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Old 07-29-2016, 08:03 AM
markfuga markfuga is offline
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Default 1978 F250 build

I started this project a year ago and knew the progress would be slow so I waited to start a thread on it. Hopefully things move a little quicker now but I’m OCD when it comes to the details so it still could take a while. The project is a combination of a 1978 F250 body on a 1996 F250 frame which rides on a 2005 F350 suspension. This build is going to be a daily driver so I shouldn’t be going as far as I am with the cleanup of everything but I have a hard time with taking short cuts. I’m close to “substantial completion” at this point so I figured now is a good time to start a thread.

The engine received mild upgrades: Full Force stage 1 injectors, Adrenaline HPOP and a Beans D66 turbo. I also did the most important preventive maintenance items such as: re-seal the oil cooler, replace the oil rail plugs, new motor mounts, silicone intake boots, IPR pigtail, dual pulley tensioner, Melling M208 LPOP, new harmonic balancer, new water pump and probably a few other things I’m forgetting.

The transmission is a recent Jasper rebuilt E4OD so I’m going to run it “as is” to see how it performs.

The suspension both front and rear got every replaceable part replaced: 6 radius arm bushings, 4 ball joints, track arm ball joint and bushing, all tie rod ends, steering stabilizer shock, new front hub bearing assemblies, new Red Head steering box, all new seals, new rear bearings, new Detroit locker, new Hellwig sway bars, new rotors and calipers, new springs and shocks all around and many more trivial parts not worth mentioning.

The Exhaust was kept simple: 3 inch down pipe into a Walker 21470 muffler and out the stock tail pipe

Here’s the picture collection from the past year. I have many more pictures that show the “gory” details of things but just staying with the highlights for starters.
Attached Images
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File Type: jpg pic4.jpg (1.68 MB, 164 views)
File Type: jpg pic5.jpg (1.59 MB, 183 views)
  #2  
Old 07-29-2016, 08:07 AM
markfuga markfuga is offline
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5 more pictues
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File Type: jpg pic6.jpg (1.45 MB, 129 views)
File Type: jpg pic7.jpg (1.29 MB, 127 views)
File Type: jpg pic8.jpg (1.11 MB, 107 views)
File Type: jpg pic9.jpg (915.6 KB, 110 views)
File Type: jpg pic10.jpg (666.7 KB, 113 views)
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Old 07-29-2016, 08:11 AM
markfuga markfuga is offline
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Another 5
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File Type: jpg pic11.jpg (1.42 MB, 142 views)
File Type: jpg pic12.jpg (1.36 MB, 160 views)
File Type: jpg pic13.jpg (1.07 MB, 155 views)
File Type: jpg pic14.jpg (1.20 MB, 145 views)
File Type: jpg pic15.jpg (763.9 KB, 187 views)
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Old 07-29-2016, 08:20 AM
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Interested to see how the sway bar works out with that mount. I wanted do mine that way but looks like there's going to be issues with the lower radiator hose.

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Old 07-29-2016, 07:33 PM
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I may have a swap like this in my future as well. Is there tons of room in the engine bay on that thing or is it an optical illusion? I wish my 78 250 had that good of a body!!
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Old 07-30-2016, 12:47 PM
markfuga markfuga is offline
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The sway bar mounts are the originals from the 05 donor; I cut them off and welded them to the 96 frame. They absolutely will not work with the 96 radiator support in that position. The 96 support sits in that area and will not fit with the sway bar mounts I welded there. I'll be modifying the 78 radiator support with parts from the 96 support so I can easily compensate where needed.

Going into the weeds a little: I made a transfer jig on the 05 frame before removing anything. Then I used that jig on the 96 frame to locate the spring perches, sway bar mounts, traction bar mount and the steering stabilizer mount. This is how I located the sway bar mounts where I have them.

The engine is a tight fit against the firewall. I'l be doing sheet metal work for the down pipe, turbo and back of the drivers side cylinder head. Plenty of room on the left/right with the original inner fenders and lots of room up front for the radiator.
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File Type: jpg IMG_0955.jpg (902.2 KB, 122 views)
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Old 07-31-2016, 10:38 AM
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Lookin good. Sub'd.
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Old 07-31-2016, 12:23 PM
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What did you use to clean and paint the frame. Working on mounting the 05 suspension on my Ex now and that will be the next step.

It looks really good how you did it.
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Old 07-31-2016, 01:07 PM
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This should be another great build. Like the 58 chevy.

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Old 08-04-2016, 09:03 AM
markfuga markfuga is offline
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The frame was cleaned with acetone to remove oil and what was left of the original under-coating. I used a variety of wire brushes on the angle grinder and sanding wheels get it ready for paint. I went the simple route of Rustoleum primer and semi-gloss black paint.

The 78 body is in immaculate shape which is the primary reason I decided to do this project. I came across the body as a "roller" without engine or transmission which made it ideal for this swap. I bought it from the grandson of the original owner, after the grandson had drag raced it for a couple seasons and got board with it. Aside from the visible surface rust in a couple places, there is no rust anywhere under the truck or hidden behind fenders, bedsides, cab corners, etc.

Here's a couple more pictures of where it's at today. I upgraded the rear tank to the 38 gallon so I could eliminate the front tank to make space for the electric pump and filters. I started the engine a couple days ago to check for any leaks or issues and found a small oil leak at the dipstick. Frustrating because I put a new oil pan on the engine and replaced the O-ring. I have a feeling the O-ring was not correct because it didn't seem like it had enough "compression" when I installed it. Now I know it didn't compress enough
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File Type: jpg pic17.jpg (751.6 KB, 130 views)
File Type: jpg pic18.jpg (818.9 KB, 148 views)
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