnum T-Case sending power to a pair of Dynatrac 60s, running 4.88 gears and lockers. Suspension under this Colorado will be modified BDS JK 4-link long arm up front with BDS coils, JKS ACOS adjustable spacers to dial in the ride height and Fox 2.5 remote resi shocks. For steering the factory rack-and-pinion setup was scrapped for a PSC JK hydraulic assist steering box, 1-ton steering linkage and a JKS sector shaft brace. While the fenders will likely need to be trimmed the goal is to clear a set of 37×12.50×17 Pitbull Rockers getting install on a set of beadlocks. For body armor this Crawlorado is getting custom bumpers, rock sliders, and rollcage tabbed up by the crew at Pacific Fabrication. Up front the high clearance bumper will house a Warn Zeon 10,000lb winch with synthetic rope and a Factor 55 flatlink. Vision X LED lighting will be used throughout the build and an Extreme Outback air compressor will be used to air up tires and run tools if needed out on the trail. Stay tuned for updates over the next few weeks as this build comes together in time for the 2015 Ultimate Adventure late June-early July.

Project Name: Crawlorado
Vehicle: 2011 Chevy Colorado 4WD
Engine: 5.3L V8
Transmission: 4-speed automotic
T-Case: ORD Magnum Box
Front Axle: Dynatrac 60, 4.88, locker
Rear Axle: Dynatrac 60, 4.88, locker
Steering: PSC JK box + hydraulic assist, JKS sector shaft brace, 1-ton steering linkage
Front Suspension: modified BDS JK 4-link long arm setup, BDS coils, JKS ACOS, Fox 2.5” remote resi shocks
Rear Suspension: BDS leaf springs w/ Fox 2.5” remote resi shocks
Tires: 37×12.50×17 Pitbull Rocker (radial)
Wheels: 17” beadlocks
Bumpers/Body Armor: fabricated bumpers, rock sliders, rollcage-rack system
Winch: Warn Zeon 10,000lb w/ synthetic rope and Factor 55 flatlink
Lighting: Vision X LED lighting