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2002 GMC Sierra 2500HD Crew Cab - Fullsize Fun

More Than Just Towing

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Fullsize trucks can often be found romping across the desert, blasting through mud bogs, or towing heavy loads. But rockcrawling though boulder-strewn canyons? That is a task typically left to the Jeeps and tube buggies. Dan Peoples didn't want a Jeep though. He wanted a vehicle that could comfortably carry his whole family and tow his quads, yet still explore the canyons found around his home of Reno, Nevada. To accomplish this goal, Peoples turned to a man who is all too familiar with rockcrawling: 2002 ARCA champion Mike Shaffer. When he is not competing on the rockcrawling circuit, Shaffer runs his own fabrication shop in Carson City.

Peoples' '02 GMC 2500HD Crew Cab shortbed pickup came from the factory with a stout drivetrain. The stock truck boasts a 300hp 6.0L engine, a burly 4L80E overdrive transmission, and an NP241 transfer case. While the running gear is tough, the ground clearance and wheel travel left something to be desired, and that is where Shaffer took over. A ball-joint high-pinion Dana 60 from a Ford Super Duty was grafted onto the front end with 14-inch-travel, 2.5-inch-body Bilstein 9100 coilovers wrapped in dual Eibach 375-pound-over-500-pound coils. The coilovers are located by a three-link and Panhard bar constructed with 2.5-inch Rubicon Express Super-Flex joints and 1.75-inch by 0.250-wall DOM tubing. In the rear, the stock leaf springs were inboarded under the frame and used in conjunction with 2-inch lift blocks, compression shackles, and 12-inch-travel Bilstein 7100 shocks.

The eight-lug Dana 60 matches the lug pattern and width of the Corporate 14-bolt rear perfectly. Both axles are stuffed with 5.13 gears and ARB Air Lockers for trouble-free driving on the street and full traction on the trail. That traction comes via 39-inch Super Swamper Irok radials wrapped around 16x10 Mickey Thompson Classic II wheels. PSC hydraulic-assist steering helps turn the big tires when they get bound up in the rocks.

  • Our destination for the day was a rocky canyon north of Reno. The length and width of this truck required Peoples to take some "unconventional" lines, but he made it through the entire trail under his own power and with minimal damage.
    Our destination for the day was a rocky canyon north of Reno. The length and width of thi
  • The custom Shaffer rock sliders are over 8 feet long! They do an admirable job of protecting the GMC's clean sheetmetal when Peoples is pretending he's driving a rock buggy. The sliders attach to the frame with scab plates in four locations for strength and protect the AMP Research retractable steps that aid ingress and egress.
    The custom Shaffer rock sliders are over 8 feet long! They do an admirable job of protect
  • Shaffer built the link front suspension for max-imum ground clearance, strength, and articulation. The components were constructed from 1.75-inch by 0.250-wall DOM and 2.5-inch Rubicon Express Super-Flex joints and configured in a three-link with a Panhard bar.
    Shaffer built the link front suspension for max-imum ground clearance, strength, and artic

A Crew Cab has a lot of sheetmetal, and after making such an investment Peoples wasn't interested in destroying his late-model truck. A TrailReady winch bumper protects the front end and provides a home for the Warn M15000 winch. With no off-the-shelf options, the sides and rear of the truck are protected by custom armor constructed by Shaffer's Offroad. The rear bumper has extraction points and a receiver hitch to ensure that the truck remains fully functional for a variety of tasks, and it wraps around to protect the sides of the bed as well.

With the build complete (and his bank account still recovering), you may expect to find this truck at the mall or on the highway towing a toy hauler. Although Peoples' daily driver can sometimes be seen in these places, it can also be found on some of the hardest rockcrawling trails in northern Nevada. Even though the rock sliders and rear driveshaft take a beating, Peoples pilots his truck through rocky canyons that we had only seen traversed by much smaller vehicles. His dream of creating a truck that can do it all has been fulfilled. If you don't believe us, just take a look at the photographs!

  • The 153-inch wheelbase provides stability on steep climbs and when towing, but the breakover angle means that the driveshaft pays the price on the trail.
    The 153-inch wheelbase provides stability on steep climbs and when towing, but the breakov
  • The engine bay houses the stock Vortec 6000 engine under a tubular cross-support for the coilover shocks. Other additions include the PSC large-capacity steering reservoir and the ARB solenoids located on the driver side of the firewall.
    The engine bay houses the stock Vortec 6000 engine under a tubular cross-support for the c
  • The front axle is a ball-joint Dana 60 from a Super Duty stuffed with 5.13 gears and an ARB Air Locker. The ball-joint, unit-bearing design of this axle has proven to be a weak link, as several broken hubs and stub shafts can attest. With 360 lb-ft of torque, 39-inch tires, and 7,000 pounds of American iron, something has to give.
    The front axle is a ball-joint Dana 60 from a Super Duty stuffed with 5.13 gears and an AR
  • A Corporate 14-bolt filled with an ARB Air Locker and 5.13 gears resides under the rear of the truck. Relocated stock springs, 2-inch blocks, and Bilstein 7100 shocks on custom mounts constitute the rear suspension. Peoples plans to shave the rear axle for more ground clearance.
    A Corporate 14-bolt filled with an ARB Air Locker and 5.13 gears resides under the rear of
  • The big GMC works equally well on the trail and the street. Even with 39-inch tires, the truck did not experience any rubbing or strange handling traits thanks to the well-designed coilover suspension.
    The big GMC works equally well on the trail and the street. Even with 39-inch tires, the
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