2006 Chevy Silverado - Custom Lowered Truck

Our Fantastic Four series has been showcasing many manufacturers and products for your trucks. We've seen quite a few of the truck models that readers have been asking about, and this month we'll be looking into taking some daylight out from underneath an '06 Chevy Silverado Crew Cab two-wheel drive. We talked to Sport Truck Direct in Phoenix and ordered a Western Chassis 4/6-drop with Air Lift Slam Air Load helper 'bags. Continental laid a set of 265/35R22 ContiCrossContact UHP tires on us and we stuffed some 22x9-1/2-inch American Racing Cryptic Black wheels into them. Feeding our addiction for more power, we sought Volant's fully enclosed cold-air intake and one of its polished stainless after-cat exhaust systems. Being the only truck magazine that matters didn't make us superstars; as during this build we had a shop begging for some exposure but didn't return any of our calls. With no time left to get this truck finished, we fell back on the professionals at HTS Innovative Design in Simi Valley, California. HTS received a phone call on Friday evening and had our truck on the rack first thing Saturday morning. Now that's what we call super customer service

Our Fantastic Four Chevy was sporting a billet grille and some window tint, but that was only the starting point. After many hours, we had made the Silverado something worth taking a look at.
Our Fantastic Four Chevy was sporting a billet grille and some window tint, but that was o
Volant's air intake for this application is a fully enclosed box that takes air in through both the factory fender opening and from underneath, between the core support and the inner fender. With this set up, there is not any under-hood heat that can travel to the intake openings. And since it is fully enclosed, the intake charge is somewhat quieter upon its entrance versus that of an open filter.
Volant's air intake for this application is a fully enclosed box that takes air in through
HTS began the installation by removing the entire factory air intake, including the support tray, as directed by the instructions. Notice that this truck has the factory electric cooling fans. The added space behind the core support is apparent, also.
HTS began the installation by removing the entire factory air intake, including the suppor

After removing the MAF sensor from the stock intake, we placed the included Volant gasket between the MAF and airbox and then slipped the sensor into position.
After removing the MAF sensor from the stock intake, we placed the included Volant gasket
Inside of the airbox, the included filter mount was fitted with a gasket and slid home. Three included bolts went through the MAF and into the filter mount, sandwiching the whole assembly together and sealing everything from any external air leaks.
Inside of the airbox, the included filter mount was fitted with a gasket and slid home. Th
Four bolts secured the box into position where the stock tray was removed. As you can see, we slipped the filter onto its mount inside of the box and cinched its clamp down tight. Our man in the know, Doug Dobson, pressed the silicone coupler over the MAF's outlet to prepare for the final couple of steps.
Four bolts secured the box into position where the stock tray was removed. As you can see,

Once the protective film was removed from the Volant intake lid, it was placed into position and then cinched down.
Once the protective film was removed from the Volant intake lid, it was placed into positi
Finishing the intake's installation, the inlet air tube was slipped into the Volant silicone MAF coupler and the factory rubber throttle body coupler. Then, all of the clamps were tightened and we closed the hood on Part One of the installation
Finishing the intake's installation, the inlet air tube was slipped into the Volant silico
Many people don't even know that Volant makes exhaust components, and sure enough, the company had one for our application. Once safely on a lift and in the air, HTS jerked the stock pieces apart and unceremoniously tossed them aside. Out of the packaging, the polished stainless head pipe was fit to the stock Y-pipe connection and we encountered our first glitch.
Many people don't even know that Volant makes exhaust components, and sure enough, the com

Either the wrong part was in the packaging or there was a problem on the jig, but our pipe did not clear the factory crossmember. As you can see from the image, it wasn't just close-it was flat out on the crossmember. Thankfully, we were in the capable hands of HTS Innovative Design and Owner Doug Dobson grabbed a pipe from a competing manufacturer's kit to save the day.
Either the wrong part was in the packaging or there was a problem on the jig, but our pipe
Moving forward, the tail pipe was fed upward and over the axle, and then mated properly to the Volant stainless muffler. We breathed a sigh of relief when we knew our Silverado was inhaling and exhaling properly.
Moving forward, the tail pipe was fed upward and over the axle, and then mated properly to
The only outward clue that we had done any modifications was this shiny, stainless double-wall exhaust tip laser etched with the Volant logo. Between the air intake and the exhaust, we had added ponies and surprisingly little noise, which makes these parts perfect for someone who desires performance without drawing attention to themselves as they roll by.
The only outward clue that we had done any modifications was this shiny, stainless double-

It was time to get our Chevrolet down on its Western Chassis and Slam Air suspension we had procured from Sport Truck Direct. The kit came with 2-inch drop coils, 2-inch drop control arms, a 6-inch flip kit with C-notch and U-bolts, shocks, bumpstops, load support 'bags and mounts, and an in-cab controllable compressor kit.
It was time to get our Chevrolet down on its Western Chassis and Slam Air suspension we ha
Doug didn't waste any time in tearing down the truck and attacked the rusty stock U-bolts with a 1/2-inch air impact gun.
Doug didn't waste any time in tearing down the truck and attacked the rusty stock U-bolts
With assistance from Doug's brother, Scott Dobson, we had the rear axle safely supported on jack stands while the duo whipped the rear leafsprings off of the truck from above the axle and then placed them back into position underneath the rear axle. And so, the rear end was now flipped.
With assistance from Doug's brother, Scott Dobson, we had the rear axle safely supported o

These saddles from Western Chassis are the key to holding everything in its place. The saddles cup the axle in place above the leafsprings and the tops of the saddles are designed to sit underneath the spring perch, as shown here, when being settled into place.
These saddles from Western Chassis are the key to holding everything in its place. The sad
With a helping hand from Scott, Doug zipped the new U-bolts down with the new spring plate sandwiched between the nuts and leafsprings.
With a helping hand from Scott, Doug zipped the new U-bolts down with the new spring plate
In this particular instance, flipping the axle required a notch to clear the rear axle's suspension movement. After careful measuring, marking, and then remeasuring again, the Miller plasma cutter was entrusted to slice through the frame in the "C" pattern the not ch is named for.
In this particular instance, flipping the axle required a notch to clear the rear axle's s

Twelve 1/2-inch bolts, per side, hold the notch in place and required plenty of time to drill. Our time schedule reached a standstill when a couple of drill bits were sacrificed to the altar of steel, while creating all of the necessary mounting holes. Although the notch could have been welded on, the owner wanted the option of possibly removing the notch in the future, should he decide to either airbag or lift his truck.
Twelve 1/2-inch bolts, per side, hold the notch in place and required plenty of time to dr
We've shown you this view plenty of times and the break down is pretty simple. After breaking the ball joints apart and popping the steering loose, HTS removed the brake caliper, spindle, and stock coil spring.
We've shown you this view plenty of times and the break down is pretty simple. After break
Making room for the Western Chassis parts, Doug and Scott pulled the stock lower control arm free and set aside the hardware to be reused later.
Making room for the Western Chassis parts, Doug and Scott pulled the stock lower control a

Side by side, it's easy to see the difference between the new control arm and the factory unit. The new control arm lowers the coil mount deeper into the arm, which resulted in a 2-inch suspension drop. Quality features such as heavy-duty ball joints and urethane bushings are why Western Chassis offers a 7-year warranty on its arms.
Side by side, it's easy to see the difference between the new control arm and the factory
By using the previously set aside hardware, the new A-arm was laid up in its new home.
With a hydraulic jack underneath the control arm, the Western 2-inch drop coil went in and the spindle was put back into its place between the two arms. The brake caliper was also placed back where it belonged at this point.
With a hydraulic jack underneath the control arm, the Western 2-inch drop coil went in and

Western supplied new nitrogen-charged shocks and shorter sway bar end links. Here the link assembly was being put in place in the proper hardware order ensuring that only the fresh urethane bushings touch metal.
Western supplied new nitrogen-charged shocks and shorter sway bar end links. Here the link
Once the steering was back on the spindle and all of the hardware had received the "once over," we were ready to move on.
Once the steering was back on the spindle and all of the hardware had received the "once o
A 4/6 suspension drop is a pretty decent descent on these trucks. To keep everything safely tucked underneath the truck, Western's kit included a raised transmission crossmember. Doug popped the retaining bolts loose and supported the transmission output shaft so the crossmember could be completely removed
A 4/6 suspension drop is a pretty decent descent on these trucks. To keep everything safel

A visual comparison shows the bolt holes and height to be identical, but the new piece does not have as much under hang below the bolt holes to possibly contact the ground.
A visual comparison shows the bolt holes and height to be identical, but the new piece doe
Next, the new unit went into place with the stock hardware. If you look closely, you can see how much material now sits below the cross member. This material needed to be cut away, and then plate steel was welded in its place to sturdy the mount and prevent flex. With this modification, the exhaust cross-over pipe became the lowest point of the truck, but a competent shop like HTS can make the necessary changes to tuck it safely away, too.
Next, the new unit went into place with the stock hardware. If you look closely, you can s

2006 Chevy Silverado American Racing Cryptic Black Wheels

Our American Racing Cryptic black wheels and Continental ContiCrossContact tires were the last parts to go onto the truck, and they made the whole thing look complete. With the low-slung stance and minimal sidewall over the black-face wheels, this once mild-mannered Chevy has taken on a whole new look that definitely says custom and cruisin'.

Our American Racing Cryptic black wheels and Continental ContiCrossContact tires were the

From The Driver SeatProblems, stutter steps, and general trip-ups seemed to pop up too often with this assembly. If you noticed, we made absolutely no mention of the Slam Air Load carrying kit. Although advertised by Sport Truck Direct as a bolt-on with the Western Chassis kit, it is in fact only a bolt-on for the Belltech C-notch setup. The hardware holes aren't even close to aligning correctly with the Western Chassis C-notch-and for that reason-the Air Lift Slam Air kit is still in the box. This Chevy tows a boat during the summer and a motorcycle trailer during the cooler months, so this modification is mandatory and we will put it on; although the mounts will have to be entirely customized from scratch. We love the transmission crossmember, but no mention of the part was referenced in the directions or the fact that we had to cut and weld steel into place to make the framerails truly flat. Western Chassis' flip kit worked just fine, but our Crew Cab's driveshaft hits one of the frame crossmembers on the upstroke long before the axle contacted the bumpstops. By our own fault, we had to extensively cut the front inner fenders to allow suspension clearance for our chosen tires, as well as cut and flare the rear bed sides so they did not drag on the tire sidewalls. Now, the truck can be driven, but the tires bottom out against the front inner fenders before the lower A-arm contacts the bumpstops. Slow and low is how this Chevy rolls. Western Chassis offers a 3/5 drop kit that would have been better suited for our wheel and tire size. Volant's equipment went on flawlessly and added power without noise; and that is new for us. So, we must be getting old because we like it like that. The Continental tires worked out perfect in this build, as the tires were actually designed for a truck and not a car. Load ratings are way above normal for a tire this size and not that our truck could get there, but the tires are Y-rated for sustained speeds as much as 186 mph. Yeehaw!

2006 Chevy Silverado Left Front View Done

YOUR QUESTIONS ANSWERED

Time Spent Working:	Approximately 12 hours
(due to plenty of cutting of sheetmetal to clear the tires)
Degree of Difficulty:	Advanced
(frame cutting, drilling, and welding)

PARTS USED:

* Western Chassis 4/6 Drop Kit	$669.95
* Doetsch Tech shocks	$44.95 each (four needed)
* Air Lift 25592 Load Controller	$149.95
* Air Lift Slam Air Load Booster	$273.00
* Continental ContiCrossContact UHP 265/35R22 Tires	$274.99 (four needed)
* American Racing Cryptic Black 22x9-1/2 Wheels	$349.99 (four needed)
* Volant 15053 Air Intake	$466.99
* Volant 15053750 Exhaust	$628.95
* Mounting and balancing tires with lug nuts	$50.00

Total Costs:	$4,968.56
(Not including tax or installation labor.)

SOURCE
American Racing 1275 Davis Rd., Suite 300 Elgin IL 60123 8-00/-321-5489 3-10/-635-7806 www.americanracing.com	Sport Truck Direct www.sporttruckdirect.com
Continental Tire www.continentaltire.com	Volant Performance
HTS Innovative Design 1825 Surveyor Ave Simi Valley CA 93063