632 OBS Build: Installing Baer Brakes, Holley Fuel System, and Cold Case Radiator

Chassis Restoration and Powder Coating

• 🎨 The OBS chassis for the 632SS build was returned from Blast from the Past with a silver metallic powder coat after being stripped of rust and grime.
• ✨ The powder coating is expected to complement the satin black body of the truck.

High-Performance Brake System Installation

• 🛑 A 14-inch Baer Brakes Extreme Plus package with six-piston calipers was installed on all four corners.
• ⚙️ The process involved installing custom 35-spline axle shafts from Quick Performance and ensuring proper fitment with the new brake components.
• 🔧 Parking brake assemblies were installed, serving as bearing retainers, with attention to detail like using silicone for sealing.
• 📐 Rotor and caliper alignment was achieved using shims, with calculations based on measured gaps to ensure optimal performance.
• 🚀 For the front end, AZ Pro Performance React 2-inch modular drop spindles were used to accommodate the Baer brake setup and allow for a speed sensor.
• 🔗 Steering components, including a RideTech turnbuckle and Duralast tie rod ends, were replaced to improve steering precision.

Fuel System and Cooling Upgrades

• ⛽ A Holley 525 LPH in-tank retrofit fuel module was installed to support over 1200 horsepower, requiring trimming of hoses and the mounting bracket to fit the fuel tank depth.
• 🛠️ A Holley 10-micron fuel filter and HP Billet EFI By-Pass Fuel Pressure Regulator were mounted on the firewall using a custom bracket and ARP fasteners.
• 💨 Earl's Performance Plumbing fittings and hose were used to connect the fuel system components.
• 🌡️ A Cold Case Products TIG-welded polished aluminum radiator was installed, designed to fit 88-98 GM pickup trucks.
• 💨 Dual electric fans were mounted to the radiator shroud, with wiring routed for a clean installation, though the included thermostatic switch was bypassed in favor of the Terminator X system's fan control.
• 🔧 A custom bracket was fabricated to secure the top of the radiator, as the factory shroud was not being used.

Drivetrain and Manual Conversion

• 🔩 A 4-inch diameter steel tube driveshaft from Chattanooga Driveline Service was installed to handle the engine's horsepower.
• 🕹️ The chassis was then reunited with the cab and bed, and the clutch and brake systems were finalized.
• 🛑 A Baer master cylinder was installed for manual brakes, replacing the power brake booster for a cleaner look and improved pedal feel when properly engineered.
• ⚙️ An American Powertrain clutch pedal and master cylinder setup was bolted in, designed to fit these trucks and sandwich the factory bracket.
• ⚠️ An issue with clearance between the clutch and brake pedals was identified and resolved by trimming the brake pedal arm and redrilling the pivot point.