The "Tan Brick" aka my 1997 Express Cobra conversion

[1project2many]

Sorry. I had to run off to a prior appointment.

Let me see if I follow. I bet the G1500 cable is the same, atleast on the pedal end. The K30 (Is this the HD truck or your normal K3500 4x4) pedal bolts right on, cut the extra off the cable by cutting that rectangular bead in half.

Yes. The K30 was a normal truck.

I looked up a pedal for a 1999 K30 on Ebay, couldn't find one, but found a listing for a K3500. List to be the same pedal from 96-99 in the OBS trucks. I think I have one of these left over from the 1999 K1500 Suburban we parted out.

They probably are the same in all C/K trucks in those years. We had a K30 here to borrow a pedal from on the day we were trying the first swap, so I always ordered a new pedal for that vehicle.

That 4WD conversion van sounds cool. I once found a Quigley conversion bus at a reasonable price but no matter how I tried I couldn't get upper management to go for it.

[Fast355]

Sorry. I had to run off to a prior appointment.


Yes. The K30 was a normal truck.


They probably are the same in all C/K trucks in those years. We had a K30 here to borrow a pedal from on the day we were trying the first swap, so I always ordered a new pedal for that vehicle.

That 4WD conversion van sounds cool. I once found a Quigley conversion bus at a reasonable price but no matter how I tried I couldn't get upper management to go for it.

No problem! I got busy with work as well.

It was threatening rain this evening and the mosquitos are worse. Even Deep Woods OFF was not stopping their thirst for my blood. I only managed to get the wiper cowls fitted. I found a battery terminal puller makes getting the wiper arms off a breeze.

[Fast355]

Finished up the wiring harness repairs at the PCM this afternoon. Ended up not labeling a wire somehow. Just pinned everything else in and tried to start the van. It started and ran, missing badly. It was luckily and injector wire and was easy to figure out.



PCM Harness Finished


Booster & Master Cylinder installed


At this point if the used Booster and Master cylinder function correctly all I have left is to bleed the brakes and install the hydroboost power steering hoses.

[Fast355]

Finally finished this project and it has been very worthwhile. Test drive revealed much better handling and ride. The hydroboost/larger bore 1-ton master also works so much better than the vacuum setup. I am having to learn how to brake all over again.

[JeepsAndGuns]

Hahaha, I know the feeling. When I did the swap on my wrangler, I had already converted to rear discs and larger dual piston front calipers. I had more pedal travel than stock (but not a unsafe amount) I went from the stock disc/drum 1 inch bore MC, to a 1-1/8 bore disc/disc MC and hydroboost. First time I hit the brakes I thought I was going to stand it on its nose and go through the windshield.

[Fast355]

Hahaha, I know the feeling. When I did the swap on my wrangler, I had already converted to rear discs and larger dual piston front calipers. I had more pedal travel than stock (but not a unsafe amount) I went from the stock disc/drum 1 inch bore MC, to a 1-1/8 bore disc/disc MC and hydroboost. First time I hit the brakes I thought I was going to stand it on its nose and go through the windshield.

Mine was just the opposite. My stock master was 1 1/8" or 28.57mm. I had already stepped up to a 34mm 2003+ Express 1500 master cylinder for disc/disc. With the original master cylinder the pedal was very vague and then transitioned to rock hard with about 1" of height off the floor. With the 34mm newer master cylinder the pedal response was honestly quick, maybe even too quick, but the pedal effort was very high and under panic type braking, it really felt like it had less stopping power than stock and it may very well have. Not really enough to be dangerous IMO, but enough to be noticeable. The 1996-2002 G3500 single rear wheel master cylinder is 1.25" or 31.75mm bore and setup for disc/drum. Its right in the middle of the two extremes above. Perhaps the reason it feels like the best of both worlds. The pedal response is quicker than stock, a little slower than the 03+ master, yet with the Hydroboost the pedal effort is less than it was stock. It would be very difficult to explain the difference to somebody that had not already felt the difference in their own rig. When I first hit the brakes hard, I felt like I was going to face plant the dashboard which is no small feat in a 6,200 lbs Express.

[Fast355]

I drove it again this morning on my way to work. Out of a red light, aimed toward an on-ramp, I jumped on it. I noticed the axle wrap/wheel hop has been greatly eliminated. The thing screeched the right rear tire, the G80 in the 9.5" locked, felt like it jumped up, planted itself, and took off! I kept it planted on the floor for ~1/4 mile uphill on-ramp, glanced down at the top of it and was already rolling 85 mph. It happened so quickly and smoothly, I did not even notice I was rolling along that well. Cruising down the highway on my way to work, I noticed having new wiper cowls probably cut down 50% of my wind noise at 80 mph. Honestly speaking, I can't wait to get the rebuilt 1-ton suspension, brakes and rear-end under it and get the Hellwig rear sway bar ordered.