SAS Suburban build.

Flick

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Joined
Aug 8, 2025
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4
Figured I could put together my timeline of my progress so far on my OBS suburban project as I'm getting close to having it back on the road.

Started with a stock 95 2500 Suburban 6.5 turbo diesel.
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It had some issues mainly just from sitting for about 5 years. Leaking power steering cooler, fuel lines, brake lines, basic gmt400 things.
Bought it and pretty much instantly tore it apart.
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Ripped the IFS off the front. Severely underestimated the amount of grinding that would be involved.
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Got frame reinforcement plates in and hanger setup installed. Running Ford 2.5in lift leafs from BDS. Hanger kit is the Skys 99 to 04 Dana 60 kit.

Rear suspension is all ORD. Shackle Flip and long travel Shackle. And a drop bracket on stock leaf springs. 20250611_194657.webp

Axles are a 2003 Superduty Dana 60 5.13 gears and a Detroit locker.
Rear is the factory 14 full float. 5.13 gears and a spool.
Running 39.5 swamper Iroks on 17in methods. (Snow storm destroyed my cheap carport hence the pile of poles)
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Front sits a little high but still have a bumper to build and will be putting fresh rear springs soon.
Been getting the steering and some other things figured out recently. Still need to order driveshafts which is my current dilemma. Front shaft seems like it's going to be a pain to figure out.

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Been getting a front bumper mocked up
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There's been lots of other upgrades as well.
Intake setup. New intake pipe. Lots of parts from leroy diesel. Fass lift pump. Big fuel lines. New stainless lines on the tank.
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Redid the interior.
New carpet and found a 60/40 bench with console. And put in a mooneyes wheel. As well as my custom t-case shift handle.
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Also I'm sure no one was worried but my carport situation improved as well. (Couple more years until I can hopefully build my shop. Daycare ain't no joke.)
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I'm probably missing some steps but that's my build thus far. Still need shocks and driveshafts and I'm sure some other odds and ends will pop up. Hoping to have it back on the road this summer.
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Also on my wishlist is wanting to build an Australian style snorkel mainly just because I think they look rad.
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