2008 Chevy Tahoe Buildup - Bulletproof 8-Inch Lift Kit

Before

New for 2011, this '08 Chevy Tahoe is one of the latest project trucks that we'll build right here in our tech stories. Making it big and mean was a must, but we also didn't want to lose any of its everyday usability. Careful planning was made to create a monster Tahoe that is deserving of a double take. Bulletproof Suspension is known for making lift kits that are almost, well, bulletproof. So, when we wanted to lift this '08 Chevy Tahoe, the Bulletproof 8-inch was an easy decision. And who in the Houston area can install such a detailed lift kit? Ekstensive Metalworks, of course. They are notorious for making trucks lay on the Texas tarmac, but they can, and will, do just about anything to cars and trucks, so making a truck go up and not down was an easy feat.

After

This Bulletproof lift adds 8 inches of height to the stock suspension. The basic lift doesn't include shocks, but we decided to go with the upgraded Fox coilovers that are a bit pricey, but offer a much better ride. With plenty of space between the lifted body and the ground, we bolted on a set of Nitto's new 35-inch Trail Grappler mud-terrain tires mounted on 20x9-inch BMF Novakane wheels. Nitto's new Trail Grappler is a hybrid off-road tire that combines the quiet and comfortable traits associated with the Terra Grappler all-terrain tire and the incredible traction and toughness of the Mud Grappler mud-terrain tire. The look of the Nitto tires and BMF wheels is uncompromising and sure to make the Tahoe look like it's ready to crush cars at a monster truck show. There are several reasons you may want to lift your vehicle, including tough looks, added off-road capability, and the ability to bolt on bigger wheels and tires, but no matter what the reason, a lift is a great way to make your truck or SUV that much better.

Highs
Better than factory ride with the upgraded Fox coilovers - Added capabilities - Aggressive looks
Lows
It's not easy to install - Fox upgrade is expensive

Arriving at Ekstensive Metalworks, in Houston, we brought the Tahoe in completely stock form. Known for airbagging trucks, we flipped the script on them and had them lift the Chevy. Here, you can see the stock Tahoe ride height in the front was 351/2 inches and the rear measured out to be 37 inches. This will give us a true measurement once the lift and new wheels/tires are installed.
Arriving at Ekstensive Metalworks, in Houston, we brought the Tahoe in completely stock fo
After Derrick removed the wheels and tires, sway bar, and outer tie-rod, three nuts from the upper strut mount and two lower strut bolts, he then removed the strut assembly in one piece.
After Derrick removed the wheels and tires, sway bar, and outer tie-rod, three nuts from t
With the help of a cordless impact gun and mallet, Derrick removed the upper and lower ball joints from the spindle, then the spindle and rotor assembly was pulled off in one piece.
With the help of a cordless impact gun and mallet, Derrick removed the upper and lower bal

Again, Derrick used the cordless impact gun to remove the upper and lower control-arm bolts and then he detached the control arms.
Again, Derrick used the cordless impact gun to remove the upper and lower control-arm bolt
Next, the 15mm bolts that held the CV axle in place were removed and the CV axle was removed from the front differential.
Next, the 15mm bolts that held the CV axle in place were removed and the CV axle was remov
With the axles and front driveshaft removed, Derrick recruited Bill and Rudy to help him remove the front differential.
With the axles and front driveshaft removed, Derrick recruited Bill and Rudy to help him r

One of the last parts of the disassembly was to disconnect the high-pressure hose from the steering system and remove the whole rack-and-pinion assembly.
One of the last parts of the disassembly was to disconnect the high-pressure hose from the
The next step was to remove the factory steering coupler that will later be replaced by a Heim joint that Bulletproof included in the lift kit.
The next step was to remove the factory steering coupler that will later be replaced by a
GM truck frames come with a rugged undercoating to protect them from environmental factors. The guys at Ekstensive melted off the undercoating to aid in the installation process and clean up the overall appearance.
GM truck frames come with a rugged undercoating to protect them from environmental factors

After melting away the undercoat, the frame was much cleaner and easier to work on. This step is what sets Ekstensive apart from other shops who rush through an install.
After melting away the undercoat, the frame was much cleaner and easier to work on. This
In order to install the new relocated upper control-arm cage, the factory control-arm stop had to be cut off.
In order to install the new relocated upper control-arm cage, the factory control-arm stop
Once Rudy removed the upper control-arm stop, he smoothed the jagged edges in preparation for the new control-arm mount.
Once Rudy removed the upper control-arm stop, he smoothed the jagged edges in preparation

Bill then used a hole saw to cut a large hole in the front crossmember.
Because of the new drop-down differential cage a corner of the front differential...
...needed to be trimmed with a cutoff wheel.

The 8-inch Bulletproof lift kit included the front differential drop-down cradle, upper control-arm relocators, and for this application we are installing the upgraded adjustable Fox coilover in the front. Out back, a coil-spring spacer is used, along with longer sway-bar endlinks, and Panhard-bar relocator brackets.
The 8-inch Bulletproof lift kit included the front differential drop-down cradle, upper co
To lower the differential crossmember, a drop-down bracket had to be installed using 7/8-inch bolts.
To lower the differential crossmember, a drop-down bracket had to be installed using 7/8-i
After a test fit of the front differential was performed, the factory crossmember bracket needed to be trimmed.
After a test fit of the front differential was performed, the factory crossmember bracket