dtc81
Member
- Joined
- Feb 11, 2026
- Member Number
- 9903
- Messages
- 21
Yep. A mail truck! A Grumman LLV if you wanna get technical...This is going to be my best attempt to build my "dream" truck. I have always wanted to turn one into a quirky "do-it-all" unit. Something that can hold its own on the rocks, be safe and capable at speed, go down the road straight, and haul the family for short fun runs.
Current Parts Spec:
Engine: GM LQ4 6.0L
Trans: 4L80e
T-Case: Ford NP205 with ORD Magnum Underdrive
Front Axle: 2015 D60 with MoFab keyed high steer arms, Barnes truss
Rear Axle: Sterling 10.5 with Artec truss
Wheel/Tire: Sidetracked Off Road 17" forged bead locks, 40" KR3
Goals:
-Push my design, fabrication, and welding skills.
-Retain LLV charm: sliding doors, rear roll up door, general proportions, basic amenities.
-Have a little bit of race car vibe.
-As Low CG as possible, ideally flat bottom the whole thing. It's going to drag.
-Safe.
Backstory:
I spent nearly 6 years trying to track down a mail truck, and finally scored this one in 2022. I tried buying this LLV in 2019 when the owner was in Colorado, but he decided to keep it. Two years later I missed a FB message from him while I was at Fabtech. He sold it the next day. I found another, much cleaner LLV in Maryland, but the owner wanted a ton of money for it. He sold it, but the buyer mentioned he had an LLV in rough shape. We got in contact, both had wives due with kids any day, so tabled the sale until the newborn dust settled a few weeks later. After a 19 hour driving day I finally had my LLV.
Well, life took over for a few years, so it sat behind the barn while we were building a new shop. I was slowly buying drivetrain parts as I found them. I work in construction, and have a small welding and fabrication business on the side. (@dcbuiltllc on Instagram for those curious). This is by far the most extensive vehicle fab project I've done, so I'd love any criticism and feedback! I've been following a bunch of different social media accounts, YouTube channels, and forums for years now, trying to soak up as much knowledge as I can.
I started by building a simple chassis table out of some channel, and then dove into stripping the LLV. I knew I wanted to challenge myself with a full chassis build, so only the body was saved. I had a 2000 Chevy Suburban for a motor/trans donor. Stripped that, and kept all the misc./wiring, although I'm leaning towards a Holley Terminator or similar. I tore down the axles so I could properly pre/post heat them during the truss install. I rebuilt and repainted the NP205 and mated the ORD Magnum to it.
Current State:
As of this post (2/11/26), the body is on stands. The driveline is roughed out onto the chassis table, and the axles are positioned. I started cutting the floor/firewall to drop the body down and clear the motor.
I have some questions; hopefully people can drop some knowledge!
1) Currently the harmonic balancer is behind the front axle. I'm 99% sold on full hydro steering after weighing the compromises. Is there any recommended clearances between engine/trans for a starting point? Once I start cycling suspension I'm sure I'll find what works and what hits!
2) Current plan is to mock up at full bump to see packaging/layout constraints. Layout linkage design and then work it to ride height. I have archived a bunch of old forum posts and online calculators to help guide me. Does this sound logical?
3) I'm open for options on suspension design - at a minimum, basic 4 link rear, but possibly trailing arms because they look fun to build. Originally planned a 3 link front, but If i can squeeze a 4 link in with hydro steering, I'd explore that option!. Plan to run a single 14" coil over at each corner. Would love to find more geometry and design info to add to my research if anyone has recommendations.
I've quickly learned this whole thing is a game of compromises! I'm enjoying the learning curve and know there will be lots of tack, test, cut, repeat in my future. Keeping the flat floor and the center cabin sliding door has really limited how low I can drop the body at this point. These things seem little going down the road, but they're nearly 6' tall from rocker to roof!
Photo Dump:
Current Parts Spec:
Engine: GM LQ4 6.0L
Trans: 4L80e
T-Case: Ford NP205 with ORD Magnum Underdrive
Front Axle: 2015 D60 with MoFab keyed high steer arms, Barnes truss
Rear Axle: Sterling 10.5 with Artec truss
Wheel/Tire: Sidetracked Off Road 17" forged bead locks, 40" KR3
Goals:
-Push my design, fabrication, and welding skills.
-Retain LLV charm: sliding doors, rear roll up door, general proportions, basic amenities.
-Have a little bit of race car vibe.
-As Low CG as possible, ideally flat bottom the whole thing. It's going to drag.
-Safe.
Backstory:
I spent nearly 6 years trying to track down a mail truck, and finally scored this one in 2022. I tried buying this LLV in 2019 when the owner was in Colorado, but he decided to keep it. Two years later I missed a FB message from him while I was at Fabtech. He sold it the next day. I found another, much cleaner LLV in Maryland, but the owner wanted a ton of money for it. He sold it, but the buyer mentioned he had an LLV in rough shape. We got in contact, both had wives due with kids any day, so tabled the sale until the newborn dust settled a few weeks later. After a 19 hour driving day I finally had my LLV.
Well, life took over for a few years, so it sat behind the barn while we were building a new shop. I was slowly buying drivetrain parts as I found them. I work in construction, and have a small welding and fabrication business on the side. (@dcbuiltllc on Instagram for those curious). This is by far the most extensive vehicle fab project I've done, so I'd love any criticism and feedback! I've been following a bunch of different social media accounts, YouTube channels, and forums for years now, trying to soak up as much knowledge as I can.
I started by building a simple chassis table out of some channel, and then dove into stripping the LLV. I knew I wanted to challenge myself with a full chassis build, so only the body was saved. I had a 2000 Chevy Suburban for a motor/trans donor. Stripped that, and kept all the misc./wiring, although I'm leaning towards a Holley Terminator or similar. I tore down the axles so I could properly pre/post heat them during the truss install. I rebuilt and repainted the NP205 and mated the ORD Magnum to it.
Current State:
As of this post (2/11/26), the body is on stands. The driveline is roughed out onto the chassis table, and the axles are positioned. I started cutting the floor/firewall to drop the body down and clear the motor.
I have some questions; hopefully people can drop some knowledge!
1) Currently the harmonic balancer is behind the front axle. I'm 99% sold on full hydro steering after weighing the compromises. Is there any recommended clearances between engine/trans for a starting point? Once I start cycling suspension I'm sure I'll find what works and what hits!
2) Current plan is to mock up at full bump to see packaging/layout constraints. Layout linkage design and then work it to ride height. I have archived a bunch of old forum posts and online calculators to help guide me. Does this sound logical?
3) I'm open for options on suspension design - at a minimum, basic 4 link rear, but possibly trailing arms because they look fun to build. Originally planned a 3 link front, but If i can squeeze a 4 link in with hydro steering, I'd explore that option!. Plan to run a single 14" coil over at each corner. Would love to find more geometry and design info to add to my research if anyone has recommendations.
I've quickly learned this whole thing is a game of compromises! I'm enjoying the learning curve and know there will be lots of tack, test, cut, repeat in my future. Keeping the flat floor and the center cabin sliding door has really limited how low I can drop the body at this point. These things seem little going down the road, but they're nearly 6' tall from rocker to roof!
Photo Dump:
