Would You Chop 27 Inches Off Your Suburban? Meet the Stuburban!!

When most people think about rock crawlers, a Chevy Suburban probably isn’t the first rig that comes to mind. But Kris from Reckless Wrench Garage has been proving everyone wrong with his incredible “Stuburban” build - a project that’s turned a square body family hauler into a legitimate trail machine that can hang with the best of them.

This whole adventure started with an ‘88 Suburban that Kris decided needed some serious modifications. The first major move was swapping out the factory powerplant for an LQ4 6.0-liter LS engine, complete with all the Denali components. Getting that harness sorted and making everything look factory took some serious patience, but the end result speaks for itself. The cooling system came over intact, which saved him from dealing with steam vents and other headaches that usually come with engine swaps.

The real character of this build started showing when Kris made the bold decision to chop 27 inches out of the body. That’s right - he literally cut the thing in half and welded it back together, creating what he calls the “Burban on the Rocks.” The shortened wheelbase completely changed the truck’s personality on the trails, making it way more maneuverable in tight spots where the original long-wheelbase Suburban would’ve been scraping paint off rocks.

But cutting up the body was just the beginning. Those factory 10-bolt axles weren’t going to cut it for serious wheeling, so out they went in favor of proper one-ton Dana axles. The front Dana 60 and rear Dana 70 HD setup gave the Stuburban the beef it needed to handle bigger tires and more aggressive terrain without grenading components every other weekend.

The suspension setup is where things get really interesting. Kris ditched the factory leaf springs in favor of a four-link rear setup and radius arms up front, all hung on King coilovers. This completely transformed how the truck articulates on the rocks, giving it the kind of flex that makes other wheelers stop and stare. The Barnes 4WD components throughout the build ensure everything can handle the abuse that comes with serious rock crawling.

Speaking of abuse, those original 35-inch tires quickly proved inadequate after the first real trail run at the New Mexico Chile Challenge. The solution? Massive 41.5-inch Pit Bull Rocker radials that completely changed the truck’s capabilities. Of course, going that big meant dealing with clearance issues, especially where the rear tires were smacking the coilovers during articulation.

The tire clearance problem led to a hub swap that’s actually pretty clever. Kris swapped the Dana 70 dual rear wheel hubs for single rear wheel 14-bolt hubs, which pushed the wheels out about two inches per side. This not only solved the clearance issue but also matched the front track width almost perfectly, giving the truck a much more balanced stance.

That same trail run also taught some hard lessons about steering geometry. Having the tie rod mounted low on the factory steering arms was a recipe for bent components when things got gnarly. The solution was a complete high-steer conversion using PSC Motorsports hydro-assist components, but that meant redesigning pretty much the entire front suspension setup.

The steering upgrade turned into one of those projects where fixing one thing leads to changing everything else. Moving to high steer meant relocating the panhard bracket, which meant moving the coilover mounts, which meant moving the bump stops. Sometimes that’s just how fabrication projects go - you start with one goal and end up rebuilding half the truck. But the end result was worth it, giving the Stuburban steering that can actually handle the demands of serious rock crawling.

Safety became a major concern as the build progressed and the truck started seeing more aggressive terrain. When you’re treating a Suburban like a carnival ride on the rocks, a proper roll cage isn’t optional. The cage design is elegantly simple - a large U-shaped roof hoop, vertical tubes at the A, B, and C pillars, and integrated harness bars that don’t force passengers to eat their knees.

The fabrication work throughout this build showcases the kind of problem-solving that makes home-built rigs special. From the custom reservoir bracket for the PSC system to the frame repair plates that prevent the steering box from ripping off the frame, every modification serves a real purpose. This isn’t just bolt-on parts - it’s thoughtful engineering that addresses the specific challenges of turning a family hauler into a rock crawler.

What makes the Stuburban project so compelling isn’t just the technical aspects - it’s the approach. Kris documents everything, shares the mistakes along with the successes, and isn’t afraid to cut up perfectly good welds when something needs to be done better. That’s the kind of honest fabrication content that actually helps other builders learn from his experience.

The Reckless Wrench Garage approach to building is refreshingly practical. They’re not chasing magazine covers or trying to build the most expensive rig possible. Instead, they’re focused on creating a truck that can handle serious terrain while still being reliable enough for weekend adventures. The attention to details like proper heim joint spacers and safety washers shows they understand that good engineering matters when you’re hanging off a cliff somewhere.

You can follow along with future Stuburban adventures and other builds by checking out Reckless Wrench Garage on Instagram at instagram.com/recklesswrenchgarage/, their Facebook page at facebook.com/recklesswrenchgarage, or their website at www.recklesswrenchgarage.com.

The Stuburban proves that with enough creativity, fabrication skills, and willingness to cut things up, you can turn just about any vehicle into a capable trail rig. Sometimes the best builds come from thinking outside the box and not being afraid to make some sparks fly in the garage.