4x4 conversion

i just picked up an 82 1 ton chevy crew cab dualie with 454 and 4 speed manual trans 2 wheel drive, what i wanna know is what would be the best way to transfrom it into a 4x4, i have a frame from an 85 chevy 3/4 ton 4x4 was thinking i could chop the frame to make the crew cab fit but ran across a few sites that said u end up making the frame weaker buy cutting it in the middle and adding lenght, thought if i used some thick guage metal for the splice and boxed the frame to strenghten it, or find a 4x4 dualie frame, or do a solid axle swap on the 2 wheel drive frame, wonderin what u guys thought  

take all the front suspension stuff our of the 3/4 ton and put it on the 2 wheel drive frame. you will need some of the rear suspension like the front leaf spring mounts on the rear axle. all the stuff will bolt right on. it will be a little easier than lengthening the frame.  

thanks  

I am in the middle of doing the exact conversion to a 86 crew cab. Put the front end parts from the 4x4 on the two wheel drive. If the rear end gear is the same as the front and you are going for stock height add a 2 inch block to the rear and leave it alone. Its easier and stronger than changing the spring mounts on the rear. Be sure to use a good block though not a cheap imitation. Don't chop the frame.  

kevin, did u have to rip the engine cradle out and put one in from a 4x4 frame, had my truk on the lift was lookin at the engine cradle(2wd) thought it might have to come out because the front diff might hit it of u were really flexing the suspension, i have a dualie dana 70 in the rear, id like to keep it and use it but dnt want the dual tires, is it possible to conver it to a single tire set up, otherwise i was going to fine a corp 14 bolt and put that in back and a dana 44 in front, thanks in advance  

even with a 4 inch lift there wasn't enough room for suspension up travel on my 86 chevy solid axle swap cause the cross member under the engine on a two wheel dive hangs much lower than a 4x4 you could try and drill out the rivots and use a cross member from a 4x4 chassis or in my case I fabed a new one out of 6x2x1/4" channel. still awful close but seems to clear. the rear dualie axle is pretty close to the same as a single wheel axle just use regular wheels the lugbolts might be a little excessive but shouldn't be an issue.(at least thats what i did with my ford)  

how bout the rear drive shaft, i think it mite need to be shortened once i get the transfer case in, it will have a sm465 manual trans and a np205 transfer case, the dualie truck has a sm465(2wd)trans in it currently  

hey i completed the same swap you guys are talking about, an 86' c2500 to k2500. with the exception of the trans. i did change the engine crossmember, and also moved the rear hanger mounts down on the frame about an inch. i think the frame widths are different on a 4x4 vs. a 4x2, but not quiet sure. i wound up adding 2" lift spring to the frame and blocks to the rear. my trouble was EVERY time i would go over a bump taller than two inches the passenger side frame rail was hitting the top of pass. side u-bolts. i also swapped in the 4x4 engine crossmember, not too bad if yo0u dont mind taking off the bumper and the crossmember behind that one. and watch out for those fuel lines if your burning off the rivets, as they are on the outside of the frame on 4x2's  

I got really lucky with mine. All the two wheel drive components unbolted and dropped out of the way. I pulled the engine and trans out of the way. I took the front clip off to gain access. The cross member just in front of the engine has to be installed from a 4 wheel drive. I also had to modify the brackets that hold the motor mounts and attach to the inside of the frame rail. I used the front spring mounts as the starting point. The engine crossmember can be changed without removing the bumper and radiator crossmember by installing the crossmember in three peices. I placed the engine by measuring from the shifter locator on the frame foward to the engine crossmember. I also had to remove some frame material at the rear spring shackles to allow the shackles to move back and forth. Burn rivets on the side where you aren't keeping things, then use a grinder to remove left over material and drive out with a punch. I bolted everything together with grade 5 bolts (stronger shear strength that grade 8). I added 2 inch blocks to the rear to make it ride level.  

I'll trade you a nice corporate 14 bolt for the Dana 70 set up for dual wheels. I put adapters on mine to accept dual wheels.  

kevin, think ill keep the dana 70, u got and pics of the front suspension on ur truck so i can get an idea, u live in wisconsin?, my email is chevysilverado454@hotmail.com