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Just as a warning / spoiler alert if you think mixing and matching parts across vehicle generations is blasphemy you may want to elect to move along. Also she is going to be more of a pavement princess / mall-crawler type build as she spends 80+ percent of the time on pavement and the rest on dirt / gravel roads. Most of the off-roading she sees a Saturn coupe could handle.

Right now is the beginning of the tear-down / build-up as I have acquired (hopefully) most of the tools and parts need for "Wry Wench".

Dropping the leaf springs to add a Indy4x 1.5-inch leaf and the two leaves from the Calmini 3-inch lift kit.
5 hours later I realize the the gas tank is in the way for removing the shackle to frame pin.
The gas tank needs dropped to reinforce the shackle frame mount, was hoping to put that off until later.
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Passenger side bolts soaking up penetrating oil.
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Door Badge prior to paint, have one for each front door to replace the "Rodeo" badges.
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Spent several quality hours with a cup brush cleaning up the gas tank skid plate.
The bottom of the gas tank looks ever so slightly better than this.
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Test fit 2003 fender to position corner combination light and mark preliminary headlight mount location.
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Now that my IP is no longer blacklist, I can post the progress I have made the past two weeks.
Still need to cut off the original left side rear shock.

About 90% through tear down for safety issues / lift install
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Rear rolled out to get bead blast the rust / old paint away
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Front diff pulled for diff drop brackets / repainting cups and housing
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Comparison on old diff brackets and DOR diff drop brackets
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Testing Placement of 2nd gen roof rails
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Looks... interesting. I do believe I'll stay up on this thread.
 

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Rehab of roof rail plastic covers (Flood Penetrol)
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Not much progress to report: too cold / wet here to paint the drive train.

I did get to apply a coat of silver paint to the new badges after spending a few hours taping off the back plate.
I applied the silver paint at work, while waiting for a server to go offline.
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I will be watching this thread also. Having a '97 myself, I may pick up a tip or two... Looking good so far! :mrgreen:
 

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Parts to fill my December order just came in for my shipment of Hella goodies.
Wired up pigtails to relay bases for splicing into headlight circuit under dash to add Mustang hi/lo floor switch.
2001 Toyota Antenna mount (Prius/Camry I think) for relocating antenna from fender to roof.
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Since it was a nice warm day and we had a calm period, I took the opportunity to scoop ABS slurry into the backside of the 2000 Rodeo Grille to fill in the Isuzu cut-out.
Taped Off front view:
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ABS slurry puddle on back side of grille:
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The ABS slurry welded with the Grille ABS a bit deeper than I was expecting.
I am going to let this to sit a week or so to make sure all the solvent has cured out,
then apply some lightweight spackling to fill in the voids and valleys before sanding and priming.

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Not much progress to show photographically, hope to change that soon.
Was in a parts and information collection mode for the past 6 months or so.

GM and apparently most other manufacturers do not provide all the nice frame dimensions, etc. in their workshop manuals as Isuzu did.
GM also does not appear to have dimensional information on the axles / brakes they use.
GM dealer parts desk referred me to their service dept. which spent several hours in GM's system to end up with no information.
So I am reaching out to AAM who is the OEM of the axles in hopes that they would have that information.

Once I have that should be able to finish up the machine work and be able to paint the Dana 44 axle and have information on a rear brake upgrade.

Did have a few minutes to try a test fit of the 2000 e-brake handle.
I am not 100% sure yet but it looks like the rear brake mounting holes did not move between 1st gen and 2nd gen.
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Im Interested! Will be keeping an eye on this thread :)
 

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Discussion Starter · #11 ·
Fuel Level Sender data for 97 - 12ths and 4ths calculated rest are from drivability/emissions manual for 3.2L,
Voltage Sensor resistor of 177 Ohms based on voltage/resistance range of F=0.44 V/17 Ohms to E=2.02 V/120.5 Ohms

Empty point - 120.5 Ohms
Empty gauge - 102.5
1/12 - 86.68, 1/6 -73, 1/4 - 63.84, 1/3 - 56, 5/12 - 49.27, 1/2 -45
7/12 - 40.18, 2/3 - 36.75, 3/4 - 33.8, 5/6 -30, 11/12 - 27.31
Full gauge - 23.5
Full point - 17 Ohms

EDIT:
Dorman 911-008 is a pretty much a direct physical drop in for the sender on the 98-99 fuel pump module, much more readily purchasable than the 80F - 290E units (at least in my area). It is an 40E - 250F unit so it has an opposite curve than will need mapped to make the PCM happy. Mapping from 250-40 to 80-290 should not be to much more work than doing 250-40 to 17-120. Once I find more data points on then 80-290 isuzu sender. My 80-290 unit has some dead spots aka off-scale readings at 2000 ohm range on my meter, so I'm skipping the 80-290 to 17-120 mapping that was originally planned.
 

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how much of a hassle was it to pull the headliner so you could get the brackets in for the racks?
 
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