3rd gen Cab Swap/Rebuild
- Thread starter Red Sleeper
- Start date
Red Sleeper
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I have seen folks use a porta-power (hydraulic ram) to push apart the two arms that the support and front fenders mount to. My thought is the arms would bend from being pushed apart that far, then you would need to pull them back together so the bolt holes will line up.
Next you run the risk of holes not completely lining up for the fenders, fenders are no longer in the factory location, body lines don't quote line up, etc.
I suppose the proper way would be to drill out the spot welds where those arms mount to the cab, which would be a royal pain.
Are you removing the cam?
Next you run the risk of holes not completely lining up for the fenders, fenders are no longer in the factory location, body lines don't quote line up, etc.
I suppose the proper way would be to drill out the spot welds where those arms mount to the cab, which would be a royal pain.
Are you removing the cam?
Red Sleeper
Active member
Not much to update on. Have been collecting funds more lately than spending them.
Just sanding, priming, and prep for paint. Going today to pick out a color.
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Just sanding, priming, and prep for paint. Going today to pick out a color.
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Red Sleeper
Active member
Red Sleeper
Active member
Loaded up and ready to have a bed liner sprayed in the bed.
SixOhh
EPA unfriendly
glad to see your getting the hard stuff out of the way, i think your over the hump now Nick!
im actually glad i am following this thread because people ask me from time to time what i would ever do if my rig got totaled.... i always tell people i love my truck so much that the only thing i would ever do different is make a mega cab long bed! my truck has Everything built but the rear end. so i would most definitely buy it back!
p.s. my shop is primarily ATV repair.... with that said, Grizzly 700 = SUPER reliable machines when maintained correctly!
im actually glad i am following this thread because people ask me from time to time what i would ever do if my rig got totaled.... i always tell people i love my truck so much that the only thing i would ever do different is make a mega cab long bed! my truck has Everything built but the rear end. so i would most definitely buy it back!
p.s. my shop is primarily ATV repair.... with that said, Grizzly 700 = SUPER reliable machines when maintained correctly!
Red Sleeper
Active member
glad to see your getting the hard stuff out of the way, i think your over the hump now Nick!
im actually glad i am following this thread because people ask me from time to time what i would ever do if my rig got totaled.... i always tell people i love my truck so much that the only thing i would ever do different is make a mega cab long bed! my truck has Everything built but the rear end. so i would most definitely buy it back!
p.s. my shop is primarily ATV repair.... with that said, Grizzly 700 = SUPER reliable machines when maintained correctly!
Thanks amigo. It's been a big hump to climb.
This was a 1 owner, low miles, virgin truck when I found it; so I was convinced (much like yourself) that I'm keeping it.
Insurance totaled it out at a high value which was nice, and by doing the labor myself, I'm coming out ahead. It's just the time factor now, and I'm not about to rush the painting. Overall, the cab swap was easier than I had anticipated.
The grizzly was an impulse buy from my old boss. Yamaha low balled him on the trade value for a 4 seat UTV. When he told me how much, we hopped in the truck and went straight to the bank. It was a sub 150hr, garage kept, Yamaha serviced quad when I acquired it. I've done the Coop45 movable scheave mod with purple spring.
Knew nothing about them when I bought it, come to find out it was a great buy.
Greetings to all.
Nick, your posts are inspiring me to do this swap. I have a 2004 Quad 3500 diesel auto with damaged cab. I picked up a good 2003 Quad 1500 gasser auto and am in the prep to swap this onto the 3500 chassis. Any pitfalls or words of wisdom from you or anyone who reads this is most welcome. I have read through this thread and lots of good stuff to make note of. Just wondering if you had to start from the beginning and do it again, would you do anything different?
Nick, your posts are inspiring me to do this swap. I have a 2004 Quad 3500 diesel auto with damaged cab. I picked up a good 2003 Quad 1500 gasser auto and am in the prep to swap this onto the 3500 chassis. Any pitfalls or words of wisdom from you or anyone who reads this is most welcome. I have read through this thread and lots of good stuff to make note of. Just wondering if you had to start from the beginning and do it again, would you do anything different?
Red Sleeper
Active member
Glad you are taking on the task. Ask any questions you have and I'll do my best to answer them.
I did a complete cab gut and swapped the shells being my wrecked cabs interior, weather stripping, hvac box, dash, carpet, seats, column, etc, were all in much better shape. I also wanted everything to work as it did from the factory; gauges, steering column, hvac, etc. Another reason for the entire interior swap.
Hardest part was honestly figuring out each individual electrical connector and how it disconnects. You will have to most likely use the SRS module from your 04 and the wiring harness. One of the mounting tabs will have to be filed down on the SRS module and one new hole drilled to mount in the 03 cab. You'll see.
I doubled up my exterior firewall insulation using the gasser and diesel insulation. If you do the dash swap, use the interior firewall insulation from your diesel, it's thicker than the gaser one.
Are you swapping a single cab or a quad cab,
I did a complete cab gut and swapped the shells being my wrecked cabs interior, weather stripping, hvac box, dash, carpet, seats, column, etc, were all in much better shape. I also wanted everything to work as it did from the factory; gauges, steering column, hvac, etc. Another reason for the entire interior swap.
Hardest part was honestly figuring out each individual electrical connector and how it disconnects. You will have to most likely use the SRS module from your 04 and the wiring harness. One of the mounting tabs will have to be filed down on the SRS module and one new hole drilled to mount in the 03 cab. You'll see.
I doubled up my exterior firewall insulation using the gasser and diesel insulation. If you do the dash swap, use the interior firewall insulation from your diesel, it's thicker than the gaser one.
Are you swapping a single cab or a quad cab,
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Red Sleeper
Active member
Rolled this project back into the shop. Weather is going to be less than desirable for the next several days, which makes for great paint weather.
Red Sleeper
Active member
Pearland to be exact. The weather was nice over the weekend, but fixing to become real crappy for several days. I bet the temps are a little frigid out there on the rigs. How long are you out there? I'll be in Odessa next week or so, not by choice.
Yes, will be painting in the humidity. It's not an issue at all actually. This is great painting weather. No bugs or dust to worry about. I bought some fast dry thinner for painting in the colder temps and the shop has a wood stove inside that will keep things warm. 65* warm. Just finished hauling a load of wood this evening that should hold me over for several days.
Yes, will be painting in the humidity. It's not an issue at all actually. This is great painting weather. No bugs or dust to worry about. I bought some fast dry thinner for painting in the colder temps and the shop has a wood stove inside that will keep things warm. 65* warm. Just finished hauling a load of wood this evening that should hold me over for several days.
Red Sleeper
Active member
Dug out the fiberglass hood I purchased back in May and started wet sanding it. Roof of the cab is only main panel left that needs attention.
SixOhh
EPA unfriendly
oh thats cool! im not much of a painter, i was just asking. makes sense
my shop is in odessa and my rig is in fort stockton. i have other rigs in coyanosa and monahans/ pecos area that i am monitoring so im kind of everywhere.
I woke up this morning to 25* weather and an ice covered 3rd gen with NO DEFROST, so im about to go outside and start tearing into the dash so i can see if it is the defroster door like i suspect because tomorrow morning will be no different!
p.m. me when you get out this way, maybe we can meet up.
-Marcus
my shop is in odessa and my rig is in fort stockton. i have other rigs in coyanosa and monahans/ pecos area that i am monitoring so im kind of everywhere.
I woke up this morning to 25* weather and an ice covered 3rd gen with NO DEFROST, so im about to go outside and start tearing into the dash so i can see if it is the defroster door like i suspect because tomorrow morning will be no different!
p.m. me when you get out this way, maybe we can meet up.
-Marcus
Red Sleeper
Active member
Dagum. You are all over that desolate land out there. Things seem to be picking up for on land oil activity. Our customers are busy and equipment sales have elevated in the oil/gas/petroleum industry.
I'll holler at you when I'm headed that way.
I'll holler at you when I'm headed that way.
Red Sleeper
Active member
Been unrolling the tape and mask paper today. Sure would be nice to have the machine that applies tape to the mask paper as you unroll it.
Dad keeps asking each day if I'm going to shoot the color today. I respond if he sticks around to help. (As he walks out the door)
Dad keeps asking each day if I'm going to shoot the color today. I respond if he sticks around to help. (As he walks out the door)
Red Sleeper
Active member
Sealer applied Friday. Took a little time today, but I figured out the sanding technique needed hopefully. All panels feel like glass when I run my had over them. My arms are about to fall off from sanding.
Door jambs are a pain. Changing overall color is a huge job to make it look right.
Door jambs are a pain. Changing overall color is a huge job to make it look right.
Red Sleeper
Active member
Spend New Year's Eve spraying color. Thank goodness I have an understand girlfriend that likes painting as well. She sprayed color on a few hidden areas.
Red Sleeper
Active member
Clear coat applied and curing in the sunlight.
Dazed&Confused
Surfing my own world
Looking good