Well, some of you may have seen I got a new project truck a few days ago, so I figured I would start a build thread because why not? I got started doing some basic stuff tonight and just removed the front clip and radiator but had to stop because theres a storm coming in. AC condenser was already out when I got the truck. Here are some of the first pictures!

 

Looking forward to the progress!

 

Aint nothing better than a build thread wuth lots of pics.

 

This will be fun!

 

What are your plans for the truck?

 

Thanks guys! This is going to be a long process! But I'm looking forward to it. Plans are to put my dana 60 under it and make it a 4wd dually, swap my powerstroke into it, and a few other small things. Engine swap is the main project but a paint job is also a big concern, the PO decided to go for an "industrial look" and paint half of it with gray floor sealer without taping. The engine looks really good though! Does anyone know where I can find dana 60 dually hub adapters?

 

Haven't been able to work on the truck all that much until today but we got the trans out! It was the first time I had pulled a trans out of one of these trucks. My buddy helped and luckily he has more experience with transmissions. That thing was heavy! we managed to get it out on 2 or 3 hours. I was surprised it only had 6 bolts holding the bellhousing on. My friends BMW has a 5 speed manual that we dropped and it had 9 bolts! Also about 200lbs lighter.









Also pulled the turbo this past week! Much easier than I am expecting my powerstroke to be. The turbo was filled with oil, so much so that as soon as I removed the intake hose it poured out the side.






Just ordered my bellowed up-pipes from Riffraff! I'm sure it will be $500 well spent.

 

What turbo is that?

 

Banks Sidewinder for the IDI.

 

The IDI is out! We got it out in a few hours but needed a much heavier duty stand. Now to get started with wiring and the front axle.

 

Looks like someone put some work into that IDI. Did you ever hear it run? Probably a dumb question, but why not just swap the rear ends and make your a dually? Seems like an easier swap. Does it have significant rust issues or something?

 

The PO said it only had 40k on it and a rebuilt bottom end, so im guessing it was painted when it was getting rebuilt. It does look good, but I never heard it run. I am kind of worried because there is a lot of oil in the exhaust system. My powerstroke has significant rust, and the frame is getting unsafe in the back, and the cab has maybe 3 years left before its completely rusted out.

 

Sorry guys, I've been pretty busy the past few days so I havent taken many pictures or even gotten much done. I got the front suspension out and also my PSD turbo off. I can feel a bit of play in the shaft, which kind of worries me. How much play is too much? Also how do I get the compressor housing off? I am trying to put my new Riffraff wheel on but it does not want to budge even with the bolts out! Also got the rest of the front axle housing ground down so it is being painted now, but is being delayed because of rain. Now messing with the frame to put the leafs on will be the next tricky part. Dont know exactly what I am going to do. FInally, I think I might put an e-fuel setup on while everything is apart. Any recommendations to use? I think I'm going to get a Bosch 69136, which is the stock super duty pump if I am understanding correctly. What filter bases have you all used? I would like to do a 10 micron pre and a 2 micron post filter setup, preferably with CAT filters.

Some pics of the front suspension once out: