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Old 02-08-2016, 02:36 PM
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Default 1978 Crew Cab F250 4X4, 7.3 POWERSTROKE Conversion

Hope I am posting in the right spot. If not, please be sure to let me know.

Noob here (to the PS Army website anyway) and I would like to tell you a story. Some of you may have heard this story on one or two other sites. For those that have not, here it goes:


8-10 years ago, my beloved Black Cadillac STS was totaled, at my work, while I was not driving, in a parking spot minding its own business. Still pisses me off to this day when I think about it.

The good news is, after arm wrestling with the driver at faults insurance agency for a month and a half about totaling the Cadillac versus repairing, common sense soon took place and I was left with a large check via the insurance company versus a repaired and questionably repaired Cadillac.

So I got to go shopping. What do I replace my beloved car with? I looked at BMW's, Cadillac's, and other cars I really didn't like. I wanted something different, something reliable, and something that if got hit by another teenager skipping class to get high, maybe wouldn't break as easily as the Cadillac did.

A quick look in the Michigan Auto and RV revealed to me my next "Cadillac", a Cowboy Cadillac to be exact. A 1978 F250 Crew Cab. A guy in the Door, MI area had a son who was a moto cross up start, and they had just bought a new bike for him, then lost a sponsor, so they were stuck with the bike bill.

So I bought their beloved hauler, complete with a 460CID, auto trans, 39.5 inch super swampers, and sexy faded red paint.

Within a few months, I blew the motor (no fault of my own). We rebuilt the 460 to the tune of 485hp, with 535 foot pounds of torque. The thing was kick ass, and I was thankful it had two gas tanks.

So fast forward a few years, my career is taking off and along comes the promotion. The promotion came with a hitch, I had to move. Whats a boy to do? I did what most dudes would do; I took the job, ditched the girl, and moved to NYC to begin the next leg of my career.

One hitch, they wont ship my truck. They shipped everything else, but they wouldn't ship the truck. After all considerations, the best thing to do is sell it. And sell it I did.

Worst mistake ever. I have owned many, many vehicles, but this one was the only one that I ever regretted selling. Thusly, my desire for the this truck, this style, has earned it the moniker "Eleanor".
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Old 02-08-2016, 02:43 PM
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Default OE= Original Eleanor

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Old 02-08-2016, 02:45 PM
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Default OE

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Old 02-08-2016, 02:49 PM
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Default The Journey

Life has come full circle. I left NYC, I moved back to Michigan, and began my life again.
My love for big vehicles, trails, and copious amounts of mud left me with a small yearning for fun.

So I bought a suburban


then I bought a Jeep


then I bought a Full Size Bronco.





Still not the same.

"Eleanor" kept calling. So became my maniacal search to replace the red beast.

I knew what I wanted:

* crew cab
* 1978- 1979
* auto
* 4wd
* as rust free as possible
* short box
* a project, not a finished good, cause I had a "vision"
* low price. I know they are rare, but I am not paying top dollar for a POS.

After about six months of searching, I found one. The perfect one in my opinion. Only one problem: It was in Washington (the State).

Eleanor; part 2. This was how I got her, minus the bigger tires( he was nice and gave me some rollers)



The seller thought I was insane. My girlfriend (ex now) thought so too. As did my son. After convincing the seller I was not insane, nor a craigslist killer, and that I could be there in a few days, he finally agreed to hold it for me.

So my oldest son and I loaded up the trailer (i wasn't sure if the crew cab would fit on my tow truck/hauler; ((more on that later))) and hitched up my truck to take a long Sunday drive.



My son and I slept and drove in 4 hour shifts. All the way from Zeeland, MI to Forks, WA. Looked over the potential "Eleanor", called it good, paid the guy $1000 for the drive-train-less truck, and continued to drive back cross country to Zeeland, MI. We did it in 3 1/2 days!

Random things I learned on the trip:
* Forks, WA is where the Twilight Series Books are based.
* Forks, WA does not have vampires that "sparkle" in the light, but they do have Meth Heads that glow in the dark.
* If you sit for extended periods of time like this, your feet swell. Not like stubbed my feet swell, think more like Lord of The Rings Hobbit's feet swollen.
* When on road trips this long, always choose the food you eat carefully. And ALWAYS check for toilet paper before sitting down...
* More importantly, choose your bathroom breaks wisely as well.
* Take lots of pictures
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Last edited by 1killerz; 02-08-2016 at 03:00 PM.
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Old 02-08-2016, 03:02 PM
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Looks like you got a good basis for a swap. A co worker of mine has a 70s Ford with an 02 7.3 swap. Said it knocks down over 20 mpgs on the highway. Good choice. Plans to keep the 7.3 mildly stock or turned up a little?
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1948 GMC Detroit 453T
1951 Mack A51T
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Last edited by superpsd; 02-08-2016 at 03:04 PM.
  #6  
Old 02-08-2016, 03:26 PM
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Quote:
Originally Posted by superpsd View Post
Looks like you got a good basis for a swap. A co worker of mine has a 70s Ford with an 02 7.3 swap. Said it knocks down over 20 mpgs on the highway. Good choice. Plans to keep the 7.3 mildly stock or turned up a little?
Initial plans are to keep it stock (the drive train)to work out any bugs, hiccups, or small surprises .

Once I have logged some miles on it, then it will be time turn it up a notch, or three.
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Old 02-08-2016, 03:40 PM
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Looking forward to watching this. Are you just going for something functional or something that looks factory?? Either way will be one of a kind. Keep us posted.
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Old 02-08-2016, 06:42 PM
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Hands down my favorite truck ever built. Good find, looking forward to see the progress
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97 cclb f350 zf5, Southbend DD, 468, 250/80's, studs, springs, pushrods, e-fuel, adrenaline, traction bars

95 rclb back to stock motor, sky rsk, sd axles, 20's and 35's
  #9  
Old 02-08-2016, 10:50 PM
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ill be watching this, I use to have a 67 highboy with a 96 PSD swap. I miss that thing. I plan to build a 4 door 67-72 some day with a 7.3
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1997 Crew Cab. 250/100s, full 5", 7" lift SAS and zf5 swap.

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  #10  
Old 02-09-2016, 12:48 AM
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subd
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  #11  
Old 02-09-2016, 01:59 AM
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I'm diggin' it! sub'd. What axles are currently in it, and will be in when completed?
  #12  
Old 02-09-2016, 07:42 AM
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Quote:
Originally Posted by gwunter View Post
Looking forward to watching this. Are you just going for something functional or something that looks factory?? Either way will be one of a kind. Keep us posted.
You know, I never really thought about that. Not sure yet in that regards. I am trying to keep the classic lines and overall vibe, but I want the conveniences, comforts, and gadgets that come with newer truck offerings.
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Old 02-09-2016, 07:44 AM
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I'm diggin' it! sub'd. What axles are currently in it, and will be in when completed?
When I bought it, they had swapped a sterling 10.25 for the rear. Still retains the dana 44 in the front.

Keeping the sterling for sure. Bought and had a correct Dana 60 rebuilt for the front, as too many have warned me the D44 wouldn't last long with that 7.3 calling the shots.
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Old 02-09-2016, 07:46 AM
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Default Plans...

My plans for "Eleanor" are somewhat simple- ish.

* diesel motor
* off road capable
* DD capable
* comfortable for my little guy on long road trips
* father-son bonding experience

Essentially the intent is to keep the classic lines, yet running as modern a diesel drive-train as possible.

Based on what I have found online, the following will take place:

* the frame will be boxed/reinforced
* the cab will stay on until I can find the drive-train I want, then we will need to mock up motor mounts
* need a complete donor truck for electronics and anything else I cant think of

What I got with the Crew Cab:

* no motor, no trans, no transfer case
* solid interior, headliner as well
* an education on "Krummy's" (apparently the west coasters referenced these trucks as Krummy)
* 4 inch body lift (which made the PS 7.3 install that much easier)
* 4 inch suspension lift
* 10.25 sterling axle rear
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Old 02-09-2016, 07:49 AM
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Default wish list

stupid stuff. may or may not make the final cut:

turbo gauge (they didn't come with one in '78)
Trans Temp Gauge
upgraded air intake
chipped (thinking BullyDog 3 positions)
6.0 intercooler (all the diesel sites have stated and proved this intercooler is much larger and better for the 7.3)
injector improvement
electronic fans
air locker front and rear (already running 4.10's, with a sterling axle in the rear)
disc brakes (upgraded as much as possible)
power windows
power rear slider window
2% limo tint
I was told Dakota Digital makes dash set ups for this year truck, may just do that too
TVs in headrest (for my little guy) ala King Ranch Interior
PS3 (plays DVD and Blue Ray, plus, I got the PS4 in the house, so what else would I do with my PS3)
auxiliary power set up
fridge in truck? (lol, my little guy suggested this because of our long road trips. we shall see)


Thinking of running 37" tires (truck has an 8" lift already)
hideaway/swing away (electronic) step ups to enter cab (don't they make these that double as underbody armor against rocks?
light bar off of the bronco (not sure yet on this one)
HID lights
Cowl Hood (thank you LMC)
Grab bars on the exterior (maybe, its a style choice and not sure I like it or not)
third brake light under tailgate (the long LED strips)
On board air set up
drive shaft loops
keeping manual hubs
bed tool box with extra tank built in
custom gas tanks to be
a. diesel compatible
b. largest capacity possible
Custom soft bed cover or just bedliner it (up in the air on this currently)
Large recovery winch bumper off of my bronco
color
a. matte black
b. body color black
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Old 02-09-2016, 08:00 AM
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don't do bully dog, don't do grab handles on the side, AMP research is what you want to look at for steps.
  #17  
Old 02-09-2016, 08:03 AM
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Default Cleaning off pieces of Washington...

So, like I said previously, the PO of Eleanor used her for mud running, trail riding, and drinking beer.

Master Chief Willard and I decided we need to hose her off and assess what we were working with...

And with that, I also wanted to see if Eleanor would have or have not fit on my car hauler.

It fit!



Master Chief knocking out the mud...



snow studded sexiness...



They painted some of the suspension "barney" purple. Wow, just wow.



Frame is pretty clean overall.



two things in this picture... one, the truck appears to have been white with red trim (santa's sleigh?). Secondly...is that a license plat up by the shock tower?



Its got some dents, but no cancer on this beast...

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Old 02-09-2016, 08:05 AM
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Quote:
Originally Posted by sootie View Post
don't do bully dog, don't do grab handles on the side, AMP research is what you want to look at for steps.
No bully dog. No problem. Recommendations?

Yea, agreed. Besides, later in the build I think I found something better than grab handles/

AMP Research. Awesome. That is much appreciated.
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Old 02-09-2016, 08:07 AM
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Default AMP research

for future reference...

http://www.runningboardwarehouse.com...FYg-aQodwtkAzg
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Old 02-09-2016, 08:07 AM
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No bully dog. No problem. Recommendations?

Yea, agreed. Besides, later in the build I think I found something better than grab handles/

AMP Research. Awesome. That is much appreciated.
TS six position or PHP's hydra.
  #21  
Old 02-09-2016, 08:32 AM
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Default Tear Down begins...

I don't have a "shop".
I don't even have a Pole Barn.
Hell, I don't even have a regular barn.

I got a three stall garage.

One of which is a make shift bar complete with pool table.

The other two stalls are crammed with my other love; classic cars.



So fortunately, I have understanding neighbors (most anyway) who respect my shade tree mechanic ways...



Master Chief cursing at hockey pucks...



And more cursing...



Remember the license plate? They were using it as a heat shield of some sort. Ingenuity= best fueled by alcohol and weed...



Santa's secret Sleigh revealed... to have some pretty dame nice cab corners (in Michigan, this here is what you call an anomaly).



Short box is not horrible either...



For the record, this bed was full of pine needles, beer cans, and other...stuff.

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Old 02-09-2016, 08:35 AM
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Quote:
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TS six position or PHP's hydra.
Excellent. Thank you very much. I will keep that in mind when the time comes.
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Old 02-09-2016, 09:36 AM
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please, please, please do yourself, and everybody else who is interested in this build a favor, and avoid the body lift. There is enough room to fit the motor with a little firewall modification. You will be much more pleased with the end result. I can get you pics of completed similar projects for reference if needed. Not only that, but think of the '94+ trucks with the 7.3. Nearly same space. Also, you might consider putting a whole newer dash inside the truck to simplify the electronics; don't. It kills the nostalgic feel of the interior. You'll probably find it best to start with the most basic base model donor to keep the wiring as simple as possible. Think manual shift t-case, manual windows & locks.
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Old 02-09-2016, 10:25 AM
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Quote:
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please, please, please do yourself, and everybody else who is interested in this build a favor, and avoid the body lift. There is enough room to fit the motor with a little firewall modification. You will be much more pleased with the end result. I can get you pics of completed similar projects for reference if needed. Not only that, but think of the '94+ trucks with the 7.3. Nearly same space. Also, you might consider putting a whole newer dash inside the truck to simplify the electronics; don't. It kills the nostalgic feel of the interior. You'll probably find it best to start with the most basic base model donor to keep the wiring as simple as possible. Think manual shift t-case, manual windows & locks.
The body lift was there when I bought it. The drive line is installed, and its based on the lift. Once I have everything situated, I will be looking at eliminating the body lift.

Please do share the other pics for reference, as this will definitely be something I will be looking at down the road.

My intent is to retain the stock (1978) dash, and work on incorporating the wiring harness from the donor.

As I am writing the story, I think I may have forgotten to add that I am already in process off 99% of this so far. This story is currently playing time line catch up for those on this site. Its been a 2 year project to date.
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Old 02-09-2016, 10:29 AM
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Default Bed removal

This was supposed to be the easy part. You know, 6 bolts and done.

Did you know I hate spiders?

Did you know that the State of Washington apparently has the ugliest, meanest, and largest breed of spider. I call it the "Devil's Assistant". It looks like the Thing and Spiderman's love child;

Tan in color
Big
Ugly
has attitude.

I mean, I can't confirm that on wikipedia or anything. But the "Devil's Assistant" apparently prefers to live in Crummy's side marker light holes and wait for new owners from out of state to purchase said trucks, attempt to restomod them, and then when the new owner is not looking, tries to eat the new owners face off. Again, I can't confirm this species on Wikipedia.

Did I mention I hate spiders?
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Old 02-09-2016, 10:39 AM
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Default spider!

First off, no I didn't get a picture.

Second, no hillbillies were injured in this bed removal...


This was the spiders home. He was not happy to see me...nor was i happy to see him...

Most spiders either freeze or back away. This dude moved over to the side marker light, put up his fists, and called my significant other a bad name....



With that, it was on like Donkey Kong...

Bleach, Raid, Power Washer, and Starter fluid was what it took to kill that fwker. Seriously...and he was pissed. I believe his last motion before death was flipping me off...

But I digress...


I checked the other side of the truck for signs of thug life, and was rewarded with...nothing. Thank goodness. I was out of bleach...


we got the bed off and celebrated
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Old 02-09-2016, 11:22 AM
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sub'd for progress! Keep it up
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Old 02-09-2016, 03:00 PM
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Default progress (in the story)...the bed is off too

So lets just drop the gas tanks and the bumper. 20 minutes right?

Of course not!!!

At least we got it down to the frame...



Not sure about the booger welds. Will need to improve on that shock attachment...




The bumper was less than fun. Another booger weld...figures



When you break something, fix it right. Nah, that makes too much sense. Oh well, at least we can get to it with an angle grinder...





Master Chief Willard and "no scope" nick are wearing the proper eye protection, they just opted out of the face shield and hearing protection.


Its off!

20 minutes later.




Keeping this and the other license plate for memories...
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  #29  
Old 02-09-2016, 03:52 PM
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Nice, Listen to Wayne, he has built some extremely nice trucks!
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'03 chev 2500 crew cab duramax 395k bone stock
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D3leted 6.0's are the best. D3lete them and replace with a Cummings.
  #30  
Old 02-09-2016, 05:10 PM
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Going to paint the rig to match the driveline and diff cover right?
Did you already get a donor vehicle? I would go with An OBS for simplicity of less electronics and a forged rod engine. Might as well do the injectors and hpop if upgrading while the engine is out of the vehicle...
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97-250 7.3 Eaton TVS Supercharged, S369sxe, R&D IDI performance T4 mount, my B350/200s, Honey Badger SR with My tunes, BMW M3 seats, Sky 5" RSK skyjacker drop pivot brackets, Sky shackles and hangers, Toyo M/T

1948 GMC Detroit 453T
1951 Mack A51T
1916 Federal 1 1/2T
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Old 02-09-2016, 07:16 PM
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Some might hate on me for this......,but I think it would be cool to put a mechanical 7.3 psd in this beast. Of course toned down making say 500-600 HP. It wouldnt be the road warrior your making but it would be so much simpler to install without all the wiring. But unfortunately the price tag of such a conversion makes this impractical. Loving this build non the less!! Gives me hope for my dads 78 f250 someday.
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Old 02-09-2016, 07:23 PM
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If mechanical kits were affordable the market would be flooded with heui parts.
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97-250 7.3 Eaton TVS Supercharged, S369sxe, R&D IDI performance T4 mount, my B350/200s, Honey Badger SR with My tunes, BMW M3 seats, Sky 5" RSK skyjacker drop pivot brackets, Sky shackles and hangers, Toyo M/T

1948 GMC Detroit 453T
1951 Mack A51T
1916 Federal 1 1/2T
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Old 02-10-2016, 07:26 AM
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Quote:
Originally Posted by superpsd View Post
Going to paint the rig to match the driveline and diff cover right?
Did you already get a donor vehicle? I would go with An OBS for simplicity of less electronics and a forged rod engine. Might as well do the injectors and hpop if upgrading while the engine is out of the vehicle...
Lol. That color, it is something else. The front components are shot in a lighter shade of blue.

Yea, I already go the donor vehicle. Twas a 1996 f250 extended cab 4x4.
Unfortunately, we already got the motor installed. But it will be coming back out soon once final assembly is mocked up.
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Old 02-10-2016, 07:39 AM
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Default interior assessment

Well now that the truck was stripped at this point in the build, we decided to look at the interior and see what we had to work with.
Keep in mind I am planning on making this a daily type driver/BOV, so creature comforts will be nice.
the seats were in decent condition, sans the "FML" and other stuff carved in the back of the driver seat...


Hipsters in Washington do not, I repeat, do not litter. Thusly explaining the amount of trash that had accumulated in the bed and the interior. On a side not, looks like a pop-riveted and sealed floor repair in the front.


The rear of the cab was just as bad in regards to trash.


When cutting speaker holes in Washington, it is always best to make them oval-ish and leave jagged metal.


Now that its cleaned and free of seating, I can look it over and see if I have a ton of floor work, or a little....



Fronts were "repaired". Good news is I can buy this floor all day. The rears, not something you can simply order from your local ford supplier...
This picture made my day. Both of the back sides are excellent!
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Old 02-10-2016, 07:56 AM
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Default trail plug...

So by the end of summer, 2014, we had this truck torn down. Only one problem:

I still didn't have a donor truck.

What I wanted:
* something affordable
* 7.3 powerstroke
* automatic
* 4x4

Did you know that if you have a powerstroke, it apparently is worth it's weight in gold? Well maybe you guys here on Powerstrokearmy knew that, but i sure as hell didn't.

So I set my handy-dandy (not to be confused with Handy Andy) craigslist search app to 7.3 powerstroke.

Finally, a few months (or years at least it felt like), I found one that met my criteria.
In chicago. Of course, why not near me. Oh well...load up the hauler and grab it...




Ex-plow truck, so low ish miles (160,000). Also meant we were going to find lots of crusty bolts and crap to get this monster motor out. 4x4, automatic, and derpy exhaust cut through the hood (think mini stack).

After a little debating, we agreed on a cash money price of $800. Truck runs, drives, stops, shifts, everything its supposed to do. Kid just needed money for college.
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Old 02-10-2016, 12:09 PM
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Thats a heck of a deal on that truck with the mileage. Engine alone is worth that. Good Score!
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Old 02-10-2016, 12:34 PM
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sounds like a killer project

diggin' the car hauler!
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Old 02-10-2016, 02:39 PM
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Thats a heck of a deal on that truck with the mileage. Engine alone is worth that. Good Score!
That's what I thought too. I kept seeing 2 grand for crap that couldn't get out of its own way. Or was twisted.

When this dude's CL ad hit, my phone lit up, and me and little dude were on the road with no hesitation.

Truck ran good enough I could have driven it home. And at that price, I didn't mind making it into a donor truck.
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Old 02-10-2016, 02:41 PM
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Originally Posted by drunk on diesel View Post
sounds like a killer project

diggin' the car hauler!
Thanks. The hauler is a 1997 F350, 2wd, with a Hodges bed. Un-tuned motor, rebuilt trans, best horse swapping I ever done to get it.
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Old 02-10-2016, 03:14 PM
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That is a damn good deal. I come across 2wd truck over here in the 1500-2k range. 800 is a steal for a driveable rig.
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Old 02-10-2016, 07:23 PM
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Love these old fords, looks like a fun project. You must be just down the road from me, Zeeland here too.
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Old 02-11-2016, 07:31 AM
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Cool, we are practically neighbors.
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Old 02-11-2016, 07:42 AM
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Default surgery with a sawz-all

So, lets do this...
"no-scope" nick researching porn while we discuss how to properly remove the heart of this beast.

Master Chief Willard see all the crusty boats and is unhappy...

Lots of crustiness, but I ain't complaining. $800 makes me smile.

Going to need that....

Maybe that too...

IDK, I have been told a '99 and up SD would be the better brake upgrade. I will hang onto this just in case...

Reference pictures



My home made gantry isn't tall enough to clear the frame!


Had to remove the tires and drop the donor down to clear the frame perch
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Last edited by 1killerz; 02-11-2016 at 07:46 AM.
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Old 02-11-2016, 07:53 AM
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Default FREEDOM!



Took a little longer than we thought, but its out and free.
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Old 02-11-2016, 08:48 AM
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Nice! I had started down a similar path on a project - but it got put on hold for other projects.
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Old 02-11-2016, 10:28 AM
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Subscribed. Awesome build.

Sent from my SAMSUNG-SM-N910A using Tapatalk
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Old 02-11-2016, 12:12 PM
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Nice! I had started down a similar path on a project - but it got put on hold for other projects.
Been there, done that. It sucks when other stuff pulls you away. I sold my other projects to keep me focused on this one. But I still managed to pick up other projects that will tide me over during the lulls in this build.
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Old 02-11-2016, 12:14 PM
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Subscribed. Awesome build.

Sent from my SAMSUNG-SM-N910A using Tapatalk
Thanks. It was initially going to simply be a gasser. But I wanted the reliability, power, and long haul capabilities of a diesel.
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Old 02-12-2016, 01:24 PM
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Default clean up

Winter is fast approaching. The township I live is displeased with my hillbilly ways. So I needed to hurry and get the driveline tucked away and unfortunately needed to hurry up and be rid of what was left of the donor.
This was easier than I thought, until I met the 1/2 lip of concrete from my driveway to my garage.


Had to let the air out of Eleanor's rollers to barely squeeze in the garage. That was not a fun job of pushing...


This was a close fit to make it all happen. But at least the township will be happy.


Not much clearance on the backside, but its only for the winter....
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Old 02-12-2016, 01:31 PM
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Default clean up with a cost

In my haste to not get fined by the township, I rushed to scavenge what I could to at least make the PS run in my truck.

So I grabbed the Sawzall, some screw drivers, and procured the wiring harness, steering wheel, connectors...


Loaded the truck and away to the junkyard we went...


What sucked was a multitude of expensive things I had but didn't know to grab at the time. Let alone the multitude of reference points I now do not have... such as:

Gas tanks with lines, including the oh so ridiculously priced sending units, axles (could have sold for money to offset cost of build), the dash itself so I would then also know where every connection went and what it was for, dual tank switch, etc.

But anyway, it is what it is.
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Old 02-12-2016, 03:44 PM
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Should have thrown a license plate on it and told them it was your daily driver. Or maybe threw a for sale sign on it. Stupid rules.
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Old 02-12-2016, 04:12 PM
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I woulda told the town to slob a knob. I have the same lip to the entrance to my shop. A good 2x4 helps to lever the leg up and push or pull in.
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Old 02-15-2016, 01:55 PM
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Should have thrown a license plate on it and told them it was your daily driver. Or maybe threw a for sale sign on it. Stupid rules.
I thought about that, of course after the fact.
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Old 02-15-2016, 01:56 PM
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I woulda told the town to slob a knob. I have the same lip to the entrance to my shop. A good 2x4 helps to lever the leg up and push or pull in.
I kind of did. I ignored them, until they called the sheriff about my car hauler. Its ugly, but its behind me now. I only play nice cause I still need to get township approval for when its time to put up a pole barn.
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Old 02-15-2016, 01:59 PM
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Default drinkin and thinkin

so here we are. Just me and my Eleanor.

My "crew chief" Willard and I have had the winter to think, plan, drink, and think some more.

After much deliberation, and beer, we determined we do not have the fabrication skills to customize/fabricate strong enough motor mounts to hold the PS's girth, and more importantly, to fit properly.

Called around. Talked to some fellow trail riders/mud eaters. They all concluded one guy would love the job and and will do it beyond my expectations.

Call me a sell out...but I concurred to use my check book as a tool on this part (motor mocked in place, motor mounts built).

In the end, I am beyond excited at his craftsmanship. (But that is a story for a later part of this build).
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Old 02-15-2016, 02:00 PM
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Default hold my beer and watch this...

...gets said more times around this part of Michigan than I can count.

But first, some hillbilly ingenuity.

Kids, don't try this level of shade tree mechanic crap at home. Always ask a hillbilly if it will work.

In Michigan, when we say "hold my beer and watch this...", you know something magical is about to take place.

Or tragic... but we don't like that kind of negative energy around these parts...

Having said that...

"hold my beer and watch this..."
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Old 02-15-2016, 02:11 PM
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Default Getting Eleanor and all her lady bits to the fabricator...

1. Get the drive train on a trailer.... by using a ratchet strap, and engine hoist, and jack stands...


2. Use struggling at capacity engine hoist to try and get high enough to clear trailer...



3. Once cleared, use jack stands to raise clearance of engine hoist's legs under the trailer...


4. Secure load, remove engine hoist...and head out.
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Old 02-15-2016, 05:40 PM
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hahahaha I like it!

reminded me of this:
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Old 02-16-2016, 04:40 AM
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Have you given any thought to the "re-wire" of the engine/trans to run in the 78 truck? I see you have an auto trans so you should have swapped in the donor rear axle so you'll have the speed sensor. The auto trans will need the VSS in the rear axle and the speedometer module from the gauge cluster. The PCM uses this signal (passed from rear axle through speedometer) as part of the transmission shifting code. Without it you'll likely be stuck in 1st gear. I've done many harness re-wires for guys that are swapping PSD's into older trucks so just let me know if you need help with the electrical portion of your swap. Good luck and looks good so far.
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Old 02-16-2016, 07:47 AM
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hahahaha I like it!

reminded me of this:
This is a typical thing in my garage, with most of my projects.
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Old 02-16-2016, 07:50 AM
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Have you given any thought to the "re-wire" of the engine/trans to run in the 78 truck? I see you have an auto trans so you should have swapped in the donor rear axle so you'll have the speed sensor. The auto trans will need the VSS in the rear axle and the speedometer module from the gauge cluster. The PCM uses this signal (passed from rear axle through speedometer) as part of the transmission shifting code. Without it you'll likely be stuck in 1st gear. I've done many harness re-wires for guys that are swapping PSD's into older trucks so just let me know if you need help with the electrical portion of your swap. Good luck and looks good so far.
Its funny you mention that.
Eleanor had a correct sterling axle in it when I bought it. In my haste to please the township, I didn't grab the two things you mentioned:
1. speedometer (although I grabbed almost every thing else, just didn't grab the gauges).
2. The speed sensor cable from the rear axle.

Don't be surprised if I do not hit you up on that offer. Electronics is not strong suit. I appreciate your input and am grateful for the offer.
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Old 02-16-2016, 07:56 AM
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Speedometer and VSS wiring can be pulled from any mid 90's truck at the junkyard. Doesn't need to be a diesel truck, just a Ford Be sure to cut the speedometer connector from the harness when you pull the module.
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Old 02-16-2016, 08:00 AM
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Default the pro has a forklift (thank goodness)...

So the removal of the not light drive train was a little more simple.


We left the short box at home, but obviously he needed the rest of the truck...


So this is only supposed to take a month...right...
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Old 02-16-2016, 08:05 AM
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Default Long wait

So apparently the PRO and his wife decided to have a child (why wasn't I consulted on this?), so a month was not happening.

So, we get bored up here sometimes. No project to play with, what's a boy to do?

Took some friends to go play in the mud with my 429 powered bronco...



Found a 1963 f100 four by four I couldn't refuse to buy and play with....




Drank lots of beer, had lots of camp fire bench racing...
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Old 02-16-2016, 08:08 AM
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Quote:
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Speedometer and VSS wiring can be pulled from any mid 90's truck at the junkyard. Doesn't need to be a diesel truck, just a Ford Be sure to cut the speedometer connector from the harness when you pull the module.
Time to head to a junkyard then. I appreciate that. This is on the top of my parts list.
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Old 02-16-2016, 08:10 AM
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You sir, have some killer toys. I've been really thinking about a 429/460 in my 79 Bronco lately....
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Old 02-16-2016, 10:30 AM
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You sir, have some killer toys. I've been really thinking about a 429/460 in my 79 Bronco lately....
I was lucky and found the bronco that way. 429 was already implanted. The motors a beast in that truck. Although big for trail riding, compared to Jeeps anyway, it made enough power/torque to the point things seemed too easy sometimes when off-roading.
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Old 02-16-2016, 10:38 AM
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Mines running a mostly stock 351M with an aluminum 4bbl manifold on 36" tires. It's a lot of fun, but leaves some to be desired in the power department.
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Old 02-16-2016, 12:21 PM
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Mines running a mostly stock 351M with an aluminum 4bbl manifold on 36" tires. It's a lot of fun, but leaves some to be desired in the power department.
I updated the four barrel to a double pumper 750. The 650, vacuum secondary was too small. 35" MT's with C6. Buddy of mine has a doubler transfer case he had in his 1978 Bronco for sale. Be kind of overkill to twin stick a big block though. or is it??
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Old 02-17-2016, 07:53 AM
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Default several months later

"It's done..."

The best text I have ever received at 7am (besides the "I'm not pregnant ones)...

The motor is in, the drive train is mounted, the down pipe is being built and will be in place, the custom radiator is almost installed, and the dual fans are to be set up...

Picture time....

Do I look like I am running a diesel?


sexy welds...


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Old 02-17-2016, 07:56 AM
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Default fits like a glove...

drivetrain is in!




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  #72  
Old 02-17-2016, 07:58 AM
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Default I know its not...

I know its not cleaned up (motor)
I know its not scraped down (frame)
I know the body needs some attention

Right now I am simply mocking everything in to place. Running wires. Figuring out where to put things, mount things, etc. The cleaning, scraping, etc., will all take place in time. I just want to be sure to do this right before I lay down major elbow grease and money in body work, paint, etc...
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Old 02-18-2016, 07:56 AM
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Default AXLES

So I have been told by many that my 44 front will not do well under the girth and torque of the power stroke. I don't know if this is true or not, but the point of the build is overkill and just-in-case scenarios, so I look as it as good excuse to upgrade the axle as well.

I shopped around. Apparently a D60 DS drop is worth more than the cure to Ebola. 1200 for an axle? And it would still need rebuilt? Wow, IDK, maybe I have been out of this too long. but that seemed very, very high.

So patience and my handy craigslist phone app couldn't help me either.

So I turned to the interweb, went to a 4x4 group I belong to, and found it, finally.

A fellow bronco rider was upgrading his ride (going to rockwells. Wow, that's massive).

Long story short, he had the correct D60. At the right price to boot. But he wouldn't separate the lot (8 inch lift springs, blocks, and a matching rear sturling axle).

We talked, he said f it. Before I did, thankfully. I bought it all at a great price (800). And he delivered it to my house and helped unload it.

For what I got, I can't complain.
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Old 02-18-2016, 08:00 AM
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Default heavy metal...

That's a lot of steel for $800. Taking up lots of space in my garage. Will need to disassemble and sell some of this.



What the seller didn't tell me, which I would have gladly paid extra for, is that the rear was disc brake converted. Bonus!

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Old 02-19-2016, 07:06 AM
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Default STANCE

And while I was on the internet, which is a 3 times minimum daily occurrence, in another site's forum, I searched and found some 37" Goodyear Military OZ tires with some rims for the right price.

So of course, I bought them even though the trucks not running at this point yet.
Got home, got excited, wanted to see how the truck sat, if there would be a terrible rake with the PS in the front sitting on clapped out current leafs. So like a kid at Christmas, I tore off the studded snow tires and installed the new hoops.

original snow studded sexiness>>>


single shock will be converted to dual shock once I am ready to put the D60 in... and after a bujillion dollars in stupid unnecessary stuff like air lockers and what not.




No real surprise, a little rake. Nothing new leafs in the front won't fix (hopefully)
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Old 02-19-2016, 07:13 AM
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Default front bumper

A few years ago, I was on a business trip. I did as I always do and searched the internet for local parts.
I came across a super heavy duty ranch hand style bumper. I bought it for Eleanor, before I ever bought Eleanor.
Weird how the mind works sometimes...

Anyway, I put the bumper on my Bronco, and now that Eleanor is here, and not running yet, I wanted to put the bumper on anyway to determine how the additional weight (its heavy) would effect the rake/stance.
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Old 02-19-2016, 07:19 AM
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Default front bumper continued...

As it was on the bronco...

[IMG]<img src="http://powerstrokearmy.com/photopost/data/500/medium/front_16.jpg" />[/IMG]


Needed to pull it off and I will put on the tube bumpers I bought to replace on the Bronco.




Pretty stout bumper...




It fits, but it needs to be set back to be more flush like I had on the bronco.


Still working out ideas for the rear bumper. I think I got an idea. More on that later.
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Old 02-21-2016, 05:36 PM
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This is a pretty cool build.

I want that 63 though.
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  #79  
Old 02-22-2016, 08:05 AM
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This is a pretty cool build.

I want that 63 though.

The 63's a bad ass. factory 4x4, 4 speed with granny. Motor was upgraded to a ford 360 before I bought it.
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Old 02-22-2016, 08:18 AM
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Default CREATURE COMFORTS

Keep in mind my Eleanor is replacing my GMC Denali. My GMC is my daily driver and takes me and my youngest to all kinds of events and family functions.

So I want my little dude (and I ) to be comfortable on our long trips just as we were/are in the Denali.

So I again began my search for some more truck parts. After a little digging around on the internet, and a little badgering on pricing, I finally got what I think will work well for Eleanor;
King Ranch Seating.
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Old 02-22-2016, 08:20 AM
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Default creature comforts continued...

Not sure how I will make these fit and work in the 1978 properly, but obviously I am a gluten for punishment...



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Old 02-22-2016, 08:21 AM
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Default creature comforts continued some more...

little dude's pretty excited about the TV's.





Going to need to find a cover for the rears, as our dog goes on our trips with us.
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Old 02-22-2016, 08:23 AM
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Default spaghetti

I have been sourcing and tracing the internal wiring harness all this winter, when I have the time and my nipples don't try and fall off from the extreme temperatures


I am still looking for a shop diagram/schematic for the donor, boy that would make life better. But in the interim, I am doing it one block at a time off the fuse block. Yea me!!!


Good news, half way there.
Bad news, its ****in cold.


Pictures to come. and much work to do. Hoping for this spring for it to be running under its own power.
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Old 02-23-2016, 07:48 AM
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Nice and clean install.......
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  #85  
Old 02-23-2016, 11:38 AM
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Nice and clean install.......
Thanks. Wish I could take the credit on that aspect...but sometimes its worth it to let a pro do some stuff.
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Old 02-23-2016, 11:43 AM
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Default D60

Tired of looking at spaghetti (wires).
So I decided to take a night...or three, and clean up the D60.







Even managed to find the factory stamping...
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Old 02-23-2016, 11:44 AM
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Default D60 drama...

So the good first:
* The Dana 60 is being done professionally (explain that in the bad news)
* The Full float sterling 10.25 axle in the crew cab when I bought it, is correct with a 4:10 gear ratio
* The engineering of the Sterling axle will make the swap of the disc brake set up on the donor sterling axle to my existing sterling axle easier than originally anticipated
* My buddy discussed temperatures created in axles under load and thusly talked me out of rhino lining the axles. Will be sticking with the chassis gloss black paint

The bad:
* The donor sterling has 3.53 gear ratio, and is weld locked. So I will not be using that axle but will instead be selling it once the disc brakes are swapped off.
* The donor D60 to replace my stock 44 has at he same 3.53 as they came off the same rig. This obviously necessitates a gear change in the D60.
* The previous owner had an issue with the lock hub on the D60, so he welded the internal clip. We had to get it off, and the outer shaft is no longer good.
* Some of the internal seals are bad, so essentially a full rebuild is coming.
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Old 02-23-2016, 07:22 PM
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Quote:
Originally Posted by 1killerz View Post
So the good first:
* The Dana 60 is being done professionally (explain that in the bad news)
* The Full float sterling 10.25 axle in the crew cab when I bought it, is correct with a 4:10 gear ratio
* The engineering of the Sterling axle will make the swap of the disc brake set up on the donor sterling axle to my existing sterling axle easier than originally anticipated
* My buddy discussed temperatures created in axles under load and thusly talked me out of rhino lining the axles. Will be sticking with the chassis gloss black paint

The bad:
* The donor sterling has 3.53 gear ratio, and is weld locked. So I will not be using that axle but will instead be selling it once the disc brakes are swapped off.
* The donor D60 to replace my stock 44 has at he same 3.53 as they came off the same rig. This obviously necessitates a gear change in the D60.
* The previous owner had an issue with the lock hub on the D60, so he welded the internal clip. We had to get it off, and the outer shaft is no longer good.
* Some of the internal seals are bad, so essentially a full rebuild is coming.
If you need someone to set up the D60 give me a shout
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  #89  
Old 02-24-2016, 05:37 AM
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Perhaps a king ranch badge to accent the body??
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Old 02-24-2016, 06:27 AM
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Quote:
Originally Posted by suprhlr View Post
If you need someone to set up the D60 give me a shout
I appreciate the offer. Got it done locally. Now all I need to do is wait for this last weather push to go away so I can install it.
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Old 02-24-2016, 06:28 AM
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Perhaps a king ranch badge to accent the body??
I thought about that. Not sure yet though.
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Last edited by 1killerz; 02-24-2016 at 06:30 AM.
  #92  
Old 02-24-2016, 06:32 AM
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Default rear axle disc brake conversion

So I sent the D60 out for a rebuild. They did all the innards, re-geared it to 4:10 to match the rear, and took care of the outer shafts.

While it was away at the shop, decided to convert the rear sterling axle to disc brake.

It actually wasn't as bad as I thought it would be.
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Last edited by 1killerz; 02-24-2016 at 06:37 AM.
  #93  
Old 02-24-2016, 06:44 AM
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Default rear axle disc brake conversion

Like I said, brakes are not my thing. But the shop manuals are usually pretty straight forward...


it even has pictures!

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Old 02-24-2016, 06:52 AM
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Default rear continued...

So step one. Open your beer. Charge up your air compressor. Look at tire....


Step two, remove the tire. Would have taken a picture, but I only have two hands; one for the beer and one for the tire.

Step 3, remove the antiquated drum brakes that barely stopped your truck adequately.


Step 4, charge up air compressor again, open another beer (it's hot damn it). See all these bolts? They need to come off.


Don't lose these bolts, they are kind of important...


Step 5. Get a oil catch pan, it may get messy.
Remove the axle shaft


Treat that shaft like gold. Don't just drop it. Carefully guide it out of the axle tube.

Step 6. Grab another beer


Step 7. There is a hub nut in here. It takes a four (4) pronged hub nut socket, not to be confused with the six (6) pronged hub nut socket found on older Dana 60's.
This is threaded specifically to the side of the truck it is on. Please consult book as I am no expert. But I believe the book set left hand thread for the passenger side and right hand thread for the driver side.



Step. 8 Comment about how hot it is and how much you love the smell of gear lube in the evening.

Step 9. Once its off, inspect the bearings for wear.


Step 10. If you can't get the hub off by hand (as some others have indicated you could do), and you can't find the part number related to the ford service manual for the step and the puller, gentle use of a slide hammer works as well.
I have no pictures here, as I was being careful as to not mar any parts, or damage any threads, etc.

I used the hub nut socket to assist in keeping the balance so as not to damage my threads.
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Old 02-24-2016, 06:59 AM
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Default finishing up the rear

Freedom!


almost there...

Grab another beer, grab some primer, grab some paint, and grab a wire brush...

Where the hub was (back part) has some accumulated debris and rust. Clean that off and be sure not to get any of the gunk on the shiny metal...



Final step of tear down: belch loudly, realize you are out of beer, realize you don't have the axle seal outer for the hub to replace the parts that were on there, and you forget to get the donor rotors (in my case) turned prior to re installation.
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Old 02-25-2016, 08:12 AM
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Default IDIOT ALERT

So, here's the low down on jumping the gun with purchasing my tire/rim combo BEFORE I bought the D60 and decided to use, the sterling axle that came with it, disc brake conversion:


Rear axle (sterling 10.25) is buttoned up except for the "o'ring" I am still chasing down a part number for.


The disc brakes are on the rear axle (sterling 10.25).


Didn't do the math, my rims are hitting the calipers. Not horribly, but enough it needs to be addressed.
three options:
1. sand disc down the caliper to make clearance
2. get a bigger spacer to push the rim far enough away for no rub.
3. buy bigger rims (hope not)


Dana 60 is done (rebuilt). Picking up and then putting on the new lock out hubs


Found a Baja cage with over roof rack. Hoping to pick up this weekend.


Pictures to come....
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  #97  
Old 02-25-2016, 08:16 AM
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Default sterling O-ring part number

So while I was picking up the D60 from the rebuild shop, I thought this would be the place to answer the mystical question: what is the part number for the O ring? I had looked every where, even called ford parts department. No one had the answer.And he had the answer, plus the part in stock!

Answer: E5TZ-4A331-A


Have I mentioned I love this shop. Old school driveline shop. He built my drive shafts for my Original CC, built the driveshaft for my 72 chevelle, rebuilt my drive shafts (including my trail spares) for my 1979 bronco, and now has built my D60.


If you are in western Michigan, need this kind of work done, this is the shop I would recommend:
D&R Driveline Inc. @ www.drdrivelineinc.com


Anyway, I digress. Many pictures to come as we are buttoning up the front end.
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  #98  
Old 02-25-2016, 12:20 PM
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Sharp guys at d&r.
Dts in ionia is another good shop.
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Old 02-25-2016, 01:18 PM
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D&R is also cheap, and do great work. Its not very often that those are used in the same sentence.
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Old 02-25-2016, 06:53 PM
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Quote:
Originally Posted by psduser1 View Post
Sharp guys at d&r.
Dts in ionia is another good shop.
Good info. Today's day an age, word of mouth in our groups online is knowledge worth it's weight in gold.
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Old 02-25-2016, 06:54 PM
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D&R is also cheap, and do great work. Its not very often that those are used in the same sentence.
Amen to that. Especially for someone like me on a shoe string budget, pricing is critical.
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Old 02-26-2016, 07:46 AM
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Default baja rack

So not that I have stopped the process, its just that more of my time was spent with my little one as he has team sports currently. That didn't stop me though from Craigslist and ebay searches for what I needed/wanted, including a Baja rack.


For you purist on these old trucks, please turn away, back out etc. You will be more than likely be butt hurt by what I am adding to Eleanor (as if the diesel wasn't bad enough).
As for the rest of you that are not going to be butt hurt, This is essentially something I wanted all along, just not in this color...


The good news is what I paid for it, I couldn't have even bought the metal to try and make it.


A quad will fit between the rails ( a smaller quad that it is), although it is designed to handle two dirt bikes.


It designed to handle two spare tires, but not sure if:
a. it will fit with these 37" MTR's
b. that would be a heavy lift.


Lights were included. Looking for military grade lockers (weather proof) such as Pelicans to put on the top rack for storage, etc.
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  #103  
Old 02-26-2016, 08:13 AM
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why do you have a pic of a guy taking a leak?
  #104  
Old 02-26-2016, 11:47 AM
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I never was a fan of Baja racks, but I'll still keep watching this thread. Whenever I see racks like this I think of Africa, Kenya, etc. Whenever I see a Toyota or land rover with a rack I think the same thing.I never think of Baja desert racing. But who knows, maybe this thread will change my thinking. Lol. Carry on good sir.
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  #105  
Old 02-26-2016, 12:04 PM
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Quote:
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why do you have a pic of a guy taking a leak?
His hemorrhoids were flaring up, so he was standing funny. That's funny though, it looks like he could possibly be taking a "break"...
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  #106  
Old 02-26-2016, 12:06 PM
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Quote:
Originally Posted by gwunter View Post
I never was a fan of Baja racks, but I'll still keep watching this thread. Whenever I see racks like this I think of Africa, Kenya, etc. Whenever I see a Toyota or land rover with a rack I think the same thing.I never think of Baja desert racing. But who knows, maybe this thread will change my thinking. Lol. Carry on good sir.
Initially I wasn't either. But once I got to looking at the amount of crap I will be hauling around for extended wilderness adventures, it makes sense.
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  #107  
Old 02-26-2016, 12:13 PM
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Could probably find the military locker boxes on eBay somewhere. Surplus is pretty cheap.
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  #108  
Old 02-26-2016, 12:17 PM
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Default spare tire carrier ideas

38.5 and a half inch tire on a 78-79 bronco. would still have access to my bed with the bronco inspired design...



But since I am running 37's, and I know the possibility of finding a replacement tire in BFE would be a small challenge, I wanted to at least be able to run the capability of carrying two spares...left side is for Jerry Can style carrying...but replace and modify for another spare tire holder...


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  #109  
Old 02-26-2016, 12:19 PM
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Default in bed storage

Having my two spares on the out side of the bed will allow me to make/buy a slide out storage kit in my bed for my..uh..tools... like so...thus leaving room on the baja rack above for more crap.

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  #110  
Old 02-26-2016, 12:21 PM
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Default had to put the rack on...

was running out of room in the garage and my trailer...









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  #111  
Old 02-29-2016, 07:40 AM
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Default got the D60 back

New from end to end...








My better half has volunteered to add some artistic touches to the differential cover. We shall see...
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Old 02-29-2016, 07:43 AM
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Default spaghetti...everywhere!

so I now have two steering columns, cause we butchered the first one unceremoniously. Master Chief Willard and I are hoping to patch the new column, the old harness, and all my crap and have a go at firing up Eleanor this coming weekend.
Mind you, not road ready, but after all this so far, it would be nice to hear her purr as only a diesel can. But we shall see.
If we manage to get everything situated, I will post a video.

Having said that, this is my current hell in the garage...


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  #113  
Old 02-29-2016, 07:45 AM
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Default go, no go...

So the weekend did not go completely as planned with firing up Eleanor.

Upon topping off the fluids, I noticed a consistent stream of oil pee from under the truck. Closer inspection revealed a small hole in the oil pan. Upon closer-closer inspection, I noticed at least four jb weld points on the oil pan (keep in mind the donor vehicle used to be a plow truck).

We had everything set up to fire, and now here we sit with a pissing dog urinating oil all over the ground (now oil pan).

I visited my 1996 shop manual for the power stroke trucks. Apparently now I know why they welded the **** out of some spots instead of simply changing the oil pan. Apparently the motor needs to be partially lifted out of the bay to accommodate the pans girth and clear the cross member.

Well s!@$, mine has a 4" body lift, is not the correct frame (78 versus 96), I should be fine.

NOPE.

The good news is I have no idea how long that hole was present, was there enough oil to keep the internals lubricated, how the hell do I get this out.

First thought, rotate the motor using the crank shaft pulley, see if this helps the pan clear the bottom end. Nope! But, the motor spun freely, so no worries about the presence of internal lubrication.

Cherry picker time. Nope, wont budge cause the arms to far extended to snatch the weight of the drive train even two inches.

More good news, my neighbor has a bobcat. We will be lifting the motor the required distance and installing the new oil pan this coming Saturday. So no video of it running as of today. Shooting for next weekend.
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  #114  
Old 02-29-2016, 08:56 AM
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To do a oil pan correctly. It need to come all the way out. Turned upside down and cleaned throughly. Then sealed up with the grey ford rtv. If you do not do this it will leak again.
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Old 03-02-2016, 07:44 AM
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Quote:
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To do a oil pan correctly. It need to come all the way out. Turned upside down and cleaned throughly. Then sealed up with the grey ford rtv. If you do not do this it will leak again.
much appreciated. It was unsavable though. Bought a new pan.
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  #116  
Old 03-02-2016, 07:50 AM
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Default oil pan and trying to fire the powerstroke

So, not all goes as planned sometimes, and life is just that; something new every moment.
My neighbor that was to help me lift the PS with his front end loader. Well, my neighbors a hunter. His dad's Bobcat is only to be run by their family. So he's hunting.
What to do? Grabbed the cherry picker (engine hoist), a bottle jack, and a few beers.


Now I always say this, and its worth a repeat. No hillbillies were harmed in the process, but damn near.


Some pictures, cause it didn't happen without a picture, right?

Not in this case. No time for picture.


The cherry picker was able to lift the girth. but just enough to tease us with maybe 1/2 inch of clearance of the front cross member. Well, lets grab a bottle jack, push up on the bell housing with it, and make it happen.
Now, at this point, I must throw out a disclaimer. Master Chief Willard was under the truck working the bottle jack, we had (disclaimer alert) assumed the transmission was bolted into its cross member (we were wrong), and I was asked to pump one or two more times on the cherry picker. The disclaimer here is never be under a truck with 1000 plus pounds overhead, without checking all mount points.


So I pumped on the Cherry Picker, Master Chief Willard pumped on the bottle jack, then the motor jumped. Not to life mind you, but forwards and up about 3 total inches, as the transmission mounting bolts freed themselves from the cross-member, enough that the oil pan freed itself from its snuggly confines and crashing to the concrete. Willard may (or may not) have shat himself at that moment, but all I could think of was "so this is how one of us dies; under a truck?"


Once again, no hillbillies were injured. Willard and I lived on to fight other battles. But I digress...


We cleaned up the oil pan mounting surfaces on the block using 000 steel wool, brake cleaner, and a modified steel scraper. Works great, as there was a ton of sealant on the mating surfaces, enough to make me wonder why I didn't have Small Block Ritchie (the guy who put in the motor and fabbed the motor mounts) at least check all that crap out first. Oh well, next time.


Oil pan went on smoothly, everything torqued down to spec, good to go, or are we?
Guess what, now we have to line it back up to make sure everything can be securely mounted again (this time with the transmission mounted as well).
That took a while...but its done....
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Old 03-02-2016, 07:57 AM
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Default oil pan

The old one was crusty, JB welded, and leaky. Was a now brainer to simply replace with the new (now that its free from under the truck).



The new one, well, its an oil pan. Nothing sexy to report here...

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  #118  
Old 03-02-2016, 07:58 AM
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Default how to post video?

So, the oil pan is in. Sealed up, no leaking, and ready for a new life in Eleanor.

Speaking of, we test fired the set up finally. And I have video... but how do I post videos on this site?

Once I have that answer, I will post up.
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Old 03-02-2016, 09:02 AM
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I upload it to YouTube and post a link. Don't know if there is an easier way.
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  #120  
Old 03-02-2016, 09:46 AM
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Quote:
Originally Posted by 1killerz View Post
So, the oil pan is in. Sealed up, no leaking, and ready for a new life in Eleanor.

Speaking of, we test fired the set up finally. And I have video... but how do I post videos on this site?

Once I have that answer, I will post up.
Typically most people host the video elsewhere (mostly YouTube) and then post a link. Here's how to embed the video: CLICK HERE
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  #121  
Old 03-02-2016, 02:47 PM
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I upload it to YouTube and post a link. Don't know if there is an easier way.
Thanks. Every sight has different ways. Didn't want to break anything.
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Old 03-02-2016, 02:48 PM
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Typically most people host the video elsewhere (mostly YouTube) and then post a link. Here's how to embed the video: CLICK HERE
Thank you kindly.

I will now see if I can make this happen or not.
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Old 03-02-2016, 02:50 PM
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Default its alive!

YouTube Video
ERROR: If you can see this, then YouTube is down or you don't have Flash installed.
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  #124  
Old 03-02-2016, 02:55 PM
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Default some more of the first running of the powerstroke in the 1978 crew cab AKA: Eleanor

YouTube Video
ERROR: If you can see this, then YouTube is down or you don't have Flash installed.
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Old 03-02-2016, 02:58 PM
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Default more questions: steering column

Spent the weekend "shaving" the calipers to accommodate the rims, working on replacing the rear driver door lock and handle assembly (using a spare door I procured with Eleanor), and was evaluating the electronic situation.

It is clear there can only be two paths (in my head anyway). Please tell me if I am wrong...

1. Use the original steering wheel. The majority of the electrical components on the donor steering wheel do not have direct plugs, more like mounting points. I would love to use the original steering wheel, thusly avoiding...#2

2. Modify the donor steering wheel to install in place of the original. The mount holes are 2 inches shorter from the wheel on the donor versus stock. Additionally, the steering shaft is 6" shorter than the stock, so I would need to have a steering shaft fabricated to make up the difference.

Oddly enough, number 2 sounds more reasonable in regards to ensuring reliability and functionality as :
1. I am not an electrician, nor electrical engineer. If something is to get FUBAR'd, it would be here and by my own hands
2. As we get older, we typically get fatter. Wouldn't 2" more of breathing room between my gut and the edge of the steering wheel after a late night 4th meal run make more sense?

I don't know yet. Still weighing the two options. If anyone has a thought, please feel free to chime in...
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Old 03-02-2016, 06:24 PM
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Maybe get a telescopic and tilting Colum out of a semi truck and the Do a race starter panel.


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  #127  
Old 03-03-2016, 03:44 AM
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Not sure what the question surrounding the steering wheel is about? Are you trying to keep the cruise control buttons? If so, find a 78/79 wheel with the buttons. Personally I never use cruise so I would just ignore it in the swap. You do want to wire the trans control button (OD light on shifter) since it's an indicator light when something is wrong (it blinks). It will also allow you that control (OD lockout). Any momentary switch/light combo can work for that and be mounted on the dash. Not wiring it won't hurt anything, you just won't have the control or the indicator.
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Old 03-03-2016, 06:37 AM
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Not sure what the question surrounding the steering wheel is about? Are you trying to keep the cruise control buttons? If so, find a 78/79 wheel with the buttons. Personally I never use cruise so I would just ignore it in the swap. You do want to wire the trans control button (OD light on shifter) since it's an indicator light when something is wrong (it blinks). It will also allow you that control (OD lockout). Any momentary switch/light combo can work for that and be mounted on the dash. Not wiring it won't hurt anything, you just won't have the control or the indicator.
Sorry.
The question was can I use the stock steering wheel in this project. I wasn't sure if everything mounted on the donor steering wheel (1996), tied to the wiring harness, was simply mounted to the the donor wheel, or if there were any grounds/issues/etc if I put the connections else where on the 1978 steering wheel/under dash.

Essentially, I believe you just answered my question. The only two electronic controls are the cruise control and the trans control button, which would make this swap a lot easier by simply keeping the stock steering wheel in place.
Thank you very much.
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  #129  
Old 04-12-2016, 03:44 PM
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any updates with this project?
  #130  
Old 04-13-2016, 03:20 PM
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any updates with this project?
Actually yes and no.

Updates:

Found a new fabricator dude here locally. He is doing the following:
1. Tied in the Baja rack to mount to the frame, through the bed, as required. Pictures to come once I get the truck back.
2. Is re-doing the massive front bumper so it attaches properly. This bumper was on a f-150 frame, which is why it fit sooo nice on my 1978 Bronco, and why it won't fit so nice and snug on my f250 frame. Once the fab man is done, it will fit as snug as it once did on my Bronco.
3. The fab man is making a piece to hold my shifting cable properly so it can be used with my stock 1978 shifting column. This will allow me to use the 1996 shifter cable as designed on 1996 trans.
4. I bought another crew. I sold my Denali to a local friend who's been eyeballing it since I bought it 3-4 years ago. Couldn't go without some kind of truck. I ended up buying a 1996 f350 crew cab, long box 4x4 powerstroke. This will also help serve as a great reference point as I finish up Eleanor.

The not so update----

The 2008 king ranch seats don't seem to fit. Way too tall. Fab man says we would need to modify the floor pan to make these work. SOOOOOO bummed about that. Wonder if they will fit in my 1996....

Also, headed to Hudsonville, MI Fairgrounds this Saturday for The Ford Truck and Bronco swap meet. Anyone else going?
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  #131  
Old 04-14-2016, 10:44 AM
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[QUOTE=1killerz

Also, headed to Hudsonville, MI Fairgrounds this Saturday for The Ford Truck and Bronco swap meet. Anyone else going?[/QUOTE]

A friend of mine puts this on every year, this will probably be the first year I wont be there, I sold all of my bronco stuff years ago but usually still go just as a social event.
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  #132  
Old 04-14-2016, 12:42 PM
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A friend of mine puts this on every year, this will probably be the first year I wont be there, I sold all of my bronco stuff years ago but usually still go just as a social event.
and the donuts served at the lunch wagon!
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  #133  
Old 04-18-2016, 08:29 AM
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Default bringing it back from the fab man

What a hectic week...





Taxes are done, trucks done, swap meet was full, springs in the air (so more yard work)...





But I digress....





Picked up Eleanor Thursday night from Four On Fabrication. If you need a guy, I know a guy. Gary's a good dude who enjoys this type of work.





The Baja rack is secured in place know, properly thanks to Gary.

The big bumper wouldn't sit right on Eleanor, so Gary fixed that too. And then trying to use the 1978-1979 column shift mechanism, while hosting a 1996 Powerstroke drive train that was also column shifted, well Gary made that a possibility too by making the bracket to secure the shifter cable properly.








We were however, unable to devise a way to make those King Ranch seats fits without modifying the floor pan. I am not a tall guy, nor am I short. but mocking those seats in, I was literally an inch, maybe 2 from the roof. So....I don't know yet. Current plan is to get it drivable and use stock seating until I figure out another plan...


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Last edited by Hotrodtractor; 04-18-2016 at 12:06 PM. Reason: Hopefully fixing image links....
  #134  
Old 05-17-2016, 09:16 AM
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Default dana 60 upgrade, along with springs



rear spring shackle shows how stressed the suspension is from the new found weight...







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Last edited by 1killerz; 05-17-2016 at 09:19 AM.
  #135  
Old 05-17-2016, 09:21 AM
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Default D60 upgrade

it took a while, but was worth it to get the d44 an overtaxed springs out...



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  #136  
Old 05-17-2016, 09:27 AM
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skyjacker spring number as recommended by their tech service based on newly added weight on front side...



go time...




its in and situated



need to shorten the u-bolts. Has to re-use them from the monster spring packs that were on the axle when I bought it.



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Old 05-17-2016, 09:27 AM
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I need to put the 37"' 's back on, so I can re-measure my front height to determine how much add a leaf I will need in the rear to level the ride out.
Once that's done, and add a leafs are situated in the rear, off to the driveline shop for some custom drive shafts.
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  #138  
Old 06-06-2016, 08:44 AM
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Wow so I just read thru this build and realized that's my old ford you originally bought from me in forks. Miss that truck so much and awesome build so far.
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  #139  
Old 06-06-2016, 08:35 PM
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Quote:
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Wow so I just read thru this build and realized that's my old ford you originally bought from me in forks. Miss that truck so much and awesome build so far.
Wow, small world!!
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Old 06-07-2016, 06:42 PM
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I can give you some history on the crew cab truck, it was originally bought in forks as a crew bus for a logging company, it made its way thru a few companies. I'm fairly certain the body is NOT original, I was told at some point it was changed. The guys dad I bought it from swapped body's and put the body lift on it. I think the truck was a 4speed truck at one time, it had some brackets n pieces left and someone put a c6 and floor shifter which I later removed and put a tilt column and shifter. The lift, suspension and rear bumper were all on the truck when I purchased it. Had some repaired floor boards which looks like they used fiberglass?? And somebody had covered it with bed liner. My foot went thru the drivers side floor and I had to make due with the sheet of metal to cover. The doors and front clip and fenders have been changed a few times from being wrecked a couple times. I know it got stuck off road before I bought it and they bent the front pretty good and I totalled a Toyota truck with it as well. Truck has had many miles and fun times. Been repaired many times some repairs not so great but it always got me down the road. Really miss the truck and wish I'd still had it. Good to see someone taking care of it and rebuilding.

If you wanna know more or anything else about it I can find out or probably know. I still know and talk with the guy I bought it from.
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Old 06-13-2016, 07:46 AM
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Wow so I just read thru this build and realized that's my old ford you originally bought from me in forks. Miss that truck so much and awesome build so far.
You guys were awesome in helping me loading it that night. Me and my son were super exhausted, and you made it very simple to get it on so we could get back on the road.
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  #142  
Old 06-13-2016, 07:48 AM
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Originally Posted by Ford460power View Post
I can give you some history on the crew cab truck, it was originally bought in forks as a crew bus for a logging company, it made its way thru a few companies. I'm fairly certain the body is NOT original, I was told at some point it was changed. The guys dad I bought it from swapped body's and put the body lift on it. I think the truck was a 4speed truck at one time, it had some brackets n pieces left and someone put a c6 and floor shifter which I later removed and put a tilt column and shifter. The lift, suspension and rear bumper were all on the truck when I purchased it. Had some repaired floor boards which looks like they used fiberglass?? And somebody had covered it with bed liner. My foot went thru the drivers side floor and I had to make due with the sheet of metal to cover. The doors and front clip and fenders have been changed a few times from being wrecked a couple times. I know it got stuck off road before I bought it and they bent the front pretty good and I totalled a Toyota truck with it as well. Truck has had many miles and fun times. Been repaired many times some repairs not so great but it always got me down the road. Really miss the truck and wish I'd still had it. Good to see someone taking care of it and rebuilding.

If you wanna know more or anything else about it I can find out or probably know. I still know and talk with the guy I bought it from.

I appreciate the info most certainly. Its a slow process, but I am making some headway at least. More to come once I get this wiring harness sorted out.
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Old 06-13-2016, 07:48 AM
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Default SOLD!

Not the truck, the seats. LoL. So without hacking the floor up and creating a super sexy one off floor, the correct way to keep this build budget friendly was to bid adieu to the King Ranch dreams and focus on what is now affectionately titled "hell's spider web" and figure out the seating at a later date.

So, the seats were sold, and I am now officially entangled in the web of wires working to make this happen properly...
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  #144  
Old 06-14-2016, 03:57 PM
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Here's a few pictures during the time I had it. I can dig up some more later.
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Old 06-15-2016, 08:53 AM
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Here's a few pictures during the time I had it. I can dig up some more later.
That's awesome!

Once I get this wiring harness situated, not much to do but sort out the minor mechanical bits and its road time (and picture time).
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Old 06-15-2016, 08:57 AM
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Default pics

And thanks for those pictures. If you find more, please feel free to post them. Talk about some motivation to get a project done. These pictures sure have done it.
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Old 11-04-2016, 01:23 PM
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Default update

In the middle of doing non-sexy, update worthy stuff such as taking dash apart, matching up wires, splicing and dicing miles of spaghetti, trying to figure out heater controls, etc.

Once the dash and internal wiring harness is situated, I will be posting pictures and updates on the build.

Building another AR and coaching my kids team had slowed me down this fall. Back into full swing of things within the past week.
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  #148  
Old 11-04-2016, 06:46 PM
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Yes, please don't let this thread die.
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Old 11-04-2016, 09:55 PM
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Agreed, let's see the spaghetti. Lol, jk
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Old 11-05-2016, 09:47 AM
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...and the AR.
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  #151  
Old 11-06-2016, 07:46 PM
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finish it!

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Old 11-10-2016, 10:17 AM
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Yes, please don't let this thread die.
Never. I am just a bit overwhelmed with the wiring.

Did I mention I am not an electrician, nor a electrical engineer. Hell, I'm lucky I can chew bubble gun and walk at the same time.
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Old 11-10-2016, 10:18 AM
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Agreed, let's see the spaghetti. Lol, jk
My thoughts exactly.
Pics coming this weekend.
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Old 11-10-2016, 10:19 AM
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...and the AR.
won't I get reprimanded by the moderators?
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  #155  
Old 11-10-2016, 10:19 AM
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finish it!

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  #156  
Old 11-10-2016, 10:37 AM
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won't I get reprimanded by the moderators?


Negative.
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  #157  
Old 11-10-2016, 06:29 PM
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um, well there is a weapons thread,,,,,
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D3leted 6.0's are the best. D3lete them and replace with a Cummings.
  #158  
Old 11-10-2016, 07:02 PM
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No we are all bleeding heart liberals around here that hate guns. Guns kill people ya know.






Only kidding.
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Just a crazy, wannabe machinist....making crazy stroker parts.
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Old 11-11-2016, 03:20 AM
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won't I get reprimanded by the moderators?
Only if trying to sell it on here.
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Old 12-29-2016, 08:01 AM
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Default non sexy stuff

Finally got the dash apart and opened to reveal nothing sexy at all.

In contrast though, amazing the lack of wiring in the wiring harness in the 1978. Removal will be easy, clean up will be nasty, but really I feel I am on the last hurdle of this project.

But, while I am in here (the dash), I will be replacing the blower motor just in case. You guys have any other suggestions on things to replace/make better under the dash of a 1978 f250 while I am in here?

Pictures coming. But be warned, nothing really exciting to see...

On a side note, the dash has been off before, that much I can tell.
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Old 12-29-2016, 12:41 PM
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Default the dash

Some where in Eleanor's history, the dash was apart before. The plastic heater switch mechanism was discovered to be broken when we freed it.





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Last edited by 1killerz; 12-29-2016 at 12:46 PM.
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Old 12-29-2016, 01:06 PM
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Pic fail
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Old 12-30-2016, 08:29 AM
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Some where in Eleanor's history, the dash was apart before. The plastic heater switch mechanism was discovered to be broken when we freed it. (Its the crappy white plastic piece behind the heater controls)
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Old 12-30-2016, 08:32 AM
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Hard to tell. But somewhere along the line in this trucks life, the radio mount was "hogged" out. Not sure what I will do about that...
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Old 12-30-2016, 08:35 AM
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When the dash was taken out the first time (not me), some how the dash got a nice notched dent and hole in it (top right of pic). Cant see it when the dash is in the truck... but definitely can see it when its out and I will know its there...

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Old 12-30-2016, 08:37 AM
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nothing really sexy to see here but some old steel. Oh wait, old steel is sexy...


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Old 12-30-2016, 08:39 AM
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so, now thats a small wiring harness.

Time to clean this up and remove the old wiring harness and lay in the 1996 donor harness.



What could go wrong?
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Old 12-31-2016, 04:03 PM
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Lookin good!
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  #169  
Old 12-31-2016, 06:13 PM
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Awesome!

Sent from my SM-N920R4 using Tapatalk
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Old 12-31-2016, 10:09 PM
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that looks like a puzzle that is way to hard for me.. lol

live life full throttle

god bless america and the farmer who feeds your fat ass
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  #171  
Old 12-31-2016, 11:28 PM
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Just got done reading through the whole thread and I gotta say, wow! Love watching these things unfold. (unfortunately sometimes in more ways than one). And about that "crummy" comment in the beginning, as a west coaster, I think that means the same thing as "in poor condition" lol.
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Old 01-04-2017, 08:39 AM
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Quote:
Originally Posted by lincolnlocker View Post
that looks like a puzzle that is way to hard for me.. lol

live life full throttle

god bless america and the farmer who feeds your fat ass
Its above my paygrade too. But I like puzzles. And I like to learn. This will either break me (and my fragile mind), or it be something to be proud of.

With my youngest boy watching me on this, I don't want to fail. so break me it is!
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Old 01-04-2017, 08:40 AM
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Quote:
Originally Posted by 1killerz View Post
Its above my paygrade too. But I like puzzles. And I like to learn. This will either break me (and my fragile mind), or it be something to be proud of.

With my youngest boy watching me on this, I don't want to fail. so break me it is!
nice!!

live life full throttle

god bless america and the farmer who feeds your fat ass
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  #174  
Old 01-04-2017, 08:41 AM
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Quote:
Originally Posted by CJunkie View Post
Just got done reading through the whole thread and I gotta say, wow! Love watching these things unfold. (unfortunately sometimes in more ways than one). And about that "crummy" comment in the beginning, as a west coaster, I think that means the same thing as "in poor condition" lol.
You could be right in regards to the condition related aspect. Either way, gonna plow through this one way or the other...
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Old 01-17-2017, 12:07 PM
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Was talking with a friend about Eleanor, and Power Strokes in general, when he stated "have you seen the Noveske Ford Crew Cab?".

No, no I had not.

Has anyone seen this? Its a PS powered 70's crew cab out in Washington. I have been looking for any information on the build. To no avail. Anyone else know where I could find the build write up on it?
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  #176  
Old 01-17-2017, 09:21 PM
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Quote:
Originally Posted by 1killerz View Post
Was talking with a friend about Eleanor, and Power Strokes in general, when he stated "have you seen the Noveske Ford Crew Cab?".

No, no I had not.

Has anyone seen this? Its a PS powered 70's crew cab out in Washington. I have been looking for any information on the build. To no avail. Anyone else know where I could find the build write up on it?
http://bfy.tw/9XOF John Noveske's truck. You're welcome.
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Old 01-19-2017, 09:36 AM
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Quote:
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http://bfy.tw/9XOF John Noveske's truck. You're welcome.
Very much appreciated.
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  #178  
Old 01-19-2017, 10:48 AM
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. Hoping that's the one you sought.
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  #179  
Old 01-19-2017, 10:23 PM
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Pretty sure it is in here someplace

https://m.youtube.com/watch?feature=...&v=JbMdPStxD10
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  #180  
Old 01-20-2017, 11:23 AM
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Quote:
Originally Posted by Sterling6.7 View Post
Pretty sure it is in here someplace

https://m.youtube.com/watch?feature=...&v=JbMdPStxD10
Oh yea, its in there. Never seen that video. Now I can't unsee it. Girls and guns, its an american dream!
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  #181  
Old 03-01-2017, 12:08 PM
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FYI, this build is not dead. I have just been super busy with consulting and general day to day with my kid.

Big change since my last post though.

Friend of mine has a pole barn. Said friend has allowed me to not only store Eleanor in his pole barn, but to work on it while its stored there. Extra extra bonus (for anyone who lives in MI), ITS HEATED. so now that its moved, time for more progress.
Additional bonus, my friend has a son the same age as my boy, so they can play together while dad plays in the pole barn.

Done with one client, so now I have some additional free time to get to crackin on this pig...
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Old 03-01-2017, 09:53 PM
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nice!!!

have I asked where you lived before?

live life full throttle

god bless america and the farmer who feeds your fat ass
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15,f350,4x4,cclb, not stock
god bless america and the farmer who feeds your fat ass