Good points Popo, you're right I probably am taking the comments a little to literally, I just get them all the time and it gets annoying, lol.
Ok to make a 1ton.
1) Completely dissasemble your truck as though you were going to do a frame off.
*I was planning on pulling the bed, not neccesarily the cab, I have a 3" body lift so there is a good bit of room to work under there w/o having to remove the cab.
2) Get a hold of 2 1 ton axles (sounds liek you ahve these) or if you insist a 1ton IFS set up they are completely diff.
*Do'nt have axles yet but I was planning on a dually 14 bolt rear and the 2500 outers in the front allthough I would prefer to not run dually if I can but if neccesary it will be done.
3) Go puchase (or build) a 1 ton frame. I would just buy one from the junk yard. You really cant modify yours. Unless you cut all the cross members out and replace the main ladder rails with apprpopriate size and thickness steel.
*I was planning on removing the current crossmembers and making a bunch more of my own out of alot stronger material as well as boxing in alot of the frame
4) Next lets address springs and shocks. Beefing up a 1/2 ton spring pack doesnt make it a 1 ton...better get new 1 ton springs. Shocks are pretty simple, just check out advance
*True, allthought the packs I have now are pretty beef and I could always add more leafs but I was planning on getting Air bags, and yea shocks I can go grab anywhere.
5) BRAKES, you should have covered this with your new axles but make sure
*Definitly, as well as a 1 ton master cylinder
6) Steering, 1/2 ton steering crap aint gonna cut it, better replace all that
*Good point, I was thinking of adapting the 2500 steering as well.
7) Now assemble all this and bolt your body back down...
OOOPS now you need motor and tranny upgrades..
*Tranny already have a 4l80e ready to be swapped in obviously with a 32 spline 241, as far as motor upgrades I'm not gonna mention what I have in mind yet cause that will open another can of worms but I've got a plan for it.
Look Rick, we all love to give ya hell, and I can understand never wanting to sell your truck (maybe it has sentimental value, liek you got your first POA in or somen)..so keep it, but it would be CHEAPER, SAFER and all around BETTER to go buy a used tow rig. Dude you can run across older 3/4 and 1 ton gas deals for 1-2 grand all the time.
Nothing against your Z71..Im sure it is a nice truck, but it is closer (and would be easier to convert to) to a world class rock rig than a 1 ton tow rig.
*I just don't see it being all that hard to do all this stuff, and I can make the frame very strong. Saftey Is obviously a huge concern, and I want to do everything i can to get it where it needs to be, by all means shoot me ideas on exactly how to build the frame to handle the weight.