1994 - 1996 F250 OBS Build

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05-04-2019, 11:49 AM

bdhenneke

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1994 - 1996 F250 OBS Build

Hey fellas, just wanted to share a project that I took on this winter/spring.

Started with two F250 extended cab trucks with 7.3Ls. One had been in a front end collision (96) and the other was sitting in a pasture for almost a decade (94). My plan was to just combine the best of both trucks into one good truck.

by https://www.flickr.com/photos/160669691@N05/, on Flickr

by https://www.flickr.com/photos/160669691@N05/, on Flickr

The frame on the wrecked truck was too far gone and the cab was tweaked pretty good so I knew most of the parts would come from the silver truck. First thing I did was start stripping down the 94 model so I could get the frame blasted and powdercoated.

by https://www.flickr.com/photos/160669691@N05/, on Flickr

by https://www.flickr.com/photos/160669691@N05/, on Flickr

Once the frame was stripped of the body and engine, the axles came off. They were 4:10 gears and the 96 had 3:55s. Wanted a little more top end speed so ended up using the 3:55s. Next step was to get the frame finished.

Before

by https://www.flickr.com/photos/160669691@N05/, on Flickr

After

by https://www.flickr.com/photos/160669691@N05/, on Flickr

While I was waiting for the frame to come back I started taking apart the 96.

by https://www.flickr.com/photos/160669691@N05/, on Flickr

by https://www.flickr.com/photos/160669691@N05/, on Flickr

At this point I realized the motor and wiring from the 96 were all in good shape so I would simply move all the components into the 94 body being that they are almost identical... Almost. Ha ha. So I dove into the turbo 7.3 and did a few upgrades and PM.

by https://www.flickr.com/photos/160669691@N05/, on Flickr

by https://www.flickr.com/photos/160669691@N05/, on Flickr

New oilpan, new oil cooler, pulled and checked all injectors, pulled and checked all glowplugs, oil pressure crossover, EBPV delete, new rear main seal, new valve cover gaskets and multiple o ring replacements. Went ahead and rebuilt the turbocharger too.

by https://www.flickr.com/photos/160669691@N05/, on Flickr

by https://www.flickr.com/photos/160669691@N05/, on Flickr

Since I was already going so far into this build I went ahead and picked up a Dana 60 axle to replace the worn out Dana 50.

by https://www.flickr.com/photos/160669691@N05/, on Flickr

Time for the fresh motor.

by https://www.flickr.com/photos/160669691@N05/, on Flickr

by https://www.flickr.com/photos/160669691@N05/, on Flickr

Next on the list was to get the cab painted. Ended up using a color from each truck just to keep the memory of the both around. Not sure if this color combo was ever offered by Ford or not. Thought it came out good though.

by https://www.flickr.com/photos/160669691@N05/, on Flickr

by https://www.flickr.com/photos/160669691@N05/, on Flickr

Probably not the easiest way to mount a cab but it worked out alright. After acquiring the Dana 60 I went ahead and bought a RSK and a set of Super Duty springs to try and soften up the ride a little. Went with V code springs but I wish I would have bought the Excursion springs. U code I believe. The V codes sit just a little too high for me.

by https://www.flickr.com/photos/160669691@N05/, on Flickr

As far as the interior goes I used the grey interior from the 94. Didnt really care for the maroon color in the 96. Also, the 94 had some custom seats in it that I wanted to use.

by https://www.flickr.com/photos/160669691@N05/, on Flickr

by https://www.flickr.com/photos/160669691@N05/, on Flickr

Once the interior was buttoned up it was time to finish up the body panels, hood, grill, lights, and bed.

by https://www.flickr.com/photos/160669691@N05/, on Flickr

by https://www.flickr.com/photos/160669691@N05/, on Flickr

I knew I was going to need new tires but wasn't sure how big I would need to go until I got everything mounted on the truck. Ended up going with 315/75R16 on the stock Alcoa rims. They rub more than I like when turning but they look good with the size of the lift.

by https://www.flickr.com/photos/160669691@N05/, on Flickr

by https://www.flickr.com/photos/160669691@N05/, on Flickr

One last thing... Ranch hand full replacement.

by https://www.flickr.com/photos/160669691@N05/, on Flickr

by https://www.flickr.com/photos/160669691@N05/, on Flickr

I'm very pleased with how it came out. It was a ton of work and there were some times where I wasn't sure if I was going to get it done, but it all came together. Countless hours of reading, turning wrenches, and more than a few cold beers and it is now complete. Probably going to hang on to this truck for a while!

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