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  #61  
Old 01-03-2014, 06:25 PM
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I got the tunnel done. It wasn't too bad to do. I 2 pieced it. I cut up in the firewall so high to get room it was easier to fit one for the upper then one for the lower. I tacked them in many places, then used body seam sealer over the edges. It turned out quite well I think.

I didn't do this just for the heck of it, I did it because it was what i wanted. If it was something that I didn't think I could do, or thought it wouldn't turn out good, I wouldn't have done it. I knew it was going to take some time and be kind of a pain. I kinda like doing this stuff though.

Here's a few pictures of the finished product.







Tomorrow I'm gonna work on the axle. My hub bearings didn't show up yet, but could be here tomorrow.
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Darin 99 ranger 76F250 66 fairlane
"TheBeast"1997F2504x4dually4.10's,160k,140VIDM,HPX ,4-5"dp, S366 turbo w/wicked wheel, 6637, elec. fuel,rosewood stage ones,php hydra,arp studs, comp springs, smith brothers push rods, honeybadgerjr hpop,riffraff res,melling lpop,180 tstat,6.0 fan and IC,trucool,coolant filter,scan gauge,lots of other gauges,racer x valve body and billet converter, upgraded trans, F550 leaf springs,SD dual tensioner upgrade, cold ac mod
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  #62  
Old 01-03-2014, 06:30 PM
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Looks good Darin! I took a lot more out of mine, and probably didn't need to, but I got all kinds of room in there now.
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'95 F350 CCLB 4x4 dually,ZF 5spd,4.10,Rosewood Stage 2s,T500,S366,IC,Tony Wildman tunes,e-fuel,6637,CCV mod,3.5" DP,Diamond Eye 5" exhaust,Valair clutch,IH water pump,Scangauge,GlowShift gauges
'92 F350 CCLB 4x4,ZF 5spd,4.10,460 gas to PSD conversion project truck
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  #63  
Old 01-03-2014, 06:33 PM
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Looks good Darin.
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Mistress 1994 f350 CCLB DRW 7.3 Power stroke ZF5 4x4,TS 6 Position Chip, 6637 filter,Rancho RS 5000 shocks,
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  #64  
Old 01-03-2014, 06:48 PM
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Thanks guys! I've got at least 1/4 inch anywhere around it, and its only that close in one spot.
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Darin 99 ranger 76F250 66 fairlane
"TheBeast"1997F2504x4dually4.10's,160k,140VIDM,HPX ,4-5"dp, S366 turbo w/wicked wheel, 6637, elec. fuel,rosewood stage ones,php hydra,arp studs, comp springs, smith brothers push rods, honeybadgerjr hpop,riffraff res,melling lpop,180 tstat,6.0 fan and IC,trucool,coolant filter,scan gauge,lots of other gauges,racer x valve body and billet converter, upgraded trans, F550 leaf springs,SD dual tensioner upgrade, cold ac mod
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  #65  
Old 01-03-2014, 07:01 PM
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That looks good Darin! That will make it a lot less of a headache to do what you want to do with the exhaust in the future too. I doubt you'll ever regret having tunneled it out.
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  #66  
Old 01-03-2014, 07:11 PM
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Originally Posted by DIYMechanic View Post
That looks good Darin! That will make it a lot less of a headache to do what you want to do with the exhaust in the future too. I doubt you'll ever regret having tunneled it out.
I don't know what else he could do after this! LOL! He's already got a culvert in there for a DP! LOL!!!
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'95 F350 CCLB 4x4 dually,ZF 5spd,4.10,Rosewood Stage 2s,T500,S366,IC,Tony Wildman tunes,e-fuel,6637,CCV mod,3.5" DP,Diamond Eye 5" exhaust,Valair clutch,IH water pump,Scangauge,GlowShift gauges
'92 F350 CCLB 4x4,ZF 5spd,4.10,460 gas to PSD conversion project truck
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  #67  
Old 01-03-2014, 07:34 PM
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I don't know what else he could do after this! LOL! He's already got a culvert in there for a DP! LOL!!!
LOL! It almost looks like one when I lay it beside the 3 inch dp.

Thanks Nate! I don't see any reason I'll regret doing it. I had to do something as the dp was hitting the bellow. I figured if I'm gonna tunnel, I might as well make room for a big pipe! Now I don't have a cut up mess under there that I had from making room for the 3 inch either. Looks a lot better, makes me happy.
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Darin 99 ranger 76F250 66 fairlane
"TheBeast"1997F2504x4dually4.10's,160k,140VIDM,HPX ,4-5"dp, S366 turbo w/wicked wheel, 6637, elec. fuel,rosewood stage ones,php hydra,arp studs, comp springs, smith brothers push rods, honeybadgerjr hpop,riffraff res,melling lpop,180 tstat,6.0 fan and IC,trucool,coolant filter,scan gauge,lots of other gauges,racer x valve body and billet converter, upgraded trans, F550 leaf springs,SD dual tensioner upgrade, cold ac mod
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  #68  
Old 01-03-2014, 08:01 PM
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Originally Posted by 427 fordman View Post
LOL! It almost looks like one when I lay it beside the 3 inch dp.

Thanks Nate! I don't see any reason I'll regret doing it. I had to do something as the dp was hitting the bellow. I figured if I'm gonna tunnel, I might as well make room for a big pipe! Now I don't have a cut up mess under there that I had from making room for the 3 inch either. Looks a lot better, makes me happy.
My floor was split in two places at the pinch weld from where the 3" was put in before I bought the truck, and I made it worse pushing on it with the porta power trying to get the 3.5" in there, so I thought the same things as you....it's messed up anyway, so might as well tunnel it and do it right.
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'95 F350 CCLB 4x4 dually,ZF 5spd,4.10,Rosewood Stage 2s,T500,S366,IC,Tony Wildman tunes,e-fuel,6637,CCV mod,3.5" DP,Diamond Eye 5" exhaust,Valair clutch,IH water pump,Scangauge,GlowShift gauges
'92 F350 CCLB 4x4,ZF 5spd,4.10,460 gas to PSD conversion project truck
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  #69  
Old 01-03-2014, 08:42 PM
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How do you actually do it, start with a hole and use a saw zall? My firewall is a mess trying to clear that darn bellow. Nice job Darin!!
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The Mare 97 dually cc,modified s366 turbo,stage II's,IC,studs,springs,rods,JW auto,4:10 LS,air bags,SD uvch,efuel,FS2500 bypass oil filter,HVHF IDM,IH WP,6.0 trans cooler & rad fan,MBRP 4",SD tensioner,AFE air filter,220 amp alt,38 gal rear tank & 33 gal aux bed tank,aux oil cooler,soundproofed,3 different TS chips,ac cold mod,XS batteries,riffraff hpop reservoir,aluminum radiator,HoneyBadgerJr hpop, water injection
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  #70  
Old 01-03-2014, 09:07 PM
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How do you actually do it, start with a hole and use a saw zall? My firewall is a mess trying to clear that darn bellow. Nice job Darin!!
I used a cutting wheel on mine Glenn. A body saw would be ideal, but I don't have one.
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'95 F350 CCLB 4x4 dually,ZF 5spd,4.10,Rosewood Stage 2s,T500,S366,IC,Tony Wildman tunes,e-fuel,6637,CCV mod,3.5" DP,Diamond Eye 5" exhaust,Valair clutch,IH water pump,Scangauge,GlowShift gauges
'92 F350 CCLB 4x4,ZF 5spd,4.10,460 gas to PSD conversion project truck
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  #71  
Old 01-03-2014, 10:19 PM
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That makes sense.
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Glenn The Mule-96 2WD F250 EC/LB auto PSD
The Mare 97 dually cc,modified s366 turbo,stage II's,IC,studs,springs,rods,JW auto,4:10 LS,air bags,SD uvch,efuel,FS2500 bypass oil filter,HVHF IDM,IH WP,6.0 trans cooler & rad fan,MBRP 4",SD tensioner,AFE air filter,220 amp alt,38 gal rear tank & 33 gal aux bed tank,aux oil cooler,soundproofed,3 different TS chips,ac cold mod,XS batteries,riffraff hpop reservoir,aluminum radiator,HoneyBadgerJr hpop, water injection
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  #72  
Old 01-04-2014, 06:21 AM
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Thanks Glenn! That's what I used too, a cut off wheel and a sawzall combination. I cut a hole inside with a cutoff wheel first. Then I had to keep going up the firewall to make room, so the sawzall got involved. I absolutely couldn't go any higher on the outside edge of my hole, i'm into a dash bracket and some other thing on the inside. There are 4 more cuts on the top part of my hole on the firewall. I pushed the firewall back in more with them. I then covered them cuts with the upper part of my tunnel. A little seam sealer where I could and the same heat reflective stuff I used on the ac box put on the firewall.

I guarantee that dp was in and out at least 15 times between clearancing for and building it.
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Darin 99 ranger 76F250 66 fairlane
"TheBeast"1997F2504x4dually4.10's,160k,140VIDM,HPX ,4-5"dp, S366 turbo w/wicked wheel, 6637, elec. fuel,rosewood stage ones,php hydra,arp studs, comp springs, smith brothers push rods, honeybadgerjr hpop,riffraff res,melling lpop,180 tstat,6.0 fan and IC,trucool,coolant filter,scan gauge,lots of other gauges,racer x valve body and billet converter, upgraded trans, F550 leaf springs,SD dual tensioner upgrade, cold ac mod
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  #73  
Old 01-04-2014, 06:35 PM
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I got the new bearings on the gears and got them setup today. I didn't get quite as much done as I wanted, my granddaughter was around all day. I've got tomorrow and monday to work on it so I'll be ready to set the box on next weekend. It's supposed to be in the upper 30's or so, that'll work. Tomorrow and monday we are looking at -50 wind chills, so needless to say, I'll be in the shop.

My hub bearings showed up today so tomorrow I'll get those done and put the axle in the truck. Probably just piddle with a few little things tomorrow besides that.
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Darin 99 ranger 76F250 66 fairlane
"TheBeast"1997F2504x4dually4.10's,160k,140VIDM,HPX ,4-5"dp, S366 turbo w/wicked wheel, 6637, elec. fuel,rosewood stage ones,php hydra,arp studs, comp springs, smith brothers push rods, honeybadgerjr hpop,riffraff res,melling lpop,180 tstat,6.0 fan and IC,trucool,coolant filter,scan gauge,lots of other gauges,racer x valve body and billet converter, upgraded trans, F550 leaf springs,SD dual tensioner upgrade, cold ac mod
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  #74  
Old 01-04-2014, 07:06 PM
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Progress, can't wait to see it! Are you going to paint the box or have it done?

I'm waiting on a new fuel sending unit, that tank has been nothing but a PITA. I have thought about putting a stock one in, LOL
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Glenn The Mule-96 2WD F250 EC/LB auto PSD
The Mare 97 dually cc,modified s366 turbo,stage II's,IC,studs,springs,rods,JW auto,4:10 LS,air bags,SD uvch,efuel,FS2500 bypass oil filter,HVHF IDM,IH WP,6.0 trans cooler & rad fan,MBRP 4",SD tensioner,AFE air filter,220 amp alt,38 gal rear tank & 33 gal aux bed tank,aux oil cooler,soundproofed,3 different TS chips,ac cold mod,XS batteries,riffraff hpop reservoir,aluminum radiator,HoneyBadgerJr hpop, water injection
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Old 01-04-2014, 07:28 PM
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I hear ya! I'm getting it painted. Won't be til summer though. I want it to look good, and I'm really not a body man. If I get after it pretty good I could probably have the dually part done next weekend. We'll see how it goes. Still gotta get 2 more tires.

That tank has been a pain. So you gotta drop it again? I really couldn't afford to, or have time to, put one in mine right now with all the other things I have going on so I didn't. I don't think I ever will either. Although it would be nice, I don't go that far from home, and I've got an easy place to stop at for fuel when I go to Pierre to the race track. I hope you get it working Glenn.
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Darin 99 ranger 76F250 66 fairlane
"TheBeast"1997F2504x4dually4.10's,160k,140VIDM,HPX ,4-5"dp, S366 turbo w/wicked wheel, 6637, elec. fuel,rosewood stage ones,php hydra,arp studs, comp springs, smith brothers push rods, honeybadgerjr hpop,riffraff res,melling lpop,180 tstat,6.0 fan and IC,trucool,coolant filter,scan gauge,lots of other gauges,racer x valve body and billet converter, upgraded trans, F550 leaf springs,SD dual tensioner upgrade, cold ac mod
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Old 01-04-2014, 07:28 PM
 
 
 
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