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Offline husker77c

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Re: Zombie Ford F-350
« Reply #150 on: November 13, 2015, 04:46:18 PM »
Got a little bit more of that turkey fried








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Offline Bigdave_185

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Re: Zombie Ford F-350
« Reply #151 on: November 13, 2015, 05:14:44 PM »
Gobble gobble gobble


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Offline husker77c

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Re: Zombie Ford F-350
« Reply #152 on: November 15, 2015, 02:38:43 PM »
Gobble



Gobble



Gobble




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Offline husker77c

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Re: Zombie Ford F-350
« Reply #153 on: November 15, 2015, 02:42:05 PM »
On a serious note I do have a question. 

The deck of my block has very minor surface imperfections towards the outside edge.  Wondering if it's normal.  I would say it was cast that way because it looks like it was machined flat over the top of them. 

And them being towards the outside edge makes me think it should be fine. 






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Offline Flyin6

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Re: Zombie Ford F-350
« Reply #154 on: November 15, 2015, 06:17:48 PM »
No, sir that block is useless and no good what so ever.
Since it's junk, I'll just give you scrap iron prices for it and dispose of it for ya!

Be over in the morning! ;)
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Offline TexasRedNeck

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Re: Zombie Ford F-350
« Reply #155 on: November 15, 2015, 07:04:54 PM »
If in doubt, have it decked.
Kids today don't know how easy they have it. When I was young, I had to walk 9 feet through shag carpet to change the TV channel.

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Offline Bigdave_185

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Re: Zombie Ford F-350
« Reply #156 on: November 15, 2015, 07:32:55 PM »
That looks yummy!!


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Offline husker77c

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Re: Zombie Ford F-350
« Reply #157 on: November 16, 2015, 02:28:57 PM »
I'm not in doubt that much to take it apart and have it decked.  I'm going to continue prepping the deck and start putting it back together tomorrow. 

Dropped off my radiator to be cleaned and tested and it held pressure but was pretty plugged up with something.  They tried cleaning it with no luck.  So I'm in the market for a radiator.  Also had my factory injectors tested to make sure they're ok before I put them back in. 

Started putting my hydroboost conversion in today and figuring out how to adapt power steering hoses.   The hydroboost adds another wrinkle to an already super wrinkled situation. 






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Offline husker77c

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Re: Zombie Ford F-350
« Reply #158 on: November 18, 2015, 06:58:53 PM »
Got some more work done. 

Torqued down with the mighty diesel head bolts.



60# valve springs and titanium retainers.



Adapter plate installed. 



I have some other pics on my camera I'll throw up tomorrow.  Hope to finish buttoning it up and possibly put it in tomorrow night. 

I have some help coming in this weekend so I'll have three additional people on it.  Shooting to have it turning over by Sunday night. 

I have some fuel fittings that won't be here till Monday. Then Tuesday pick up my driveshafts and she should be a runner.


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Offline husker77c

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Re: Zombie Ford F-350
« Reply #159 on: November 19, 2015, 08:39:35 PM »
Almost ready to set in.



In and bolted down.


Should have it all hooked up and the tranny in by the end of tomorrow.  After that it's reassembly and fab mounts for the intercooler.  Starting to think about my exhaust situation.  May use flex pipe liberally to get it going.  I'm having difficulty finding an exhaust shop that can bend 4".  I know I'll have to fab up a downpipe but I think if I can get a 90 on the back of the turbo I can use flex pipe to connect to my existing exhaust. 




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Offline Bigdave_185

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Re: Zombie Ford F-350
« Reply #160 on: November 19, 2015, 09:21:38 PM »
That looks tasty for sure. 


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Offline husker77c

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Zombie Ford F-350
« Reply #161 on: November 21, 2015, 02:31:20 PM »
Engine is in and bolted down fully tranny is in.
Have to cut my floor pan to line up the transfer case shifter then the bottom can be buttoned up and measured for drive shaft on Monday. 

I'm running into all sorts of little problems.

AC in the way.


Mostly stuff like that so I go like crazy then have to stop and scratch my head for an hour   till I figure it out.   AC is probably coming out. I'm not able to use the factory condenser anyway so that will wait till summer to get fixed.  Only need heat the next 6 months anyway. 

Goal is to be started by tomorrow night.


« Last Edit: November 21, 2015, 02:32:15 PM by husker77c »

Offline cudakidd53

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Re: Zombie Ford F-350
« Reply #162 on: November 21, 2015, 02:41:03 PM »
Is there room to move the engine forward some?  Changing up the motor mounts might give you enough clearance if there's room to go forward.
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Offline KensAuto

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Re: Zombie Ford F-350
« Reply #163 on: November 21, 2015, 03:21:51 PM »
Have you researched what others have done? That's a pretty common swap...I'm sure there's an easy fix out there somewhere ?...?
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Offline husker77c

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Re: Zombie Ford F-350
« Reply #164 on: November 21, 2015, 04:44:03 PM »
There is.  People use an industrial manifold off of a bread truck or fed ex style truck.  Or they flip the manifold over so the turbo comes out the top.  The problem with flipping though is the compressor housing hits the exhaust so you have to put a spacer in.  And the wastegate hits the AC box that way.  No real way to make that work although some people have, I don't know how. Maybe a different wastegate actuator? 

There is no wiggle room in the mounts.  And as it is I had to modify my radiator support to move the radiator forward because it was hitting the fan.

I think I finally have the engine plumbed except for the radiator.   

Fuel lines are done. I had to rig up a remote fuel filter mount because the kid that took my motor out lost all the important things like banjo bolts and v band clamps etc.   

Remote mount will get finished up tonight.  I put ball valves on either side so I can change filters without losing prime.  One dedicated filter and a dedicated water separator.  I grabbed Napa filters for the time being but I plan on running Cat filters.

Power steering is done with the exception of the hydroboost return line.  Waiting on a fitting for that.  I think I'm going to lose the battery on the passenger side so I'll have to compensate for that somewhere.  If I was still in Texas I'm sure one battery would start it fine but up north I want two.   


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Offline Flyin6

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Re: Zombie Ford F-350
« Reply #165 on: November 21, 2015, 05:21:10 PM »
You are definitely making progress!
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Offline husker77c

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Re: Zombie Ford F-350
« Reply #166 on: November 21, 2015, 06:21:34 PM »
If anyone wants to chime in I have a question.  I'm starting to think about wiring up the starter.  I don't remember what went where on the 7.3 and I'm not sure I ever even knew to begin with. 

Let me see if I've got this correct. The passenger side fender has the starter relay.  One side of that goes to the starter.  The other side gets a smaller 12v wire from the battery. The ignition wire goes to the top little post. 
Does that sound correct?

Do I need to run a large wire from the battery to the starter and also the wire from the relay to the starter?   There is two big terminals on the starter. Assuming one gets the cable from relay and other gets cable from battery?   

I imagine I'm making this harder than I need to but googling isn't helping terribly much.


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Offline KensAuto

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Re: Zombie Ford F-350
« Reply #167 on: November 21, 2015, 09:12:11 PM »
The ford setup is battery cable to starter solenoid, another battery cable to one side of solenoid on fender. Other side of fender solenoid smaller gauge (10 iirc) down to starter solenoid small terminal. Small terminal on fender solenoid gets power from ignition.

Is this the starter you have ? or is it the newer, smaller style? If it's this style, the large terminal on top gets battery cable, large one on bottom hooks directly to starter motor, and the little one gets power from the fender solenoid (or you could discard that one and run straight from ignition).
I would keep it and maybe move it to the left fender and just run everything off the left battery.


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Offline husker77c

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Re: Zombie Ford F-350
« Reply #168 on: November 22, 2015, 06:19:48 PM »
Man it was one of those days. That is the type of starter I have.  So it shouldn't be too bad to wire. I'm going to have to throw another wrinkle in the mix.  I'm going to remote mount both my batteries to the tool box. I wanted to run an aux set back there but it will be primary until I can fab up some new battery trays for under the hood. 

I spent all day almost fabbing up the intercooler mounts and cutting my radiator support.  Landlord doesn't want me throwing sparks in my shop so I have to measure go to in laws house and cut and fab them back to shop to measure.  But it's starting to look like a truck again.



I'll get back at it in the morning. Still have a day or so before I will be able to start it up. 

I've set a new goal of having it running and moving by thanksgiving.  I'm not enjoying this anymore lol


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Offline husker77c

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Re: Zombie Ford F-350
« Reply #169 on: November 23, 2015, 06:36:45 PM »
Time for the daily update.  Engine just needs fluids and power for a test start.  Still have to fab intercooler pipes but I know what I'm gonna do so its just a matter of assembling.

Got tranny moved back and a couple bolts in the transfer case so I can mock up the driveshaft length and take it to the shop in the morning to be cut.  Gonna have all new spicer u joints put in.  I think the front one will still work. 

My solution for tranny mount instead of moving entire cross member.



Not my fab work but only cost $50 for that pretty set up.

Some small stuff remaining like throttle cable and fuel shutdown but I have plans for them so it's just a matter of execution.   

I've added so many new skills to the skill set on this project.   


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Offline stlaser

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Re: Zombie Ford F-350
« Reply #170 on: November 23, 2015, 07:24:40 PM »
I did a similar tranny mount on an 87 Monte Carlo I swapped a 5spd in to in high school. Nice welding skills there for $50
Living in the remote north hoping Ken doesn’t bring H up here any time soon…..

Offline KensAuto

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Re: Zombie Ford F-350
« Reply #171 on: November 24, 2015, 09:32:38 AM »
Yeah, the mount looks great for 50 bones.
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Offline JR

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Re: Zombie Ford F-350
« Reply #172 on: November 24, 2015, 12:17:18 PM »
What are the measurements on that cooler? I heard the ford fits the GM grill nice.

 

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Offline husker77c

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Re: Zombie Ford F-350
« Reply #173 on: November 24, 2015, 03:17:53 PM »

What are the measurements on that cooler? I heard the ford fits the GM grill nice.

That's a 2nd gen dodge intercooler.  I should have used a 95-97 powerstroke intercooler but I was trying to shave costs anywhere I could.   Saving $200 on a used intercooler cost me ~5 hrs of labor and $150 worth of extra parts.  Live and learn. 


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Offline KensAuto

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Re: Zombie Ford F-350
« Reply #174 on: November 24, 2015, 03:47:38 PM »
Man, isn't that the way it goes.
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Offline JR

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Re: Zombie Ford F-350
« Reply #175 on: November 24, 2015, 05:38:29 PM »
Funny, It looked like it fit to good!

I can get them new on ebay for around $200 once I verify fit.

thx
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Offline husker77c

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Re: Zombie Ford F-350
« Reply #176 on: November 24, 2015, 05:41:22 PM »

Man, isn't that the way it goes.

That is the whole story of this swap. Solving one problem creates two more. 

Daily update.

I just have to hook up my starter and battery cables and mount my batteries in the tool box and I'll be ready for my test start.  Going to drop off some stuff to my welder in the morning to get the exhaust workable. 

If the test start goes ok I'll be able to finish the exhaust and intercooler pipes then work on hacking up my grill to fit the cooler and it will be done. 

I already have some things I want to change but I need to get it running and moving and then we go on a shakedown run to MI this weekend if all goes according to plan.




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Offline JR

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Re: Zombie Ford F-350
« Reply #177 on: November 24, 2015, 05:45:05 PM »

Man, isn't that the way it goes.

That is the whole story of this swap. Solving one problem creates two more. 

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Thats how it goes with any swap and why we enjoy them!!
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Offline husker77c

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Re: Zombie Ford F-350
« Reply #178 on: November 29, 2015, 08:33:17 PM »
Victory



Should be able to take it for a drive tomorrow




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Offline KensAuto

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Re: Zombie Ford F-350
« Reply #179 on: November 29, 2015, 08:43:49 PM »
Congrats!
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Offline TexasRedNeck

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Re: Zombie Ford F-350
« Reply #180 on: November 29, 2015, 08:54:59 PM »
Very nice.  A cummins swap that runs!  (stickpoke:Don)
Kids today don't know how easy they have it. When I was young, I had to walk 9 feet through shag carpet to change the TV channel.

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Offline Sammconn

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Re: Zombie Ford F-350
« Reply #181 on: November 29, 2015, 10:32:51 PM »
Great job! Congrats!





Oh, how come you were able to do this so fast... 8)
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
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Offline husker77c

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Re: Zombie Ford F-350
« Reply #182 on: November 30, 2015, 08:53:24 AM »
I don't have the attention to detail some others on this board have.  I'm more of a quick and dirty kind of guy. 

And quick is a relative term.  I'd hoped to have it done in ten days. I'm close to a month


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Offline husker77c

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Re: Zombie Ford F-350
« Reply #183 on: November 30, 2015, 04:41:42 PM »



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Offline stlaser

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Re: Zombie Ford F-350
« Reply #184 on: November 30, 2015, 04:44:48 PM »
Congrats
Living in the remote north hoping Ken doesn’t bring H up here any time soon…..

Offline EL TATE

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Re: Zombie Ford F-350
« Reply #185 on: November 30, 2015, 06:57:21 PM »
Excellent work there sir.
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Offline Sammconn

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Re: Zombie Ford F-350
« Reply #186 on: November 30, 2015, 07:15:00 PM »
Moving under its own power. There's success!
Granted there may be some bugs still, but that's a huge step.
I just don't want to wind up missing a digit or limb.  I can sometimes get in a hurry to get results.
Sam

Offline cudakidd53

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Re: Zombie Ford F-350
« Reply #187 on: November 30, 2015, 09:50:14 PM »
What?  No SMOKE?  I thought those motors smoke a bunch when you first start them........#pokeDon  ::)
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Offline Flyin6

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Re: Zombie Ford F-350
« Reply #188 on: November 30, 2015, 10:22:38 PM »
Very nice.  A cummins swap that runs!  (stickpoke:Don)
I feel bad...
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Offline Bigdave_185

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Re: Zombie Ford F-350
« Reply #189 on: December 01, 2015, 11:23:04 AM »
That turkey looks like it survived the holiday!!  Congratulations.  Sounds like a dodge


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Offline JR

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Re: Zombie Ford F-350
« Reply #190 on: December 02, 2015, 04:07:56 AM »
Ahead of BD and me!
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Offline Flyin6

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Re: Zombie Ford F-350
« Reply #191 on: December 02, 2015, 12:14:39 PM »
Ahead of BD and me!
Apparently much farther ahead of me than I once thought!
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Offline husker77c

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Re: Zombie Ford F-350
« Reply #192 on: December 03, 2015, 08:10:07 AM »
Oh you guys really really really shouldn't feel bad.  I only had a month in the shop I rented so this truck is held together with duct tape and bailing wire.   Why do you think I haven't posted any more pics?   I'm not proud of some of the things I had to do to get it out of the shop.


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Offline TexasRedNeck

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Re: Zombie Ford F-350
« Reply #193 on: December 03, 2015, 08:30:29 AM »
As I remind my team frequently, don't let perfect be the enemy of good.  Sometimes getting moving is better than endless contemplation
Kids today don't know how easy they have it. When I was young, I had to walk 9 feet through shag carpet to change the TV channel.

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Offline husker77c

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Re: Zombie Ford F-350
« Reply #194 on: December 03, 2015, 10:41:41 AM »
Very true.  I can polish it up now that I can drive it.   There's so much still to do.  Transfer case linkage isn't hooked up, front driveshaft is in the bed,  I still have to mount and secure the second battery in under the hood. 

The long run of cable to the tool box was drawing too much current.  I let some magic smoke out of the cable ends while trying to crank it.  I got a couple Optimas that both fit on the drivers side.

I have a massive boost leak I have to find.  I'm only building 12# going up hill and if I don't get out of it the EGTs head for the moon.

The downpipe dumps into 3" flex pipe with no clamp because I can't fit one around it due to the starter. The flex pipe is tie wired up next to the frame and current exhaust. 

I've ordered the pieces to finish the exhaust but just regular shipping finally instead of next day air. 

There are some really cool optima battery trays on eBay I may get a couple to secure the batteries.

http://pages.ebay.com/link/?nav=item.view&alt=web&id=121693175529


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Offline EL TATE

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Re: Zombie Ford F-350
« Reply #195 on: December 03, 2015, 11:12:42 AM »
How would you go about finding the boost leak? Smoke test? I'm pretty sure I've got one also but don't know where to start.
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Offline husker77c

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Re: Zombie Ford F-350
« Reply #196 on: December 03, 2015, 12:18:56 PM »
Couple ways I've found. 

1) ether.  Spray it lightly around all the boots and places it could leak.  If it sucks the ether in you get a quick jump in your idle.  I tried that I didn't get anything though.  I'm not entirely sure of the theory because after the turbo all the piping is going to be pressurized. Even with a leak it should have at least some pressure which I would think would prevent ether from entering the system. 

2) build a boost leak detector.  It's basically some plumbing fittings from the hardware store with an air stem in the end.  I have to research a little further but i think it's a fernco rubber coupling with a pvc pipe cap on the end.  Drill a hole in the cap and insert air stem.  Shouldn't cost more than $10 to make.   Hook it up immediately after the turbo and apply about 20# of air to the system and listen for leaks.   Have to make sure you're regulated so you don't blow things apart.  From what I hear it's pretty easy to hear the leaks with that deal.  If you can't then spray soapy water on connections and look for bubbles.   

If you google boost leak detector you should bring up some threads other places that have pics and such. 


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Offline Bigdave_185

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Re: Zombie Ford F-350
« Reply #197 on: December 03, 2015, 07:26:25 PM »

As I remind my team frequently, don't let perfect be the enemy of good.  Sometimes getting moving is better than endless contemplation
wise words.

I am a IPC certified micro Tec.    Some people push so hard for target when acceptable is all that is needed.   Often times to correct something that is already  acceptable in means to achieve you usually scrap the part beyond use.   It's better to build from a manufacturing point of view to the acceptable level and if target happens great


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Offline husker77c

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Re: Zombie Ford F-350
« Reply #198 on: February 01, 2016, 06:18:11 PM »
Finally got the truck down to the new house from the in laws.  The 150 mile shakedown run was a success. Kind of.

I had suspicions the external voltage regulator wasn't working properly and I was right.  The alternator wasn't charging the entire trip.  I lost my speedometer about 75 miles into the trip and lost all my other gauges about 100 miles in.   The truck still ran no troubles other than the already known issues.  I knew it would run with zero electrical but to actually do it was a pretty cool feeling.  The only downfall was with the boost leak I have to keep an eye on my EGTs and when I lost all gauges I was blind.  I just made sure I babied it and didn't stay in the throttle going up hills. 

So today I got some work done on it.  Didn't take any pics along the way but I got both batteries mounted and tied together.  Also started on the rats nest of wiring with the regulator.   I have to get it running and charging first then I'll work on the boost leak then on exhaust. 




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Offline husker77c

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Re: Zombie Ford F-350
« Reply #199 on: February 02, 2016, 02:52:29 PM »
Figured out the voltage regulator issue.  Fuse duh haha

Also ran two 1/0 from the batteries to my distribution post instead of the one I had before. The post would get hot if it didn't crank immediately and this should help with that. 

Still a rats nest but coming along.





I'm going to re make the short piece from the distribution post to the fuse block and figure out something besides the twisted wires running into the second fuse block.  I had the fancy fuse block forever and didn't really know what to do with it so I figured I'd throw it in there and use it.   It has a built in voltmeter that I am going to hook to a switch so it's not a constant current draw.  Then I can flip a switch and check battery voltage and when the trucks running I'll be able to make sure the alternator is working.

Started so much stronger with the two runs of cable and two batteries.  Fired off in what seemed like an instant.   

As long as the weather holds out I'll start tackling the exhaust later this week.   Going to start a thread asking for tips on welding exhaust pipe in another section.


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