[ARCowboy]

Hello All,

How To Section:

Mods:
Recommended First 3 Mods/Accessories
How To: Inverter + 120v Outlets
How To: Switch Pros 9100, Power Tray, Blue Sea Systems design/install
How To: Rear seat extinguisher mount
How To: 589Fab Skid Plate Support Bracket Install
How To: ARB Twin Compressor install | 589fab mounting bracket | ARB Manifold | S&B CAI
How To: ROKBLOK ZR2 Mudflaps on non-ZR2
How To: DIY Shock Boots - Filthy Motorsports Style
How To: HD Mil type battery terminals
How To: Rago Fab Tailgate Gap Antenna Mounts | + NMO conversion
How To: Fix 4x4 selector knob vs Headlamp knob confusion

Maintenance (mx):
My Consolidated 2.8L Duramax Diesel Maintenance Plan
Checklists: 6L50 Transmission Pan Drop, 2x Diff change, Transfer case fluid change
How To: Bleed Brakes with pressure bleeder
How To: Clean & Shampoo Neoprene seat covers (CoverKing, WetOkole, etc...)
How To: Rear Leafpack replacement in 43 easy steps !
How To: Diesel MAP Sensor Cleaning

Misc:
How To: Four corners rapid air up air down system
How To: Modify Igloo 6gal water containers with spigot & vent
Farkle Factory Aluminum Fuel Drain Plug - Pictures & Diesel Immersion Test
From Diesel Colorado to Electric Car

CAO 2/2023:


Stock with my 2005 2500HD Duramax trade in:

CAO 11 Feb 2023
Disclaimer: I don't carry all of the gear all the time. Check boxes toggle whether the weight value is included. I leave all checked for planning/mod purposes and adjust based on the trip.

 

[ARCowboy]

PHASE 1 - Daily Life

2016 Z71 Crew Cab Short Bed Diesel Colorado

[REMOVED] Bakflip G2

[INSTALLED] Sapphire V1 Ceramic Coating
Never wax + easier wash + hydrophobic + protection

[INSTALLED] Weathertech front & rear floor liners + 360* sunshades (TX was hot)

[INSTALLED] DECKED Truck Storage System+Dividers+L Tracks
Corona always seems appropriate for wrenching on things after growing up on Fast & Furious movies

[INSTALLED] Mann Provent 200 Catch Can because oil in intake =/= longevity

[INSTALLED] Coverking Neoprene seat covers

[COMPLETE] AJT Designs Key Fob Swap (Bad-donkey + Waterproof

[INSTALLED] Center Console Organizer

[INSTALLED] NFAB RKR Rails with removable steps

[INSTALLED] Colorado Powered Accessories Mount (CPAM)

[INSTALLED] ZR2 ROKBLOKS

 

[ARCowboy]

PHASE 1.5 - Offroad Power Prep

[INSTALLED] HD Mil type battery terminals

[INSTALLED] SWITCH PROS 9100
Interior

PowerTray Setup

[INSTALLED] Samlex 600W Pure Sine Wave Inverter + 120v Oultets front+rear

 

[ARCowboy]

PHASE 2 - Offroad
[INSTALLED] ARB Summit Front Bumper

[INSTALLED] Engo 10k winch with Viking Synth Line. "Custom" Solenoid box. lol.

[INSTALLED] Merchant Automotive HD Tie Rod Sleeves.

[INSTALLED] Custom King Coilovers, OME HD rear leafs, SPC UCAs, SR Track bar relocation, & Prothane extended end links.

[INSTALLED] AEV Snorkel

[INSTALLED] S&B Cold Air Intake with oiled (on road) and dry media (offroad)

[INSTALLED] ARB Twin compressor with manifold

 

[ARCowboy]

PHASE 3 - Light/Comms
[INSTALLED] ARB lights

[INSTALLED] RAGO Fabrication tailgate gap antenna mount modified for NMO.

[PREPPED] Modified bullbar light brackets to make NMO antenna mounts

 

[ARCowboy]

PHASE 4 - ARMOR
[INSTALLED] 589fab Skid Support Bracket

[INSTALLED] 589fab Ultimate Shock Skids


[INSTALLED] Kaufu Front Skid Plate

 

[ARCowboy]

Garage Porn !

Sockets

Spare/oversized sockets

German NWS pliers rebranded by Irwin

Nothing special, but how nicely these fit together makes me happy.

Gotta start somewhere... Yellow bins from Harbor Freight medium organizers (black and clear plastic bins)

This vacuum is a game changer. 18V ?! 20V ?! and a cord ?!
Disclaimer: Do not be alarmed by the HF jack stand. It's from the original run, not the recalled run

Everyone should have a label maker, especially one that makes heatshrink labels for wiring.

Anti headache medicine:

 

[ARCowboy]

Did some experimenting with battery cable end terminating/crimping. Purchased both lug crimpers (bolt cutter crimpers) and a hydraulic crimper (yellow handle special). Both produced cold welds and excellent ends, but the hydraulic wins for not creating a pinch of excess material. Both the bolt cutter and hydraulic crimper were actually metric and bastardized for AWG, but the hydraulic style evenly applies pressure to the fitting whereas the bolt cutters, by design, start towards the handles and finish at the end, which is where the excess goes.

Dealing with 1/0 AWG & 4AWG Ancor marine grade tinned copper battery cable. Runs about $5-8/ft for 1/0 and $1-2 for 4AWG. Found easily on Amazon and at West Marine stores.

Bolt cutter style 4AWG for winch (excess copper to the left side...):

Bolt cutter 1/0 AWG for battery cable:

Angle grinder cutoff wheel shows a nice cold weld. Not easy to get through:

Hydraulic yellow handle 1/0 AWG crimp:

Angle grinder cutoff. Very pleased with it:

Just for fun, I cut into some factory crimped cables for comparison.
From top to bottom:
Bolt Cutter Crimp 1/0 AWG
Bolt Cutter Crimp 4 AWG
Auto parts store special 4AWG...
Engo original battery cable 4AWG

Sealed all my new winch cables with marine grade dual wall adhesive heatshrink:

 

[bumbletruck]

Oh man, jealous of your garage/tools set up. Like how much planning you've put into this. Following!

 

[ARCowboy]

Oh man, jealous of your garage/tools set up. Like how much planning you've put into this. Following!

Thanks ! I know it was just straight up bragging but I was hoping someone would appreciate it.

I'm also an excessive planner. Professionally and personally haha. Build thread is a reflection of the spreadsheet that tracks weight & balance, maintenance checklists, torque specs, and generic stuff I don't want to have to look up every time. Every time I learn something about the truck, or find something I want to do, I'll throw it in my nerd spreadsheet.

 

[ARCowboy]

Why do my posts sit "awaiting approval before being displayed publicly" ? That a forum thing now ? (Not saying it wasn't before, but it has not been on previous/other forums I've been a part of)

 

[WV NATIVE]

An estimated $15k+ to go “overlanding”?

I hate being poor.

 

[93Duc]

Oh man, jealous of your garage/tools set up. Like how much planning you've put into this. Following!

What he said ^

 

[bumbletruck]

An estimated $15k+ to go “overlanding”?

I hate being poor.

I'm of the camp that I'm glad there are people like this so we can see what $15k might look like, even though it'll never be in my budget or interest to do it myself. "Your money, your truck", etc. plus we get a cool thread to follow!

 

[ARCowboy]

An estimated $15k+ to go “overlanding”?

I hate being poor.

I should rephrase. $15k to build the overlander of my dreams. haha. I have camped and done some mild trails in it basically stock with slightly oversized tires. h

I'm of the camp that I'm glad there are people like this so we can see what $15k might look like, even though it'll never be in my budget or interest to do it myself. "Your money, your truck", etc. plus we get a cool thread to follow!

haha great attitude friend. I wish more people in the world had your attitude as opposed to the "I'm not interested in this so it must be banned and illegal". Can't stop the tinker; I enjoy doing the work. I'm also hardly alone. I've really enjoyed lurking on G2Skier's ZR2 build, F8l's 2018 Canyon, and Deadly 99's Canyon+Trailer Build.

Edit: Forgot about Golee33's insane(ly awesome) Z71 build.

 

[WV NATIVE]

I should rephrase. $15k to build the overlander of my dreams. haha. I have camped and done some mild trails in it basically stock with slightly oversized tires.

Looking forward to your updates. Your budget is impressive.

I looked at your build sheet and I’m trying to figure you out.

I find this build interesting and count me as subscribed.

 

[rotaryenginepete]

Very well organized, you and I are both spreadsheet nerds! I very much appreciate someone who pays close attention to detail. So, I do have a few initial questions/comments:
1. What purpose does the trim removal tool serve for changing the cabin air filter?
2. I have always found the Weathertech floormats to be the best floor liners for keeping out dirt, sand, etc...except in this case (have them in all of my vehicles, except the Canyon). It may surprise you that the OEM GM all weather floorliners are better quality and provide far more coverage than the Weathertech ones, including a lip that covers the sill plate and much taller/longer side walls to protect from dirt getting flung between the rug and liner.
3. Have you considered creating a tool kit for maintenance or repairs in the field? Stuff happens, and it appears you have plenty of spare sockets.
4. What branch did you serve in? The Pelican case, spartan stencil, and tool organization seem to hint at veteran...

 

[ARCowboy]

Very well organized, you and I are both spreadsheet nerds! I very much appreciate someone who pays close attention to detail. So, I do have a few initial questions/comments:
1. What purpose does the trim removal tool serve for changing the cabin air filter?
2. I have always found the Weathertech floormats to be the best floor liners for keeping out dirt, sand, etc...except in this case (have them in all of my vehicles, except the Canyon). It may surprise you that the OEM GM all weather floorliners are better quality and provide far more coverage than the Weathertech ones, including a lip that covers the sill plate and much taller/longer side walls to protect from dirt getting flung between the rug and liner.
3. Have you considered creating a tool kit for maintenance or repairs in the field? Stuff happens, and it appears you have plenty of spare sockets.
4. What branch did you serve in? The Pelican case, spartan stencil, and tool organization seem to hint at veteran...

0. Really appreciate your input, on all the threads !
1. I honestly have no idea. I've changed it twice now with just a flathead (to remove the stupid glove compartment hinge pins. Do you have a better way of doing this ?)
2. Reeeeaaaalllly. GM actually got that one right ? Damn. Well, the truck came with the original floor mats in the original packaging in the backseat, and they're still that way.
3. I have a toolkit in my decked drawers. A full set of box end wrenchs in a canvas roll, orange big box store special screwdriver with both ends, long flat head screwdriver, adjustable wrenches, small socket set, black rtv, jb weld steel, some 3/8 hosing, vinyl tape, etc...
4. Still active duty; aviator by trade. Don't want to go into any further personal details; I'm sure you understand. Yourself ? Those are pretty intricate details to pick up on without some inside familiarization.

 

[ARCowboy]

Looking forward to your updates. Your budget is impressive.

I looked at your build sheet and I’m trying to figure you out.

I find this build interesting and count me as subscribed.

Well if you figure me out, would you mind letting me know ? hahahaha.

If everything goes according to plan, I'll have some Merchant Automotive tie rod sleeves and GM leveling kit on this weekend to regain some of the front end height I lost with the ARB summit bumper & winch. The MA tie rod sleeves weren't really planned, just fell into my lap. Figured if I have the the front suspension disassembled already and need an alignment, might as well beef up an exposed skinny component.

 

[ARCowboy]

Labor day proved very fruitful !

First on the agenda was properly routing the battery cables for my winch and finishing up wiring for that.

I ran 1.5" split loom with 2x 1/0 AWG cables from the winch to the battery:

Then I spent about 2 hours with my trusty Fluke trying to figure out why the winch wouldn't run... Wiring diagram for the solenoid was incorrect -,- There was no 12v running to the remote, so no way to complete the circuit and engage either the forward or reverse solenoid. Frustrating, but had the opportunity to refamiliarize myself with DC systems.

Runs like a champ now and I wound it under load so it's good to go, should the occasion call for it this weekend

After it ops-checked good, I finalized the wiring. Since I built that solenoid box, I labeled the wires correctly for in vs out on the remote, used clear heat shrink, and then covered them in split loom + zip ties to prevent them from touching each other.

Labelled and heat shrunk:

Split loom covering each:

Also if anyone is curious about the ground point driver's side front:

It's an interesting bolt indeed ! 13mm to remove it and it's an M8x1.25