From Frame to Finish: The Ultimate Chevy Tahoe Overhaul

There comes a time in most truck builders’ lifetimes when picking up on a project where someone else left off is inevitable. It can be difficult sometimes to find popular older-model vehicles that haven’t been previously altered and/or butchered by another aspiring customizer. Hey, it’s just how it goes out there, especially if you’re hoping to find a deal. Every now and then, if you want to take home that specific make and model truck or SUV, you just have to take what you can get, prepare for the worst, but still hope for the best during the rehabilitation process.

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Brian Nelson, a proud member of Relaxed Atmosphere and a longtime fan of Chevy OBS SUVs, found himself in a similar predicament as he shopped around for the best two-door Tahoe he could find. After some time spent digging around, he did find one that he felt confident enough to drop some money on even though he really didn’t have the clearest picture of its condition at first inspection.

“Any time you buy a project someone else started, you’re bound to end up fixing some of issues,” Brian admits. “My friends and I ran into enough problems that we figured it would be less stressful and work out better in the end for the Tahoe if we tore it down to the frame and started all over again.”

STRIPPED AND LOWERED

With the factory chassis exposed, Brian and a few pals got down to business by first creating a plan to ‘bag the frame and then making the first cut by C-notching the rear rails. The factory front arms were scrapped to make room for a new set of tubular arms that were better equipped to jibe with the upcoming air-suspension system. A 2-link setup was then assembled for the rear before the Slam Specialties SS6 ‘bags were mounted and plumbed to an Accuair VU4 manifold and control box to ensure smooth operation of the Tahoe’s newfound adjustable ride height. To achieve an even lower cruising altitude, the guys body-dropped the SUV a solid 2 ¼ inches, which has gone a long way in allowing Brian’s ride to make a huge impact in the way it looks when in motion or aired out to the ground.

To make the most of the Tahoe’s killer new stance, Brian selected an equally impressive set of 22×9 American Racing Nova wheels along with fresh 255/20 Lexani LX-Twenty series rubber. While the majority of the factory braking components were good enough to keep intact, a billet master cylinder from TransMount Racing was added to the mix. With a completely refreshed chassis system now complete and rolling to Brian’s standards, he was able to move on to the next phase of the project.

RECONDITIONED 350 V-8

The stock 350 V-8 was soon yanked and fully rebuilt for many more years of dutiful service. To assist with this portion of the build, Brian recruited Kelly’s Engine Service in Union City, Tennessee, due to the crew’s overall expertise in this line of work. While the factory engine was left largely in its freshly reconditioned state, a few billet parts and accessories were set aside to be painted to match the exterior paint that would be coming in the very near future.

One of the most exciting things to witness during the evolution of a full show-worthy truck project is the reinvention of its overall appearance. Brian had some great things in the works for the Tahoe’s exterior metal, such as the shaving of the door handles and relocating the gas door since the position of the fuel tank was moved during the chassis overhaul. Custom bead-rolled inner fenders were also fabricated for the engine bay as well as for the rears. One addition that Brian was dead set on including into the build was a huge 40×80-inch sliding ragtop from Legacy that requires passengers riding in both rows of seating to apply high-SPF sunscreen.

A Goodmark cowl hood, a smooth Keystone chrome front bumper, and a custom roll pan were also locked down to change up the Tahoe’s profile, but it was ultimately the paint selection that truly transformed its appeal. Craig Dugger of Troy, Tennessee was given the opportunity to spray the PPG Sunset Gold hue that is both luxurious and classic—an ideal choice for this two-door stunner.

SOLID GOLD INTERIOR

To complement the fresh coloring on the exterior, Brian orchestrated for the entire interior to be gutted so the dash and all panels could be painted and upholstered for total uniformity within the cabin space. Clayton Custom Upholstery in Dyersburg, Tennessee, was called on to wrap the ’96 regular cab bench seat and portions of lower portions of the door panels in vinyl material that mimics the look of distressed leather. To top off the interior restyling, a throwback white face APC gauge overlay was applied to the dash, and a Billet Specialties flamed steering wheel was added for a dash of timeless street machine charm.

Brian’s Tahoe project evolved into what it is today in just about three year’s time—not bad considering what he started with and where his build has come so far. While we dig everything he has done, he still has a few more plans to rollout before he can truly consider it a done deal.

“I think I want to add some graphics to the paint in the future,” he says. “I also want to add a big stereo system like the ones that were common back in the ’90s. Whether those happen sooner than later, I can say that I’ve enjoyed my time spent with my friends and wife as we rebuilt the Tahoe from the condition it was once in. My advice to others looking to do the same is to not take shortcuts with their trucks. They will always come back to haunt you or someone else in the end.”