Ultimate Diesel Builder's Guide - - Suburban Denali Hd -

Of course we don’t have the space in the mag­a­zine to show the com­plete build from start to fin­ish, but we chose a few pic­tures from the MA build team to help show you some of the work that went into this amaz­ing Sub­ur­ban Denali HD build. En­joy—ed.

The chas­sis was blasted, then painted with Dupont In­dus­trial Coat­ing gloss black to hold up to the harsh Michi­gan weather with­out rust­ing like it did be­fore. It also looks a whole lot bet­ter.

It was lit­er­ally stripped down to the frame to build the Duramax-pow­ered Sub­ur­ban project from the ground up, with a “like new or bet­ter” build phi­los­o­phy.

As the chas­sis is com­ing to­gether with the driv­e­train in­stalled and work pro­gress­ing on the wire har­nesses, it’s easy to see that this swap was a very se­ri­ous un­der­tak­ing.

The plain white, 3/4-ton 2008 Chevy Sub­ur­ban was orig­i­nally a bor­der pa­trol ve­hi­cle, but the Mer­chant Au­to­mo­tive team had much bet­ter plans for it.

The orig­i­nal roof panel was re­placed with a new fac­tory Sub­ur­ban panel with a sun­roof for much bet­ter fit, fin­ish and func­tion­al­ity than an af­ter­mar­ket sun­roof.

Jake Phaff looks on as the body and chas­sis are test-fit­ted one of the many times dur­ing the build. The turbo diesel 6.6L Duramax engine takes up a lot more room than the 6.0L gasser that came out of the Sub­ur­ban.

To meet Mer­chant’s high ex­pec­ta­tions and stan­dards, the Sub­ur­ban re­quired ex­ten­sive body work to all the body pan­els, in­clud­ing a com­plete re­moval and re­place­ment of the roof.

The body looks stun­ning in the GM Ar­rival Blue fin­ish that was flaw­lessly laid down by the team at ND Col­li­sion.

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