Harry Dawg's 2002 'Burb-a-Haul

Harry Dawg

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Howdy Y'all.

I finally had to turn a wrench on the old girl, so I guess it's time to start a proper build thread.

Took it down to Mustang Island in South TX a couple weeks ago. Hauled my dirt bike down and camped out on the beach for the weekend.

On the way down there, I developed a slight trickling leak from the transmission cooler line right at the radiator. It's been a nagging issue (already paid a "shop" to fix it, and we see how that went). They installed a new trans cooler line, but upon further review the coupler to the radiator is actually what was leaking.
The factory flared line goes into the coupler, but instead of being held in with a threaded fitting, a horseshoe shaped clip maintains pressure on the flare and the inner O-Ring.

I trust gas station sushi about as much as this design (+ the part was out of stock at Advance Auto Costs), so I went ahead and installed a barbed fitting on the radiator and connected it with a piece of 3/8" Fuel Line and some hose clamps.

Planning on purchasing a camper soon, at which point I will upgrade to a TruKool 40K Trans Cooler and AN lines. My trail fix is holding up fine for now though.

It was pretty uncomfortable sleeping in the back with the third row seat still installed, so I think this will be coming out soon. I hate to toss it because it's mint, but I don't have any where to store it (camper will be for full time living. Currently staying in an Air' B n B ) and it won't serve me any good.

Other upgrades I want to do -

1) Front Hitch - This way I can carry my dirt bike while hauling the camper, and this would also accomodate a winch cradle (It's a 2WD unfortunatley)
2) Full Length Roof-Rack
3) MAYBE - Stiffer rear springs and a spindle lift / leveling kit - Still not set on this, but I suspect one of the spindles is bent. My buddy and I were road tripping to Florida in this truck many moons ago, and he hit a semi-truck tire in the middle of the night. Blew the radiator hose, bent the wheel and ruined the front bumper and valence, but I suspect it knocked the spindle out of alignment as there is a rotational whomping noise ever since. Checked wheel bearings, wheels, tires etc and everything is solid. We've probably put 50K miles on it since then without an issue though, so who knows.

I also plan to build a interior camper system once the back seat comes out. I'll start with a basic wooden platform system that has slide out drawers, and then add some side shelving and additional storage on the side doors. Not going crazy with van life conversion, and mainly just need the storage space for camping gear, tools, MX equipment, fishing gear etc.

Definitley looking forward to some more organization, as i've been spending a lot of time in the rig and it gets messy pretty quick.

That's it for now. Will post some updates as more things get checked off the list.
 

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Harry Dawg

Member
Joined
Aug 13, 2025
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Location
Texas
Just rolled over 10K miles since I left GA for Texas.

I didn't realize trip odometer only went up to 10K, and I was sad to have it reset and loose all the miles I accumulated. Not sure why tracking miles traveled is a hobby of mine lol.

Anyways, I finally got around to tricking out the Burb'a'haul to make it more overland worthy.

I've been bouncing around from place to place since I got out here, and have found myself needing a place to crash several times. So, I built a "mobile man camp" as I have coined it.

Scored a used roof rack on FB Marketplace for $100. It's not the full length 90" one I had my eye on (closer to 84", but for 1/3 price I figured I'd compromise) I blacked out the Mockins logos with some flat black paint.

Also finished building out the drawer system and sleeping platform. Now all my clothes, MX gear, kitchen and food supplies and fishing gear can be neatly arranged.

Still on the list is to get a waterproof plano box for the roof rack to store fluids and tools (currently in a over stuffed tote behind the driver seat)

Also want to get a 270 bat wing awning with the attachable walls, just so I have more room in bad weather conditions and don't have to be inside the truck.

Lastly, solar panels and auxiliary battery.

Still have some of the mechanical / utility upgrades to do as well. These tires are getting pretty thin, so in the next 6 months or so I plan to do front end service and get some new wheels and tires.

It definitely rides low in the back / wants to bounce around over bumps with the added weight from the camper box + the bike on the hitch rack, so stiffer springs and front hitch are a must have.
 

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Harry Dawg

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Location
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Just completed a 1,000 mile overlanding trip from Austin TX to Broken Bow, OK and then the Arkansas Side of the Ouachita National Forest.

The Burb-A-Haul ran flawlessly, and even performed better than expected on some trails we most certainly should not have been on lol... At least for a 2WD.

Me and my girlfriend camped out of the back the whole week, and saw some incredible scenery.

Something about touring this great nation in an old Chevy just feels right.... Classic Americana.

Anyways, here are some pics of the burb and some of the stuff we saw. I had a bunch of pics of wildlife, but that's not really the focus of this forum lol.

Haven't really been wrenching on it, as I have some what adopted the K.I.S.S mentality with this one... Definitley need some new sway bar links and I think a passenger shock. The washboard gravel roads kind of beat the front end up and we left AR with some new sounds and rattles lol.

Just over 296K miles on the old girl.
 

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