With the help of my cousin, who graciously allowed me the use of his shop and tools/equipment, I have nearly completed this truck as of this date. I am going to try to upload the photos in roughly the order that the work was done. I have seats to replace and all things in the bed left to do to include a B&W Gooseneck, toolbox, maybe transfer tank, and a spray in bedliner. At some point I will get into installing a Pac Brake as well.

As part of the build I swapped in a 12v Cummins that I got a good deal on. Initially I intended to swap it into my 2wd SuperCab, but it snowballed from there into what it is now.

The trucks I started with are:
1995 Dodge 2500
1993 CC 4wd SRW F-350
1992 CC 2wd DRW F-350

 

I'm going to post basic specs up front to get them out of the way.

Engine: 5.9 Cummins ~160k if I remember correctly
Head rebuilt with Pac Brake springs int/exh, new Cummins bolts
4,000 rpm governor kit
50hp injectors - Industrial Injection
KDP
AFC Live Stage 2, w/max travel
16* timing
Intercooler from 2000 7.3 PSD
Solid power nothing crazy.

Transmission: ZF-5 S-42, manual t-case
Transmission and Transfer Case were both completely rebuilt.
South bend single disc clutch (part of DCS conversion)

Axles:
Front: Dana 60
Complete rebuild with 3.73
Detroit Truetrac
New dually front hubs found locally
Warn Premium hubs

Rear: DRW 10.25
Complete rebuild with 3.73
Detroit Truetrac

All steering, suspension, springs, brakes, body mounts, A/C system is new.

 

I lost many of my pictures during this build so I don't have many specific photos, but can get some if there are any questions along the way.

First up for disassembly was the 4wd truck. It was an absolutely filthy mess. It had a 7.3 N/A (but with turbo) and ZF-5, but I later found out it was originally an automatic. To start required pouring gas in the intake. Blowby was very severe and the truck had puked oil underneath the entire length of the truck. Three separate washes with a caustic cleaner and a pressure washer got it reasonably clean. It was painted with a gallon of Chassis black paint.

Then tanks were opened up and I replaced the shower heads in both.

I ordered 4 new springs from SD Truck Springs according to the spring code on the door, but I feel like they lifted the truck a good bit. More than I would relate to sag.

All the steering, susp., and brakes came from Rockauto. I used Moog and Motorcraft everywhere it was available.

 

Transmission/T-case as it came back from rebuilder.

Again, the process will seem fragmented because I lost many of my photos near the end of the project.

 

Trial fitting the engine/trans with the frame and cab. DCS components were used for the conversion. The lip formed by the firewall and trans tunnel had to be rolled back to clear the bellhousing and exhaust. Everything was shifted 2" rearward; accommodations were easily made with the trans crossmember, shifter openings, and of course modified driveshafts.

 

Next was pulling engine/trans and getting the body put together while gutting the cab entirely in preparation for paint. I found a dually bed that was a new take off in 1996 to make a welding truck. It sat unused for 20 years until I bought it.

 

While the truck was out at paint work was started on the engine, getting it ready to be installed. I chose Detroit Diesel green for the engine because Detroit Diesel.

 

Now the task was to make all fluid and electrical connections to make the thing run. DCS was a help in getting the groundwork laid out although I ran into some problems along the way. My priority was to have a 100% reliable and functional truck. I am glossing over many, many, details in doing this quick write-up but if there is any interest in the details I can answer questions or give advise to anyone attempting a project like this. I made many mistakes and learned lessons the hard way. Sometimes more than once.

 

These are the latest pics I have of the truck. I had the interior panels and dash refinished and replaced pretty much everything inside. I am waiting to decide on Super Duty seats or recovering what is in it currently. I had custom A/C hoses made up recently as well to get that functioning.

Wheels and Tires are 16x6 Alcoa's with 235/85-16 Michelin XPS Traction.

 

Looks great! I really like the color combo and wheels.

 

Beautiful truck!

 

great job!

 

Looks good. Any pics of it making the marks in the driveway?

 

Those aren't my marks! I want to get all the little bugs worked out before I go breaking stuff. This truck flexes like a wet noodle when I get on it. So far this week I got the cruise control working which then made me fix the speedo wavering. Only 1-2 mph but enough to make the cruise hunt. Next up is brake controller and the junction box for all the trailer wiring.

I had it painted with the codes off of my F-250 shown carrying the bed because I planned to get rid of it, but now I don't want to. It's been a great truck since I bought it close to 4 years ago.

 

My brother had a brand new '91 extend cab with long bed. I was used to the '90 F150 I had at the time, and commented on the flex and bounce his truck had. It's what they do...

Don't sell the F250...find a F150 regular cab and paint the same as the other two. LOL