Archive for the ‘Custom Built Trucks’ Category

Kustom Truck was approached by RB Crushing, a division of Petro West that operates out of the Grande Prairie, Alberta Canada region to to build a pair of twin 2012 Peterbilt glider kit trucks model 389 to serve as lowboy’s.  The one stipulation about the trucks, could RB Crushing get a new Peterbilt glider kit truck with a non EGR engine.  The current production motors require engine REGEN and is simply is not working in this region.  A REGEN requires extreme high heat to clean the DPF filter and burn the carbon buildup that accumulates, a process that is extremely challenging with the cold weather experienced in Canada.  Not a problem for Kustom Truck, this is what we do!

The Peterbilt Glider Kit Trucks were brought in from the factory as rolling gliders with 46K lb rears sitting on Peterbilt Air Track suspension, 48″ flat top sleepers and platinum level interiors.  Kustom Truck spec’d out a drive train package to include a pre emission 2002 model Caterpillar C-16 engine rated 600 HP @ 2050 torque.  In order to handle the power output the Caterpillar engine put out, a Fuller transmission model RTLO-20918B was chosen.

The day the trucks showed up as rollling Peterbilt glider kit trucks piggybacked into the lot

The twin Caterpillar C-16 engines sitting on the Kustom Truck shop floor up-fitted with the peripherals (starter, alternator, fan hub, belts, ect) waiting to be dropped into the engine compartment.  The Fuller transmission is already bolted to the flywheel housing as well.

Both Caterpillar C-16 engines are now installed in the engine compartment and the electric plumbing has begun a lot of work yet to be completed before we fire these trucks up.

The Caterpillar C-16 engine are now plumbed for electrical and all engine piping is installed as well as the hoods are back on the the Peterbilt Glider Kit Trucks.

Now it’s time for the Kustom Truck shop to start on the extra goodies that the customer has requested in order for the fit and finish to be acceptable.  Here’s the list of custom options:

  • 11″ drop visor by Roadworks
  • accessory lights to include: breathers, side skirts, under cab and sleeper all LED lights by Roadworks
  • Diamond plate half fenders, step boxes, chain hangers and a custom headache rack by ProTech
  • 7″ exhaust system with muffler inserts by Dynaflex
  • A custom water manifold and ceramic detail package by Kustom Truck
  • The ceramic detail package included the jake stand, cam cover, dipstick and oil fill tubes, turbo lines, the turbo hot and cold housings, thermostat housing, exhaust manifold and heat shield
  • Custom polished stainless charge air cooler and radiator pipes by B & H Tubes

Now that the trucks are assembled, test drives are complete and the trucks are awaiting delivery to RB Crushing, Kustom Truck leaves you with these parting shots.

After a few hurdles that Kustom Truck had to overcome, the Western Star glider kit truck model 4800 project is finally wrapped up and ready for delivery.  The C-12 Cat engine fitment went very smooth and provides plenty of power for the application.  In a feed truck application DPF and SCR have significant drawbacks, a engine REGEN takes valuable time away from what the truck is intended to do, Feed Cattle.  Having the ability through a glider chassis to install a pre 2002 EPA motor solves a major issue for dairy and cattlemen that want a truck mounted feed mixer truck.  For those that don’t understand EPA regulations, were talking an engine, turbo and exhaust.

Here are some photo’s of the completed project

A few interior pictures, with no need for a flashy interior a base model was chosen for this glider kit that will be used on the dairy

And finally some pictures of the Cat C-12 plumed into the Western Star 4800 Chassis

Thanks for following along as Kustom Truck built a current production 2012 Western Star Glider Kit Truck Model 4800 and fitted it with a 2000 EPA Caterpillar C-12 engine

The truck entered the Kustom Truck shop a little over 2 weeks ago as a 1988 Peterbilt 379 Extended Hood with a 3406B model Caterpillar engine that was no longer CARB compliant to run in the state of California.  After the engine conversion the Pete left with an 07 platform Cummins ISX engine complete with DPF, compliant through 2023 in California.

With the project complete there is not much left to say other than thanks for following along.  Here’s some pics of the final project before it left on it’s way back to it’s owners Galindo Construction.

Now that the 3rd segment of Kustom Truck converts a 1988 Pete 379 to meet the California Air Resources Board compliance through the year 2023 is complete, let’s show what was done.  In the 3rd part we dedicated it solely to the Diesel Particulate Filter (DPF) integration into the chassis since this is such a major part of the project.  Not taking anything away from the engine conversion cause that was a huge hurdle to overcome in itself.  To complete the engine swap to include plumbing and wiring took roughly a weeks worth of labor, no small task.  The most labor intensive was obviously the wiring since the chassis came with a mechanical engine and had to be converted to accept an electronic motor that the cab was able to communicate with for all the necessary engine monitoring functions.  With that said it’s time to detail how the DPF was installed and take you through the process.

First things first a mounting location had to be chosen to house the DPF.  Where to put the large filter assembly that’s roughly 45″ in length? The passenger side step box …

We chose to custom build a step box that would be located on the passenger side of the cab, just below the door and replace the existing factory box.  The inlet comes in the front side of box through 7″ hole

The back side of the new step box was left open so we have easy access to the DPF filter as well as heat transfer and to provide an easy outlet so we can tie back into the factory exhaust system.

Once Kustom Truck bolted the step box back into the existing location of the old box it was time for a mock up of the DPF to make certain fitment and dimensions were adequate with no clearance issues

Now that the custom step box along with the DPF filter are in place it’s time to get to work on plumbing and piping to get the exhaust from the engine and out the exhaust pipes.  The turbo down pipe was first, the pipe runs down the inside of the frame rail and exits just behind the rear leaf spring hanger.

After some carefully placed bends the pipe was ready to be welded up and attached to the inlet of the DPF filter located inside the step box.

The DPF is bolted into place, the plumbing is complete, all exhaust has been custom bent and hooked up

Here is a shot from under the cab so you can see the DPF mounted in the box from the backside.

There was some custom pipe bending that had to take place in order for the DPF outlet to hook up to the factory Y-Pipe in order to make the exhaust fully functional

And finally a few shots of how the project looked once the lid was installed back on the step box.

Only one more phase of the project is left, Part 4.  In the final stage Kustom Truck will show you the conversion as a completed project, only a few loose ends still need to be tied up before we start the truck and take it on the test drive.

Now that is how a DPF should look! Stay tuned Part 4 will come early next week ….

Since 2003 as a result of the unreliability of the current production Exhaust Gas Recirculation (EGR) engines in feed mixer trucks, many of the feedlots and dairymen have gone to tractor pull-behind mixer bodies instead of truck mounted mixer bodies.  Kustom Truck solved that uncertainty by offering a feed mixer truck up-fitted with pre 2002 EPA Cummins or Caterpillar engines, which do not require DPF or SCR.  The end product is a feed mixer truck with proven reliability and performance.

A customer recently contacted Kustom Truck with an inquiry to build a current production feed mixer truck with a pre-02 emission engine.  The customer selected a 2012 Western Star 4800 series rolling glider kit truck with a 20M FA, 52M RA, 52M Hendrickson HN suspension, and a 3/8 steel double steel frame.  They also decided on the CAT C-12, 430HP 99 EPA certified CAT engine, and a fuller 9LL transmission all interfaced into the chassis with new parts.  Was it possible, could Kustom Truck complete the project and have a chassis that met or exceeded factory level quality, offer comparable OEM warranties, while providing superior performance and reliability to a new factory production unit?  Follow along as we complete the project.

The 2012 Western Star rolling glider chassis has just been delivered ..

First things first, the hood and cooling package need to be removed so we can get to work.  The radiator has been sent out to be re-cored to a 8 fin per inch feedlot style core that will be easier to clean and trap less debris as a result of the environment the truck will operate in.

All glider kit trucks come with what is referred to as a Kit Box, in the kit box contains the miscellaneous parts that are supposed to be what’s needed to finish the build (minus the drive train components) … Key word here is supposed to be

A 2000 EPA CAT C-12 factory reman was the engine of choice for this build.  The engine is rated at 435 HP @ 1650 torque rating and since it’s a factory reman, it’s backed with a 2 year unlimited hours, parts, labor and towing CAT registered warranty serial number specific in the purchaser’s name.  The warranty is valid through any authorized CAT dealer in North America.

The CAT C-12 on the floor of the shop that has been up-fitted with the peripherals (starter, alternator, fan hub, ac compressor, ect) prior to be bolted in the chassis.  The RTO-16909ALL transmission has also been bolted to the back of the engine along with a new 1650 lb clutch.

The fan that you see mounted is a Flexxair Variable Pitch, in the dairy environment with radiator clogging such an issue the customer opted for a self cleaning fan that automatically reverses the blade pitch to purge the cooling system.

In the final phase of the 2012 Glider Kit Truck build we will show the engine bolted in the chassis, drive lines installed, the engine compartment plumbed, all piping installed and a finished product.  Stay tuned for Part 2 ….

Time for the second installment of Kustom Truck converts an 88′ Pete 379 to meet CARB compliance through 2023 to run in the state of California.  In Part 1 we detailed how the truck showed up with a mechanical B model CAT engine and the tear down process.  Now it’s time to show the freshly painted Cummins ISX installed in the chassis as well as the Kustom Electronic Engine Control Harness being installed so the engine can communicate with the cab to allow electronic control of the engine instead of mechanical “rods and switching functions”.

The Cummins ISX after the first coat of paint prior to being up fitted with any peripherals

Once paint was completed it’s time to up-fit the engine with the associated peripherals, alternator, starter, ac pump, fan hub, filters, elbows, engine control harness, ect …

The transmission is ready to be installed on the back of the engine now that it’s been plumbed and yoke installed

The Cummins ISX has now been bolted in the chassis and the fun begins.  All the plumbing and electronic interface into a chassis that was originally set up for a mechanical engine will take place

The wiring in the dash needed to be cleaned up prior to the new Kustom Electronic Engine Control Harness being installed.  This particular dash took a little more work than usual since the existing wiring was in such poor condition.

In order for the engine and cab to communicate electronically rather than mechanically with levers and rods a new engine control harness was required, the addition of the Kustom Electronic Engine Control Harness was installed in order to facilitate communication.

A new set of dash panels were used on the job since the old panels were in such poor condition.  The Speedometer and Tachometer were replaced with electronic gauges so the engine could be monitored properly.

As a Kustom option the customer (Galindo Construction) opted to have the Kustom Water Manifold installed which is mounted to the frame on the passenger side.

In order to handle the increased heat rejection that the new Cummins ISX puts out a new cooling package had to be installed.  The radiator was increased from a 3 row to a 5 row core, as well as a new Charge Air Cooler and AC Condenser.  The new package increased the cooling capacity by about 40%

Now that the radiator, charge air cooler and a/c condenser has been placed in the chassis the rest of the engine plumbing will start coming together quickly.

Part 3 will be completed soon, stay tuned in for the next installment of Converting an 88′ Pete 379 to meet CARB Compliance through 2023 ….

Galindo Construction based out of Walnut Grove, California came to Kustom Truck with a dilemma.  The California Air Resources Board (CARB) recently passed regulations making pre 07′ EPA engines non compliant to run in the state of California.  Since Galindo Construction had a 88′ Peterbilt 379 they either replace the truck (which was in great mechanical working condition) or find a way to upgrade to meet current CARB compliance.  One phone call to Kustom Truck and the problem was solved; upgrade the engine to meet current CARB requirements, better yet meet CARB requirements through 2023.

The 88′ Peterbilt 379 Extended hood came to us with a 3406B model CAT Engine that met CARB compliance through January of 2012.  Behind the CAT engine sat a Fuller RTO-14613 transmission.  Galindo Construction opted for a 07′ platform Cummins ISX with a DPF Filter system rated at 475 HP @ 1650 Torque that would meet CARB compliance though 2023.  Since the old transmission was no longer within torque spec there was also a transmission upgrade in store for the old Pete, a Fuller RTLO-18918B would do the trick.

The Galindo job shows up with the 3406B model CAT engine that was no longer compliant in the state of California … time for an upgrade!

First up is to get the cooling package removed, disconnect all the hoses and lines, drain the necessary fluids and get the engine ready to be pulled

Time to get that old iron outta there and get the engine compartment cleaned up …. Notice the passenger side step box, this is where the KPI DPF interface will be installed in Part 3

Now that the engine compartment has been cleaned up, time for the project to start gong back together

The customer wanted the engine to match the paint code of the red on his truck … so the Cummins ISX was stripped to get ready for a repaint

Stay Tune for Part 2 where we will be installing the 07′ EPA Cummins ISX