Dweano's 1996 AND 2001 Front End Swaps

[Dweano]

Hey guys, I know I have made some threads before about this, but I am finally home and I have both trucks in my possession. This week I will start taking things apart and see whats up. I will be swapping the front end from the 2001 (black truck) to the 1996 (blue truck) and then the 1996 front end back onto the 2001 and then sell the entire 2001 truck. I am hoping things bolt up but I am guessing it would be easiest to swap both core supports so I do not have to do alot of cutting and trimming of things twice because I am doing 2 front end swaps at the same time. If anyone has any helpful comments or questions etc etc please ask.

Pics time:

The two trucks:

Front side of 1996:

Front of 1996:

Angled other side of 1996:

Side of 2001:

Front of 2001:

Again:

Other side of 2001:

Hope this isn't too hard!

P.S. Please excuse the embarrassingly bald and small BFG All Terrains. Temporary Measure. Before the end of summer I will be rocking some 315/75/16 Treadwrights

 

[Josh40601]

you should look up my thread about installing the 98+ style on a 93-97.....

Its not just a bolt on, and if you do it without changing the core supports, there will need to be a little fabbing. Nothing crazy, just want you to know it isn't just a bolt on deal

 

[Dweano]

If I do change the core supports will it be more bolt on and less fabbing? I have actually checked out your thread actually. I will probably use it when I actually get to the project. Thanks for writing it up man

 

[Josh40601]

if you do change the core support, all you have to do is drill new holes for the fenders. That's it. The core support is riveted to the inner fenders. It can be done, I was just lazy. lol

 

[Dweano]

If I am actually swapping the front ends it would probably save me alot of hassle eh? Cuz everything you did I have to do twice. I think I will swap the core supports. Whats the best way to do that? Drill out the welds, reweld? The fenders need new holes drilled for...? like the flares or the actual connections. Thanks!

 

[84stealthranger]

mac tools or matco makes a spot weld drill bit they work really good and should out last this project and many others. im not sure how much they cost but its worth it, u might be able to find a cheaper one some place else.

 

[Dweano]

Whoop Whoop! Finally got started on this today. Way too long after I said I would. I also picked up some spot weld cutters recently so that should help me out. Heres how far I got:

I am pretty much just taking things off willy nilly...is there an order I should be following? Then reverse it for reassembly? Any input would be much appreciated as I am feeling quite over my head.

I also have a few questions...

1: How is a 2001 bumper going to go on a 1996 and vice versa? It looks MESSED UP

2. On my 1996 (and probably 2001...haven't got that far) the last bolt to undo the fender is buried beneath many things. How do I get to it? Do I have to take out the air intake thing?

More questions will ensue most likely, if anyone who has completed this already has any answers I would greatly appreciate it!

 

[Josh40601]

You will have to build bumper brackets to make each front bumper fit. The frame is completely different.

This is why i went on and had a custom bumper built.

As far as the bolt goes, i need you to be much more specific.

The holes you will need to drill in the fenders are on the top of the fenders. if you look at both trucks side by side, you will see that bolt holes are opposites

Anything that is bolted to the radiator support will have to come out. I'm not sure if the 96 radiator will work in the 01 support, and vise versa.

 

[Dweano]

I'm a massive noob but I am assuming the radiator support is the thing that the radiator attaches too? Haha. Yeah I was thinking custom brackets for bumpers, shoot. The tops of the fenders shouldn't be too hard. Umm...the fender bolt is towards the front of the fender, looks like it bolts the blue part under my grill to the fender. I have that blue strip that is under my grill and it attaches to the fender via that one bolt on both sides. Side note is "that blue strip under my grill" called the header panel? Haha. Thanks for your help!

 

[Dweano]

Due to work and no shop and crappy weather and my procrastination skills..this is the slowest progressing project in the world. I did manage to get the fenders off tho, and the header panel and lights are off, all I have left to do is swap the core supports and start putting things back on. How do I swap the core supports tho? There seems to be millions of spot welds everywhere...should I just drill them out and use bolts? Of use my spot weld cutter and just cut the one layer and leave the other stuff intact? Also..the bottom of my 96 core support is rusted to crap. I guess I will just have to make due with whats left. Heres some pics with the header panel still on:

 

[Josh40601]

you need to take the header panels off. They are still on there. Its the black and white thing on the front of the core support for the 01, and the blue thing that is bolted on the core support of the 96.

If it is rusted, you are going to have a hell of a time getting it back on the 01.

I have a buddy on another forum that did the swap. I am trying to find his thread, I will get all the info you need, and get back to you

 

[Dweano]

Yeah I did take the header panels off...just after I took the picture, I am learning what all this stuff is now that I am diving into it. Slowest progress ever but its coming slowly. Its rusted at the bottom...I can snap some pics sometime...I think if it comes off good getting it back on shouldn't be too bad. The core support just looks like a biotch to get off...randomly spot welded and what looks like patch welded onto the inner fenders. That Josh! That would be helpful, thanks for your help already

 

[-Nathan-]

looking good D. Nice to see you getting elbows deep in there!

 

[4.0B2]

nice. 'scribed.

 

[Josh40601]

Yeah I did take the header panels off...just after I took the picture, I am learning what all this stuff is now that I am diving into it. Slowest progress ever but its coming slowly. Its rusted at the bottom...I can snap some pics sometime...I think if it comes off good getting it back on shouldn't be too bad. The core support just looks like a biotch to get off...randomly spot welded and what looks like patch welded onto the inner fenders. That Josh! That would be helpful, thanks for your help already

yea man, no worries. I know they are welded on there pretty damn good, which is why i sent him an email asking him if he could help out. As soon as i hear something, I will let you know.

BTW, you will have to swap the hoods too.