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  #361  
Old 06-16-2014, 08:31 PM
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Thanks guys! I'm sure it will look a lot sweeter when i get some tires and rims, the visor, and my brand new shiny big rig cab lights mounted! As well as the grill and bumpers.

I plan on running the original bumper up front with a sweet set of bumperettes that i've had in my collection for a while. The rear bumper is starting to get quite a few rust spots so i think that i will fab up a custom aluminium one.

The trim actually went on pretty good. I opted to not use those goofy factory clips that are for above the rear wheel well (lower trim) and used the ones with the little studs and nuts that get used on the rest of the lower trim. This created a little problem because it is almost impossible to get your arm up in behind the inner wheel well support panel to put the nuts on. So since the truck won't be winter driven and i won't be worried about catching road salt, I used my 1 1/4" hole saw and cut some access holes in that little support...worked like a charm. I only drilled 2 holes on the passenger side because i could reach the two nuts closer to the edge, but upon inspection of the drive side it looks like i will have to drill at least three holes because the fuel tank filler neck will be in the way of getting my hand up in there on the rear side.
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1977 F250 4x4 Crew cab, 5.9 Cummins, ZF5, Divorced 205, Dana 60's
http://www.ford-trucks.com/forums/10...ins-build.html
1977 F250 4x4 Reg Cab highboy, 460, C6, Divorced 205
http://www.ford-trucks.com/forums/12...ter-truck.html
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  #362  
Old 06-17-2014, 09:55 AM
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Awesome.... paint looks great, trim looks great. looking good sir...
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http://www.yotatech.com/f116/95-cummins-build-250594/

72 f350 crew cab long bed cummins
http://www.ford-trucks.com/forums/11...d-cummins.html
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  #363  
Old 06-17-2014, 02:24 PM
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Aaron-71 Aaron-71 is offline
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Aaron-71 has a very good reputation on FTE.Aaron-71 has a very good reputation on FTE.Aaron-71 has a very good reputation on FTE.Aaron-71 has a very good reputation on FTE.
Keep it up!

For the record... ANY pics are good pics.
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Aaron, you are the man.
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  #364  
Old 07-11-2014, 09:53 PM
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Finally after a busy couple weeks at the shop, i am all caught up and can get back to work on the crew. Unfortunately the shop jobs take priority...i gotta finance these old ford projects somehow...

Down to business...

First off, i got my new cab lights. The previous owner was a heavy truck mechanic so he installed a set of highway tractor cab lights. They are like 11" long! They actually looked too big when the truck was a two wheel drive, but i figured they'd look good once the truck was a big 4x4. The chrome on the original set had started to flake so i bought five new ones from a local heavy truck dealership. (and they were listed as a ford light too)

old on left, new on right


Click the image to open in full size.

And while we are talking about lights, i was going to install my headlights but i noticed that the adjusters were siezed and in rough shape. I started to pull a set from a spare rad support/grill assembly that i had, but i wasn't happy with them either so i decided to make new ones. I used some SS 10-32 socket head cap screws. I drilled out 4 nuts and slit them up the shank of the screws and tacked them to create the little gap that catches the headlight pot. Then i tacked a nut to a little piece of 16 ga mild steel that i will tack onto the location that the original adjusters went through the headlight pot support.

Here's the new ones with the original one to the left.


Click the image to open in full size.
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1977 F250 4x4 Crew cab, 5.9 Cummins, ZF5, Divorced 205, Dana 60's
http://www.ford-trucks.com/forums/10...ins-build.html
1977 F250 4x4 Reg Cab highboy, 460, C6, Divorced 205
http://www.ford-trucks.com/forums/12...ter-truck.html
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  #365  
Old 07-11-2014, 10:06 PM
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As i have been starting the truck and moving it in or out of the shop the last month or so, something didn't seem right with my cummins. I noticed it was blowing some whit smoke and the turbo didn't seem to have the same ol' whistle that it had before. I decided to investigate. I pulled off my air breather...and i could see where my turbine had been rubbing the aluminum housing...not good.

Luckily for me i had this sitting in the corner of my garage...


Click the image to open in full size.

Its my spare cummins engine that i picked up a year ago or so. The previous owner said that he had put a new turbo on it a year or so before he parked the truck...for 1200 bucks he added. I pulled off the turbo and it is like brand new. The tag even says that its a reman by cummins...Perfect.


Click the image to open in full size.


Click the image to open in full size.

Yesterday i pulled the turbo off of the engine in the crew and my suspicions were correct. The turbine had been rubbing due to a bad bearing, and with the bad bearing comes a bad seal and inside the compressor side was all black and oily. So the turbo was letting oil right into the intake, hence the white smoke...

Here you can kinda see the rub marks from the turbine.


Click the image to open in full size.

Am i ever glad i caught this now. New turbo installed and no more white smoke...and the whistle came back!! Nice little puff of black when she fires up now!!!
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1977 F250 4x4 Crew cab, 5.9 Cummins, ZF5, Divorced 205, Dana 60's
http://www.ford-trucks.com/forums/10...ins-build.html
1977 F250 4x4 Reg Cab highboy, 460, C6, Divorced 205
http://www.ford-trucks.com/forums/12...ter-truck.html
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  #366  
Old 07-11-2014, 10:13 PM
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77_crew 77_crew is offline
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On another note. For all you guys that are building fuel tanks, id suggest that you invest in one of these. Its an inline fuel screen/filter that is re-buildable/washable. I bought mine from Napa for cheap and bought a couple extra screens too. My engine obviously has its main fuel filter, but this thing is clear so you can see what kind of gunk is coming out of you tank before it gets to your lift pump.

I noticed mine was starting to fill up with this black gunk/snot stuff so i decided to rebuild it. I assume its soot and residue left on the inside of my tank from the welding process...


Click the image to open in full size.
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1977 F250 4x4 Crew cab, 5.9 Cummins, ZF5, Divorced 205, Dana 60's
http://www.ford-trucks.com/forums/10...ins-build.html
1977 F250 4x4 Reg Cab highboy, 460, C6, Divorced 205
http://www.ford-trucks.com/forums/12...ter-truck.html
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  #367  
Old 07-11-2014, 10:24 PM
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I also got around to installing my new e-brake cables. I ordered new ones from JBG that were the same length as each other with a longer sheath than my originals. The problem was that the crossmember that the cables originally mounted into is the crossmember that is directly in front of my fuel tank. And now that the truck is lifted doesn't help things either. I took apart the rear brake/hub assemblies and installed the new cables. i then fabbed a cross plate that spanned from crossmember to crossmember with a drop plate to accept the cable ends. It actually worked out really well and the cable ends are within a 1/4" of the front cable ends...perfect. I still need to make something to hook the two cables together, or find the original parts somewhere..


Click the image to open in full size.


Click the image to open in full size.


Click the image to open in full size.
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1977 F250 4x4 Crew cab, 5.9 Cummins, ZF5, Divorced 205, Dana 60's
http://www.ford-trucks.com/forums/10...ins-build.html
1977 F250 4x4 Reg Cab highboy, 460, C6, Divorced 205
http://www.ford-trucks.com/forums/12...ter-truck.html
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  #368  
Old 08-12-2014, 12:16 AM
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Well its been quite a while since my last update so i figured i'd give you a progress update. I haven't made a whole lot of progress but i was on holidays for the last week and a half... We rode the motorcycles down to Nashville and toured around down there, so it was kind of hard to get any truck work done...But we had lots of fun! Some nice country down there, especially in the smoky mountains and in the area of the Blue Ridge Parkway!!

First off, i bought e-brake cable connectors from NAPA and got my e-brakes all hooked up and adjusted.

Secondly, I installed my cab lights. It was easy to do since i still don't have a windshield installed, so i sat on the dash and worked though the window opening. Still need to do the wiring, but all the original wiring is still there.

I also welded my new headlight adjusters onto the headlight assembly frame and i installed my headlights.

Next i took a look at my grill. it had a slight bit of damage on the lower right corner where a bumper must have been pushed back into it at some point. Nothing a little hammering couldn't fix. I then installed the grill. I haven't installed the grill inserts yet. I'll do that last once the headlights have been adjusted and all the other lights/wiring is hooked up.

I also finished my upper rear door trim piece and got it installed. And i don't have any pictures of it yet, but i did get the last 3 small pieces of cab trim installed on the passenger side. The passenger side chrome trim is officially installed!! And it looks great!!! On to the drivers side. I don't have any trim mounted yet, but i did start riveting on the clips for the upper trim.

Now for some pics...

The quality of the pics isn't great because they are from my crappy phone...i still need to get my good camera fixed..


Click the image to open in full size.


Click the image to open in full size.
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1977 F250 4x4 Crew cab, 5.9 Cummins, ZF5, Divorced 205, Dana 60's
http://www.ford-trucks.com/forums/10...ins-build.html
1977 F250 4x4 Reg Cab highboy, 460, C6, Divorced 205
http://www.ford-trucks.com/forums/12...ter-truck.html
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  #369  
Old 08-12-2014, 12:40 AM
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77_crew 77_crew is offline
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My initial goal is to get the outside completed before i move onto the interior, but i know the day is going to come when i'm ready to install the interior and i don;t have stuff ready.

I borrowed an XLT door panel that had the two tone (blue and white) padded section above the arm rest from a friend as an example. I took the trim panels off of my front and rear door panels, and the example one i borrowed to an upholstery guy to have him copy the pattern on mine but with burgundy and silver. sorry i don't have any photos yet, but i dropped them off before i went on vacation and haven't talked to him yet..I hope they turn out nice!

I also dug out my selection of rear door panels so i can clean them up and spray them black. But here's my dilemma.

I have two driver's side door panels that both need some work and i can't decide which one to work with.


Click the image to open in full size.

The black one is mint on the outside and already has the holes to mount the upper padded panel, but almost all the mounting points on the back are snapped of. I think there is only one that is any good.

The tan one has all good mounting points, with the exception of one that might be a little rough, but it has a chunk missing and a bit of a crack on the upper rear corner...and no holes for the padded panel (minor).


Click the image to open in full size.


Click the image to open in full size.

So what do i do? Should i find a creative way to mount the black one? Or a way to fix the mounts?

Or do i try and repair the tan one by trying to epoxy a piece in there or something?

Any Tips or input is greatly appreciated...Has anyone fixed a door panel before?
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1977 F250 4x4 Crew cab, 5.9 Cummins, ZF5, Divorced 205, Dana 60's
http://www.ford-trucks.com/forums/10...ins-build.html
1977 F250 4x4 Reg Cab highboy, 460, C6, Divorced 205
http://www.ford-trucks.com/forums/12...ter-truck.html
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  #370  
Old 08-12-2014, 02:22 PM
oddfordjunkie oddfordjunkie is offline
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Forgot or didn't realize how big your truck is, what size tires do you plan on running?

I would use the black panel as all the repairs will be where you don't see them. There are a few threads on guys repairing the clip mounting areas, unfortunately I did not bookmark them on the computer but a little work with the search feature on the forum should find them pretty quick.
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  #371  
Old 08-12-2014, 07:19 PM
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Quote:
Originally Posted by oddfordjunkie View Post
Forgot or didn't realize how big your truck is, what size tires do you plan on running?

I would use the black panel as all the repairs will be where you don't see them. There are a few threads on guys repairing the clip mounting areas, unfortunately I did not bookmark them on the computer but a little work with the search feature on the forum should find them pretty quick.
Thanks, i will do a search and see if i can find out some more info...

I plan on running 37" Cooper STT's. Way back when, when i was rebuilding my axles, i had to decide what i was going to use for gearing. I had a set of 4.10's, and a rear 3.54. After talking to some friends that drive cummins powered trucks as daily drivers, they said that the optimal rpm for best fuel economy was around 1700 rpm. I wanted to run a taller tire, so i did the calculations with my ZF5 OD ratio, 4.10 gears, and 37" tires and it worked out right where i wanted to be in the RPM department. It was so long ago that i don't remember the exact numbers though.

I hope to order the tires in the next couple weeks. I can't wait to see them on there.
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1977 F250 4x4 Crew cab, 5.9 Cummins, ZF5, Divorced 205, Dana 60's
http://www.ford-trucks.com/forums/10...ins-build.html
1977 F250 4x4 Reg Cab highboy, 460, C6, Divorced 205
http://www.ford-trucks.com/forums/12...ter-truck.html
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  #372  
Old 08-14-2014, 12:43 AM
oddfordjunkie oddfordjunkie is offline
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With a ZF5, 3.73 and 35" tires I'm at 1,850 rpm at 60 mph so you should be good
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  #373  
Old 08-14-2014, 01:16 AM
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HardkaseDaddy HardkaseDaddy is offline
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Quote:
Originally Posted by 77_crew View Post
So what do i do? Should i find a creative way to mount the black one? Or a way to fix the mounts?

Or do i try and repair the tan one by trying to epoxy a piece in there or something?
I used a product called Rapid Fix. I used the glue and the powdered plastic to rebuild the mounting points on my door panels. I have used just the straight glue to bond a hard rubber and an abs fitting on the dishwasher in my house.

In my experience with it Rapid Fix actually does work the way the advertising says it will. Oh and don't worry, I am not a salesman for rapid fix.

http://www.rapid-fix.com/
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  #374  
Old 08-18-2014, 04:55 PM
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77_crew 77_crew is offline
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Quote:
Originally Posted by oddfordjunkie View Post
With a ZF5, 3.73 and 35" tires I'm at 1,850 rpm at 60 mph so you should be good
Good to know! Thanks.
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1977 F250 4x4 Crew cab, 5.9 Cummins, ZF5, Divorced 205, Dana 60's
http://www.ford-trucks.com/forums/10...ins-build.html
1977 F250 4x4 Reg Cab highboy, 460, C6, Divorced 205
http://www.ford-trucks.com/forums/12...ter-truck.html
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  #375  
Old 08-18-2014, 05:46 PM
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77_crew 77_crew is offline
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Quote:
Originally Posted by HardkaseDaddy View Post
I used a product called Rapid Fix. I used the glue and the powdered plastic to rebuild the mounting points on my door panels. I have used just the straight glue to bond a hard rubber and an abs fitting on the dishwasher in my house.

In my experience with it Rapid Fix actually does work the way the advertising says it will. Oh and don't worry, I am not a salesman for rapid fix.

http://www.rapid-fix.com/
Ya i have watched some videos on this stuff and it looks pretty good!! Nice to hear from someone that actually has experience with it!!

I saw where i can buy it online up here in Canada, so i asked at my local NAPA store if they have ever heard of it. They gave me some stuff that looks the same but with another name (which i can't seem to remember right now). They didn't have any in stock but had an open package behind the counter with a little out of it so they gave it to me for nothing. I haven't had a chance to try it yet though.

What i did do though is go to my storage trailer at my buddy's farm and dig out an old damaged door panel that i can use to cut off sections of mounting clips to glue onto my panel.
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1977 F250 4x4 Crew cab, 5.9 Cummins, ZF5, Divorced 205, Dana 60's
http://www.ford-trucks.com/forums/10...ins-build.html
1977 F250 4x4 Reg Cab highboy, 460, C6, Divorced 205
http://www.ford-trucks.com/forums/12...ter-truck.html
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Old 08-18-2014, 05:46 PM
 
 
 
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