REAL MAN TRUCKWORKS & SURVIVAL

VEHICLES, CAMPERS, and BOATS => Build Threads => Topic started by: husker77c on March 10, 2015, 10:52:32 AM

Title: Zombie Ford F-350
Post by: husker77c on March 10, 2015, 10:52:32 AM
I figured I would jump in with both feet and share my ongoing project with you guys.  It's a 94 F-350 Crew cab long box with a 7.3L IDI, and a ZF5 transmission.

A little background on why I chose/was forced to do this build.

I worked pipeline construction for 12 or so years and I was always away from home.  Not just a few hours but usually 1000s of miles.  Ever since I read the book One Second After i always had the thought in my head about an EMP attack.  I know, I know its very unlikely that a scenario such as that would play out but I figured if I could build a vehicle to survive that then it should thrive in lesser threats.

I am also building this because I stopped pipelining a few years ago and moved to south Texas to try my hand at OG oil field work (frac, drilling, etc).  Well as many of you know the price of oil has tanked in the last few months and it has hit us pretty hard.  I've gone from 100+ hours a week, every week to no more than 40 hours a week.  I was barely making it before the cut in my hours due to some stupidity on my part in my previous life, and now with the cut its time to start selling toys and things I really don't need.  Thank the lord I still have a job even if its woefully inadequate currently.
   
None of that bothers me much because I am selling what I don't need.  I have 4 trucks currently a 2012 Ram 2500 CTD, two 97 Dodges with 12 valves in them, A harley, an 86 CJ7, and various other items.  Who needs all that?  Especially considering that most of it is still spread out over the country, Dodges in PA, Jeep in NE, etc.

OK background is done TL;DR version Im building my F350 to survive all threats short of a direct missile hit and I am doing it on a budget.

My requirements or plans for this truck include.

1) swapping one of the 12 valves into the truck eventually.  I will build it to provide a similar power level as my 2012.  I want reliable power, no twins or anything else that adds complication simple, tough, proven mods.

2) Increase off road capability (not going for rock crawler or mud truck here just make it more capable to navigate tore up    back roads or interstate shoulders that may be packed with people fleeing an incident).

3) Increase reliability i.e. make it darn near bulletproof.

4) Increase range

5) Increase creature comforts and have mobile communications.  I have my ham radio license so I am going to try to incorporate that into my interior build when it comes time for that.

I apologize in advance for how slow this build may have to go and along with that the corresponding updates.  I will do what I can with the budget I have and hopefully some things go my way and I can get it done by the end of the year.  Plus in the next month or so this will become my daily driver so doing anything that causes the truck to be down for more than a few days will have to planned very carefully so I can still get back and forth to work.

Imgur is slow uploading my photos.  I hoped to post some before I go to work but I may have to wait till this evening or tomorrow.





Title: Re: Zombie Ford F-350
Post by: Flyin6 on March 10, 2015, 11:08:50 AM
No apologies needed, friend!

We appreciate you bring this and sharing it with everyone. We are all the better for it. Build away at any pace you wish!
Title: Re: Zombie Ford F-350
Post by: husker77c on March 10, 2015, 11:18:16 AM
I bought this truck originally to save wear and tear on my 2012 Dodge running back and forth to oil field locations.

Before I did anything other than window tint.
(http://i.imgur.com/DtmC2sn.jpg)

She went through the major tornado that tore up Moore, OK a few years back so the body was kind of rough when she came home.  This is a little memorial to the tornado the previous owner did.
(http://i.imgur.com/qrUipTX.jpg)

(http://i.imgur.com/ABYJPhb.jpg)
Title: Re: Zombie Ford F-350
Post by: husker77c on March 10, 2015, 11:23:35 AM
I started on the body work first because most of my tools and parts are in storage in PA.

(http://i.imgur.com/pPVexIq.jpg)

(http://i.imgur.com/EtnI8kb.jpg)

Small dents like this all over
(http://i.imgur.com/ag6xauN.jpg)

I had never done any kind fo body work before this so it is a learning experience for me and it is much more difficult than I ever imagined.  Flat panels are easy with a hammer and dolly and a little filler but I'm having trouble with places where there is a body line.  Some of it will need to be redone before Paint but that's a long ways down the road and from a distance it looks OK

(http://i.imgur.com/UIkMzuX.jpg)
Title: Re: Zombie Ford F-350
Post by: husker77c on March 10, 2015, 11:35:02 AM
No amount of bondo in the world could save the bed so I searched for a few months to find a replacement.  Everyone wanted 5-700 dollars for one that wasn't even in decent shape.  I finally found one a couple hours from me off a F-150 $300 for the bed tail lights and harness.  He even had an overhead lift so we just sat it right on and bolted it down but first some things needed to be addressed under the bed.

These Fords have a known problem with the fuel pickup breaking off inside the tank which causes the truck to run out of fuel at a quarter tank.  Unacceptable, so I modified the pickups with a piece of fuel line so they extend all the way to the bottom of the tank.  I also ordered a 38 gallon rear replacement fuel tank for it.  I don't have any pictures of this process but If anyone has questions I can try to explain better what I did.

(http://i.imgur.com/RywPm0o.jpg)

Now with the factory 19 gallon front tank and the new 38 gallon rear I have 57 gallons on board fuel.  With the current IDI getting around 13 mpg I should be able to get 700+ miles out of this setup.  I have a combo auxiliary fuel tank tool box in PA that I am going to put in and when you add the extra 105 gallons of capacity it has that should bring my range to over 2100 miles before having to refuel.  That should cover my increase range requirement.   8)

And if I can eek 17-18 MPG out of the cummins, which with timing and tuning should be easily achievable.  That will give me 2600 miles + of range.  this should be more than enough to get well out of harms way if I go back on the road and start pipelining again next year
Title: Re: Zombie Ford F-350
Post by: EL TATE on March 10, 2015, 11:45:34 AM
Dents and all it's a good looking truck. I have to admit that I've always liked the earlier fords for pure truck styling. Nice work on fuel storage; I know who to target for siphoning :P
Title: Re: Zombie Ford F-350
Post by: BobbyB on March 10, 2015, 01:43:38 PM
I like this build. There are a few trucks of that body style for sale up around here with the 7.3, and I like them a lot.
Title: Re: Zombie Ford F-350
Post by: Flyin6 on March 10, 2015, 01:49:49 PM
I actually owned a 92 7.3 IDI truck. I added a hypermax turbo kit to it, turned the pump way up and WHEW it really woke that thing up. Mileage improved. When I traded Big red in on Great White a newer 94 PowerStroke, I'd have to say the IDI was right there with the stock PS.
Have you experimented with turning up the stock pump yet?
Title: Re: Zombie Ford F-350
Post by: husker77c on March 10, 2015, 02:18:03 PM
I haven't played with the idi much yet. I don't know much about the platform I've always been a cummins guy I just love the look of an older ford truck. 

The engine has 300k on it now and I have no clue how it was treated before I bought it.

Glow plugs are a beast I'm learning to hate. It starts really hard under 40*.  I replaced the glow plug relay and it starts better but still hesitant when it's chilly out.  I'm sure it needs a few plugs replaced so I will do that when funds allow because I have several more months of driving before I can think about starting the swap. And I have family and I've worked in some pretty frigid places so another requirement for the truck is to start in sub zero temps.   I've started my cummins no problem at -30 before and I know if the ford in its current state saw those temps it would be a block of ice till spring. Lol

Where would I start learning about tuning the injection pump?
Title: Re: Zombie Ford F-350
Post by: husker77c on March 10, 2015, 02:19:27 PM
I actually owned a 92 7.3 IDI truck. I added a hypermax turbo kit to it, turned the pump way up and WHEW it really woke that thing up. Mileage improved. When I traded Big red in on Great White a newer 94 PowerStroke, I'd have to say the IDI was right there with the stock PS.
Have you experimented with turning up the stock pump yet?

It's also funny you have the same names for trucks as I do.  One of my 97s is a 3500 we call big red and the other is a 2500 that is little red and my 2012 is great white.  Great minds haha
Title: Re: Zombie Ford F-350
Post by: Flyin6 on March 10, 2015, 08:45:57 PM
I haven't played with the idi much yet. I don't know much about the platform I've always been a cummins guy I just love the look of an older ford truck. 

The engine has 300k on it now and I have no clue how it was treated before I bought it.

Glow plugs are a beast I'm learning to hate. It starts really hard under 40*.  I replaced the glow plug relay and it starts better but still hesitant when it's chilly out.  I'm sure it needs a few plugs replaced so I will do that when funds allow because I have several more months of driving before I can think about starting the swap. And I have family and I've worked in some pretty frigid places so another requirement for the truck is to start in sub zero temps.   I've started my cummins no problem at -30 before and I know if the ford in its current state saw those temps it would be a block of ice till spring. Lol

Where would I start learning about tuning the injection pump?
Ya know, I forgot about that.
My IDI wouldn't start either...Can't make it start
Cummins
Definitely!
Title: Re: Zombie Ford F-350
Post by: Flyin6 on March 10, 2015, 08:49:00 PM
I actually owned a 92 7.3 IDI truck. I added a hypermax turbo kit to it, turned the pump way up and WHEW it really woke that thing up. Mileage improved. When I traded Big red in on Great White a newer 94 PowerStroke, I'd have to say the IDI was right there with the stock PS.
Have you experimented with turning up the stock pump yet?

It's also funny you have the same names for trucks as I do.  One of my 97s is a 3500 we call big red and the other is a 2500 that is little red and my 2012 is great white.  Great minds haha
Cool!

Yep Great white was dead on cool. A plain jane F250 XL. Rubber floor, AM radio, now power anything. Only option was AC. Had a 5 speed and a 4.10 gear. I lifted it 6", ran 33" mud tires, built a crazy set of bumpers and built the engine. While I was getting divorced, the X sold it on me without my knowing...Yup...
Title: Re: Zombie Ford F-350
Post by: JR on March 10, 2015, 10:01:57 PM
Man it is getting busy around here, and the cummins are here in force.
Title: Re: Zombie Ford F-350
Post by: OldKooT on March 11, 2015, 08:13:00 AM
Go Huskers!!!!  Ok a little premature but we can use all the help we can get LoL

Those are good old Ford trucks, I look forward to watching the build while I putz around with our build. As for starting....it's a International....don't drive it when cold LoL

Title: Re: Zombie Ford F-350
Post by: Flyin6 on March 11, 2015, 09:36:03 AM
I have to admit, I have a real soft spot for these trucks as well, the F350's that is.  Sitting up a few inches with that big brawny D60 sitting there for all to see, they look great.

The common denominator for all these builds is the 12 valve Cummins engine. Whether it's a classic 1st gen Dodge, a 80's Chevy, or one of these Fords, with the 12 valve providing the push, any of these trucks becomes a total lifetime keeper.
Title: Re: Zombie Ford F-350
Post by: BobbyB on March 11, 2015, 10:36:57 AM
I have to admit, I have a real soft spot for these trucks as well, the F350's that is.  Sitting up a few inches with that big brawny D60 sitting there for all to see, they look great.


Well then lookie at this beasty:

http://greenbay.craigslist.org/cto/4923475114.html
Title: Re: Zombie Ford F-350
Post by: husker77c on March 11, 2015, 10:51:45 AM
I have to admit, I have a real soft spot for these trucks as well, the F350's that is.  Sitting up a few inches with that big brawny D60 sitting there for all to see, they look great.


Well then lookie at this beasty:

http://greenbay.craigslist.org/cto/4923475114.html



Holy rust batman, Green bay...what do you expect i guess.  That's the exact amount I paid for mine.  I kind of want that bumper.

Bobby are you around GB?  My dad lives in Escanaba, MI and I lived up there for about 6 years.  That is the frigid location I was referring to a couple posts up.
Title: Re: Zombie Ford F-350
Post by: husker77c on March 11, 2015, 11:02:34 AM
Ok I had to go to work yesterday so I didn't get all of my pics uploaded in time so I will finish up here and bring you all up to where I stand today.

The new bed when I brought it home, I even like the plain tailgate with the big ford logo better than the later years.

(http://i.imgur.com/YqrrzbQ.jpg)

More body work on the bedsides but overall it was in great shape for the year.

(http://i.imgur.com/RdreaiN.jpg)

(http://i.imgur.com/WAw9DX3.jpg)

Started masking for the full coat of rattle can primer.

(http://i.imgur.com/nxplFaj.jpg)

And where it is now.  AHHHH a blank slate

(http://i.imgur.com/AG8zb1Z.jpg)



Title: Re: Zombie Ford F-350
Post by: husker77c on March 11, 2015, 11:33:39 AM
A few more

Closer look at the larger fuel tank  I used all thread because I wasn't sure if it would need to be raised or lowered in the frame rails to accommodate the bed.  and it was cheap and easy.  Took up all the room I have for my spare tire though.  I think a bumper mounted tire carrier will go on in the distant future but for now i'll Probably just bolt it in the bed

(http://i.imgur.com/4Ay6f8y.jpg)

Future prep for a trailer brake controller.  The truck when i got it had all the wires t-tapped for the trailer brakes and it was only a 4 pin flat connector.  I cut off the plug and soldered the wires into their respective spots and heat shrinked then covered with that liquid electrical tape stuff. 

(http://i.imgur.com/mS7AvhS.jpg)

(http://i.imgur.com/VrukXwk.jpg)

My only major problem with the bed swap.  This body line is not matching up.  I've researched and it seems to be a common problem for trucks like these with a lot of miles.  The cab body mount compresses and you get a mis alignment.  Other side is perfect.  It bothers me but not so much that I am going to take any corrective action for awhile.  doesn't hurt anything.

(http://i.imgur.com/RAEFjTX.jpg)

And the souvenir I saved from the original bed so I can tell people what she went through.

(http://i.imgur.com/OBNiBLU.jpg)


I just went on my days off rotation so I have 7 days off starting today.  My plans are to hopefully build an overhead shelf like Square D has and possibly extend it into an overhead console that runs back to the dome light.  It will look like I am copying Square D in some of my ideas but I swear I had them before I found this site lol.  The overhead shelf is an excellent place to mount my CB and VHF/UHF radios and give me a place for some light switches and other items.  I am also wanting to wire up some red overhead lights to be able to see in the dark without killing my night vision.  I'm leaning towards LED semi truck tail lights at this point but I havent figured out how to mount them or where to mount them.

After that I'm going to try to wire up some relays for my headlights to give them full voltage instead of having to run the voltage from the battery through the switch to the headlights through tiny wire.  Supposed to help tremendously.
Title: Re: Zombie Ford F-350
Post by: BobbyB on March 11, 2015, 11:46:58 AM
Holy rust batman, Green bay...what do you expect i guess.  That's the exact amount I paid for mine.  I kind of want that bumper.

Bobby are you around GB?  My dad lives in Escanaba, MI and I lived up there for about 6 years.  That is the frigid location I was referring to a couple posts up.

Yep there's rust. Pretty much unavoidable in this area.

I'm around the GB area.
Title: Re: Zombie Ford F-350
Post by: cruizng on March 11, 2015, 03:26:57 PM
I have to admit, I have a real soft spot for these trucks as well, the F350's that is.  Sitting up a few inches with that big brawny D60 sitting there for all to see, they look great.


Well then lookie at this beasty:

http://greenbay.craigslist.org/cto/4923475114.html



Holy rust batman, Green bay...what do you expect i guess.  That's the exact amount I paid for mine.  I kind of want that bumper. Husker... be careful what you wish for. Big D has a fat lip front bumper from his Square D that looks pretty close to that front bumper that he might part with!  :o

Bobby are you around GB?  My dad lives in Escanaba, MI and I lived up there for about 6 years.  That is the frigid location I was referring to a couple posts up.
Title: Re: Zombie Ford F-350
Post by: BobbyB on March 11, 2015, 04:49:53 PM
So it all seriousness adn wondering, how much work / how hard is it going to be to swap over the 12V?
Title: Re: Zombie Ford F-350
Post by: husker77c on March 11, 2015, 08:49:04 PM
So it all seriousness adn wondering, how much work / how hard is it going to be to swap over the 12V?


All the major pieces for the swap are available from various vendors.  I will probably buy the adapter plate for the transmission and the motor mounts.   Then just tear into it and piece it together as I go.  Kind of a haphazard plan but I haven't got to terribly deep in the research other than knowing parts are available and quite a few people have done it.  I believe the only main issues are the space for the turbo is a little tight in the passenger side. And it can get a little tight up front when you add the intercooler due to the cummins being longer than the Ford engine. 

It will be a pretty monumental undertaking for me anyway as I have never done anything like this before.   It's not completely out of my wheel house as I've done a lot of mechanic work on various vehicles I've owned in the past. But I'm not trying to pretend it's not a huge job. 

Add to that I am going to try to run a 250amp alternator off of a big rig and I'm researching an engine mount air compressor as well so that will add to the complication.  Air compressors came on some 12 valves that were originally in buses so the parts are out there but there is talk that some of them won't fit due to fender clearance on the drivers side. 

When I get the donor truck down here hopefully around Easter time I will start getting more serious about the swap.  First thing will be to pull the 12 valve and due a light rebuild.  Head studs, gaskets and whatever else it might need.  The donor only has 130k on it so I'm hoping to find factory cross hatching in the cylinders.  If that's the case then it will be mostly clean it up and do mostly external things.  I want to unbolt everything that's on it and give it all a good coat of paint and make sure it's ready to run a million miles.

Quite a few build threads over on cummins forum
Title: Re: Zombie Ford F-350
Post by: Flyin6 on March 11, 2015, 08:54:24 PM
How does one eat an elephant?

One bite at a time!
Title: Re: Zombie Ford F-350
Post by: Dustoff35 on March 13, 2015, 08:52:27 AM
I really like this generation of Ford truck.  Its going to be great with a 12v in it.  Take lots of pics!
Title: Re: Zombie Ford F-350
Post by: husker77c on March 13, 2015, 05:07:18 PM
Thanks for the compliments and words of encouragement guys they are appreciated.

As I stated above I am on my days off and I've been working on some cheap things I have wanted to do for awhile.

I started building an overhead shelf and overhead console for radios and lights etc.

I started off finding a bracket template online.  A piece of thin gauge steel and some jigsaw work later I had a couple brackets.

(http://i.imgur.com/o46mSKZ.jpg)

(http://i.imgur.com/A3wO9Hs.jpg)

I cut the shelf and after fitting it onto the brackets I realized it was going to be a little to large.  SO i cut out a portion over the drivers head to allow for some more room it also created a perfect angled spot to mount a CB or other radio.

(http://i.imgur.com/CTRYPU5.jpg)

Here I am mocking up the center portion of the console  It was originally going to be straight all the way back to the dome light but after looking at it I saw I could angle it down and create the other spot for another radio.  This way I can have a dual band mounted overhead as well as a CB.

(http://i.imgur.com/YhvI61H.jpg)

I can't decide If I want to try to keep the factory dome light and attach it to the console or just use the two 2" truck lights I got for that purpose.  They are both clear lenses but one is white LEDs and one is red.  I will wire the clear into the factory switched dome light wiring and wire both the clear and the red to separate switches so I will have the clear when I open the door and then with the door closed I can run the red, and or white at any time.

(http://i.imgur.com/V8tjWDT.jpg)

It all looks pretty rough currently but It will all get covered in carpet which will hide my amateur woodworking skills. And its rough due to the fact I built the whole thing with nothing but a jigsaw, because yet again all my tools are in storage with the exception of a few.

And an overall picture to show where I'm going with this.

(http://i.imgur.com/zBeEhP0.jpg)

It will attach just at the edge of the overhead shelf , I had to shove it in there farther to get it to hold up for the pic.  mostly all thats left is to wire in the lights, create some trim pieces to go between the shelf and the roof, and cover it then final assembly.

Title: Re: Zombie Ford F-350
Post by: Dawg25385 on March 13, 2015, 05:15:47 PM
Looks like pretty good woodworking skills to me! And all with a jigsaw! Wow nice work
Title: Re: Zombie Ford F-350
Post by: BobbyB on March 13, 2015, 09:34:26 PM
Looks good to me, my woodworking skills are subpar. I can design stuff in my head, but when it comes time to make it.. well there's a disconnect and it doesn't turn out how I thought it out. But I like the progress.
Title: Re: Zombie Ford F-350
Post by: JR on March 13, 2015, 09:44:23 PM
Great work, about to build one for the sub.

As a teaser, hers a shot of my old 77 interior. Both the overhead and the console was custom.

Just noticed you can see the behind the seat storage box too.
Title: Re: Zombie Ford F-350
Post by: husker77c on March 13, 2015, 11:15:59 PM
Great work, about to build one for the sub.

As a teaser, hers a shot of my old 77 interior. Both the overhead and the console was custom.

Just noticed you can see the behind the seat storage box too.

Thanks guys.

^^^^^ this pic right up here though is artwork. 

I worked at a car stereo shop right after I left college and learned that you can cover big problems with carpet. If you want to use vinyl to cover something you better have your skills tight and if you want to just finish the wood you need to be a master.  That's very nice work JR
Title: Re: Zombie Ford F-350
Post by: JR on March 13, 2015, 11:20:56 PM
Thanks. The center counsel I had done and a buddy made the overhead out of 060 alum. Used twist locks to hold up the back and it was hinged up front. Side was contact paper that matched the dash.

I never got to drive it much like that, had a garage fire and it sat until I finally sold it.

Title: Re: Zombie Ford F-350
Post by: Flyin6 on April 21, 2015, 09:39:44 PM
Any progress?
Title: Re: Zombie Ford F-350
Post by: husker77c on April 22, 2015, 10:45:25 PM
Any progress?

A little progress.  I am pretty close to completion of the overhead console.  It went through several small tweaks which basically meant me using darn near an entire 4x8 sheet of plywood to finish it.  When i made cut outs for the lights they were to big, so I had to cut a new shelf portion, then I decided I wanted to go another route with the lighting, I'm pretty happy with it now.  I'm still waiting on two 3/4" courtesy lights to show up from Amazon then I will wire those into the dome light and should be finished with it until I get my radios.  I'm debating on how to run additional wires up to it because there isn't enough room to run them all up through the A-pillar.  In the end I will probably copy Flyin6 and run some split loom up alongside the pillar to run the wires and antenna coaxes.

Here it is uncovered starting the wiring.
(http://i.imgur.com/ge6vFk6.jpg)

More wires and covered with carpet.
(http://i.imgur.com/m1nbLxX.jpg)

First switch plate for measurements and proof of concept.
(http://i.imgur.com/pVeyWYb.jpg)

Finished switch plate
(http://i.imgur.com/4vMqxsg.jpg)

And overall shot
(http://i.imgur.com/c4PNt6m.jpg)
IT also gives me a nice place to display all the patches I've picked up over the years.

Hopefully the rest of my lights will be delivered tomorrow and I can finish the console with the exception of running wiring down from the plethora of switches I installed for future expansion.  I have 8 standard switches and two with safety covers which in all honesty are not needed but look really cool and i've always wanted a vehicle with them. :)

I'm currently only using one switch to activate my red map lights.  Future lights hopefully will include front light bar, front fogs, roof light bar and reverse lights.  Safety switches are still up in the air.

Today I worked on wiring my headlights up to relays.  I had a headlight go out when I was leaving for my last 14 day hitch so while I was gone I ordered new Hella 100/80w bulbs, new headlight assemblies and all my relays and wiring to upgrade the stock 18ish gauge headlight wiring.  I ran 14 gauge to the lights via a relay so i should gain 1-3 volts over the crappy Ford design that runs from the battery through the switch back out to the lights. 

Tomorrow I will tackle pulling my grill and headlight assemblies.

Thats all for now
Title: Re: Zombie Ford F-350
Post by: JR on April 22, 2015, 11:33:11 PM
Careful you'll make her top heavy!!
Title: Re: Zombie Ford F-350
Post by: husker77c on April 23, 2015, 10:21:14 AM
Careful you'll make her top heavy!!

I won't be worried about that until it gets a topper, roof rack, and a spare tire up on the roof.  Since this is my post apocalyptic cruiser I figure it should have two spares. One on the bumper and one on the roof.   
Title: Re: Zombie Ford F-350
Post by: husker77c on July 11, 2015, 11:33:43 AM
Well the old Ford just made the 1400 mile trek up to where I am working so I can start updating this thread more often.

The truck will have an added purpose in addition to the duties layed out above.  It will be my pipeline Right Of Way truck.

I'm not going to beat my nice truck to death using it for work.  I don't want to pay though the nose to repair it back to stock if I break something, after having several issues with my aftermarket rims I have no desire to modify it any further.  I need it to stay reliable to haul my camper now that I'm back on the road working.

So the Zombie Ford is a much better candidate for this type of use because if something breaks I can modify it better than it was before and It's not as big of a waste as it would be with my good truck. 

Now I need some help

This is the type of terrain I will be dealing with, this is one of the milder hills I may have to negotiate.
There are occasions where I will have to be pulled up, or let down, some very steep hills.

(http://i.imgur.com/tPd2aIw.jpg)

That being said I need to build some bomb proof shackle mounts for the front of my truck, for the rear I am thinking about just using the reciever and  a shackle.

These mounts need to be able to support the weight of the truck being drug in neutral up the side of a mountain.  Also I figure while Im at it i will build a bumper around these mounts.

I got some images from the web of the bumper mounts on my Ford.  I don't want to pull mine off until I have a solid game plan.

(http://i.imgur.com/RmUJ1Bz.jpg)

(http://i.imgur.com/m7M4EYh.jpg)

My questions are numerous but the most glaring thing I'm wondering about is if the factory angle iron mount is going to be sturdy enough to meet my requirements?

If it is I was thinking of bolting a piece of flat bar between them and then welding the shackle mounts at a 90* angle from that piece.  From there they could protrude through the front of the bumper and be welded on both sides of the plate, or channel iron, front piece of the bumper.  I'm thinking that they are because almost every bolt on aftermarket bumper uses these and you can get shackle mounts on most of them.  But can i trust that you could basically lift the truck up with them?

If they aren't going to be strong enough then i was thinking about bolting some 1/2" flat bar to the outside of the frame rail sticking straight out. Those could then go through the bumper in the same fashion.

After I figure out how to attach the mounts to the bumper I will beef them up on both sides after they come through the bumper to where I have Approx a 1" thick mount drilled for a 1" shackle.  A Crosby 1" Shackle has a WLL of 8.5 tons so that should be more than enough for one shackle to be able to handle the load (although i would use both whenever possible).

Any thoughts?



Title: Re: Zombie Ford F-350
Post by: Flyin6 on July 11, 2015, 12:46:35 PM
Hey, I can help here

I actually did this on my 94 F250

The front of the frame finishes off as a flat surface, more or less.

I welded a piece of 7/16" plate over the end to cap it off, then welded clevis eyes like the ones I just welded onto SquareD yesterday in the middle of that plate. I thin built a bumper around all that business. It never failed me and I pulled all sorts of things...like my truck buried being yanked out by heavy equipment.

Hope this points the way
Title: Re: Zombie Ford F-350
Post by: JR on July 11, 2015, 01:09:08 PM
I would not trust bolting to the angle for what you need. As you said, run a plate to the frame and use multiple bolts to hold in place and mount the eye to that, build the bumper around it.

Depending on what you have to work with, have you seen the DIY bumper kits. Found them looking for ideas and they take alot of the work out of it. You just need a welder, all the bending is done, but could be tweaked.
Title: Re: Zombie Ford F-350
Post by: husker77c on July 11, 2015, 01:33:48 PM
Thanks for the help guys.   The plate over then end of the frame is by far the simplest way to go but I'm scared of that for one reason......I don't trust my welding.   I can stick two pieces of metal together well enough to hold the rest of the bumper together I'm sure.  I'd even trust my welding for the grill guard.  I'd trust it for that because if it fails the worst case scenario is some body damage and I have to build a new bumper.  If a shackle mount breaks while I'm being pulled the results would be catastrophic to say the least.  Backwards down a mountain while in neutral does not sound like a pleasant afternoon.  Anything to do with the shackle mounts my plan was to tack it in place and take it to a shop to have it welded out.  If I could use the bolt on method the bumper would be removable also.

I have seen the diy kits and  they are appealing. I've even tried to get ahold of the one I saw but never got a response from the vendor. Those kits are pretty slick and i will probably use one if I can find one

  I also found a local guy that would build me one for around $600. Basic bumper no grill guard.  He said his mounts would be strong but if it just mounts to that angle then it won't be strong enough. 
Title: Re: Zombie Ford F-350
Post by: KensAuto on July 11, 2015, 03:09:29 PM
Thanks for the help guys.   The plate over then end of the frame is by far the simplest way to go but I'm scared of that for one reason......I don't trust my welding. 
 

Soooo, i take it you're not a pipeline welder? lol

Anything strong enough to make it safe, must be welded or bolted to the frame....Don's idea sounds the easiest. Tack the plates on and have someone weld it up, if that's your only concern. You won't get a stronger attachment point than the very end of the frame (ie very little side loads). If a bumper is not in the budget at the time, just punch some square holes, for the shackles, thru the stocker for now.
Title: Re: Zombie Ford F-350
Post by: Sammconn on July 11, 2015, 04:08:54 PM
IF it were me I don't think I'd trust the factory mounts.
Never looked at the Ford ones and they could well be more significant than the sheet metal holding on the 40# chevy bumper. The factory chevy ones I do t think could pull the truck up an incline in loose dirt. Not much to them.
There should be a way to make something that is still bolt on.

If you've found someone that is willing to do it for $600 I'd jump all over it.
But make sure the mounts are to a higher spec for strength.

After I did mine, I realized why the charge so much.
It's a lot of time and effort, now I don't for one second regret the time spent on mine.
Title: Re: Zombie Ford F-350
Post by: JR on July 11, 2015, 05:21:35 PM
600 sounds like a great price, half of what many ready to bolt ons go for and about the same for  DIY by the time you pay shipping and get the welding done.

For what you want I think the strongest is get some plate and make the bumper mount that goes right down the frame rail and it held on by several bolts. Make it long enough so you can have the eye built on the same piece. That way there is no way a weld could fail and muiltiple bolts increase clamping area.

I bet you could make a template out of cardboard and have it made up for a fair price, like from Ron Bonnet or other fabricator. Then build the rest of the bumper around that.
Title: Re: Zombie Ford F-350
Post by: husker77c on July 12, 2015, 08:03:30 AM
Yes I am NOT a welder by trade. Kind of wished I'd have gone that way early on in life but I won't lose sleep over it.  I'm 99% a bumper I weld will handle a deer or a zombie but that 1% is what makes me second guess anything life threatening.

The $600 bumper is a great deal but it will still bolt to the factory angle iron mounts so I'm left relying on those for the ultimate strength of my tow points.

I'm leaning towards the mounts bolted to the side of the frame rails.  Probably use 1/2" plate or 5/8".  I was thinking last night if I went that way I could have a winch plate welded in on the bottom side of the two frame rail pieces to tie them together and allow a winch to be attached.

I probably will make a template and then take them to a machine shop to have the pieces built and welded together.  Once that's done then I can start building the bumper.   I'm leaning towards 10" channel that I will cut reliefs in the web to allow it to angle back and then I can cut wedges out of the bottom on the sides to angle it up towards the outside of the truck.  Then throw a piece of 3/16 plate on top of that and have the bumper done.  Very few welds and most of the strength of the channel will remain intact. The less welds the better so I'm not spending days grinding down my welds.   I have an idea for the grill guard using rectangular tubing for the uprights and square tubing for the headlight guards.  That will come after a little while though.  I want to get the basic structure down so I can put the truck to work first. 
Title: Re: Zombie Ford F-350
Post by: Flyin6 on July 12, 2015, 09:06:40 AM
Tell ya what, Just drive it over to my place and I'll weld those two little squares I spoke of earlier on myself. Then we'll lift the truck up in the air from that bumper with Big Red
Title: Re: Zombie Ford F-350
Post by: husker77c on July 23, 2015, 12:58:45 PM
A little update.  I've been driving the ford for work the past few days and started having some issues.   I posted a thread over in the drivetrain section about noises in hearing in the front end.    Well after a few days I have the noises I posted about and more clicks, clanks, bangs, and snaps than I can decipher.  So since the dodge is getting out of the shop today the ford will be parked until the front end can be addressed.   I put it in 4x4 a few hours ago and I have some really nasty noises that I am thinking is bad u joints again. Last night I crawled under it while my girl was turning the wel heel and he tie rod is rotating front to back and there is quite a lot of play in the steering before it catches and actually turns the wheels.   As per suggestion I jacked up the front wheels and checked the ball joints.  Let's just say the only thing they are doing is holding the knuckle on at this point.  A couple bolts and large washers would do the same thing.  So for the last hour I've been in my phone sourcing parts and price shopping for the parts here's what I found. 

This is for every seal and bearing on both ends of the axle, new u joints, ball joints and tie rod and tie rod ends. All moog brand steering gear, spicer u joints and timken or CR seals and bearings.

Rock auto is around $600 with shipping.

Napa was going to be close to $900 with Napa premium ends and joints and Napa brand u joints.

Advanced I stopped looking after the moog ball joint was a few dollars shy of double what rock auto had them for.

So after burning up the credit card I have everything on the way to completely rebuild the front end with the exception of anything in or attached to the pumpkin. 

I'm sure some of the noises are coming from the wore out leafs and their non existent bushings but those will have to be lived with until I decide what to do in the way of suspension mods.
Title: Re: Zombie Ford F-350
Post by: EL TATE on July 23, 2015, 01:09:15 PM
sounds like you done well. My dad had an 87 f250 xlt, 460 gasser. two lane truck was an understatement. you never knew which direction the suspension was going to kick the steering at any given bump. drove like a dream after I did same as you there. better to just get it all done at once.
Title: Re: Zombie Ford F-350
Post by: husker77c on July 23, 2015, 02:40:24 PM
Yep that's what I thought too.  Have to take the tie rods off to do the ball joints anyway so might as well do it once and get it done.   Front end work is arguably the worst work to do on a vehicle so I don't want to do it twice for sure.  I'm gonna start working out and hit the punching bag to prepare for an epic battle I'm sure.  Every time I've done something to the front end of one of my vehicles it sucks. I survive it......but just barely. 
Title: Re: Zombie Ford F-350
Post by: EL TATE on July 23, 2015, 04:16:54 PM
well with as much play as you have you are going to need an alignment since marking the ends with slop is asinine. spose you could do the old "trail alignment; have the wife hold the wheel and keep her straight, and measure distance between front of the insides of the tires and rear of the insides of the tire. give her a tiny bit toe out keeping the front inside distance a little bit wider and she should track right on down the road with good tire wear. Done that one more than a few times when breaking steering parts off road.
Title: Re: Zombie Ford F-350
Post by: husker77c on July 23, 2015, 04:50:21 PM
I will cowboy the alignment up to get it close then takebit for a spin and see what I've got.  If it's too bad there's a tire shop within a half mile from where I am so that's a last resort of I need it
Title: Re: Zombie Ford F-350
Post by: Flyin6 on July 24, 2015, 12:41:43 PM
There's another thing about these vintage Fords...bump steer.

We have discussed it before, but in this truck it was bad, mostly on the strange hinged Dana 50 equipped F250

Has to do with the angle of the steering link from the steering box to the far side.

I almost swapped ends with my F250 once and completely solved it by installing this cool helicopter like linkage that got the tie rods to a level stance
Title: Re: Zombie Ford F-350
Post by: husker77c on July 24, 2015, 01:34:24 PM
I will keep that in mind when installing the new parts.  It seems to just drive like an old truck currently but after checking things like you suggested I can see there is a whole world of room for improvement.   

Well with my 5% discount code it turned out to be $585 shipped for all the parts.  I don't think that's terrible for all that I got. 

I figured while my card was still smoldering I would just make it scream a little bit more.  I ordered a reverse shackle kit for it.   This kit puts the shackle at the rear of the front spring and mounts it solid at the front.   Supposed to give you a much improved ride and allows the use of super duty springs. 
With the shackle kit and the springs I should gain about 4" of lift in the front which will allow me to run 35s trouble free.  I may have to run taller blocks in the back or I may even do completely different springs back there.  The kit was right around 400 shipped and it comes with a track bar bracket to lower the track bar.   Found some junk yard SD springs for $75 ea so this is a fairly economical way to lift the truck while gaining a substantial increase in ride quality.

Hoping to pick up the springs next week and get started in all this.   When I pick up the springs I think I will change the bushings out for energy suspension units before I install them that way I know everything in the front end is as new as it can be. 

I may need a new pitman arm some say yes some say no so I'll see how it goes without it first. Also probably have some longer brake lines made up. 
Title: Re: Zombie Ford F-350
Post by: OldKooT on July 24, 2015, 05:06:57 PM
Is this a solid 60 front axle or a TTB 50 axle? Reason I ask is if it's a TTB axle, replace the center beam pivot bushing while you have it apart.
Title: Re: Zombie Ford F-350
Post by: Flyin6 on July 24, 2015, 08:08:17 PM
Is this a solid 60 front axle or a TTB 50 axle? Reason I ask is if it's a TTB axle, replace the center beam pivot bushing while you have it apart.
Norm,
F350 here...has a Dana 60, not that weird TTB D50 found in the F250's.
Good axle in this truck
Title: Re: Zombie Ford F-350
Post by: husker77c on July 27, 2015, 10:17:19 PM
A little update.  Here is my 97 getting the 12 valve lovingly plucked from between the frame rails.  Did some horse trading with a guy who is pulling the engine for me. Saves me from having to part out the truck like I was going to and I get the axles, engine and the wheels and tires.  He gets the rest of the truck and provides the labor to remove the parts.  I could have made a little more money on the deal but the time involved to do so wasn't worth it.  This way I roll up to his house pick up my parts and I'm done with it.

(http://i.imgur.com/74kiyLI.jpg)

Next pic is of my Dodge this afternoon which has me re thinking my original bumper plan.  Approach and departure angles are key with the type of terrain I'll be dealing with in the Ford.  The 10" channel iron I was thinking about for the bumper is going to down to 8" or possibly 6". Or maybe just build a strong center section and tubing up the sides.  Who knows just need clearance.  Thats my license plate almost dragging on the ground.  If you listen real close you can hear the rubber air dam on the bottom of the bumper screaming for dear life.

(http://i.imgur.com/zvyibJR.jpg)
Title: Re: Zombie Ford F-350
Post by: husker77c on August 07, 2015, 08:31:49 PM
A little update.  I didn't order enough parts to rebuild the front axle and I squandered my time that the girl was away for her work so that will be a bit before I tackle that.   But I am looking forward to it because of the sweet parts Mr El Tate hooked me up with.  Ended up buying the 35 spline stub shafts and the Yukon locking hubs so it should be bulletproof when I get done with it. 

Did some maintenance on it since I am still going to drive every so often to work. 

Changed the tranny fluid. It was a burnt up sludge that probably had never been changed.  Treated it to some Royal Purple full synthetic ATF and she shifts so much smoother now. Used to be a little hard to get in second gear.  Not broken parts hard just took a little extra effort and now it's smooth smooth. 

I did run into a problem I need some help with.  Before we moved the temperature gauge stopped going up to the normal spot between the O and R on normal on the gauge.  Also it was cool then and my heat wasn't blowing hot.  Didn't drive it very much after that but but I did drive it a bit when it was hot out and my AC wasn't blowing cold.   Thermostat right?  Yeah I thought so too. So I replaced the thermostat and just took it out for a drive.   Exact same thing. Temp gauge won't go up past the N and AC blowing warm.  I bought an autometer temp gauge and I installed the sender while I had the coolant drained for the Tstat but wasn't going to hook it up till I got some more things in the can squared away.  So I rigged up the gauge to the battery and the sending unit to get a temp reading and after the drive and idling in my parking spot the gauge is reading right around 190*.  The Tstat is a 195* Motorcraft part so that seems to be where it should be.   OK so the gauge must be bad right?  Well how do you explain the AC and heat issue?  If it was one or the other then might be easier to diagnose. Maybe AC needs services or heater core is plugged.   But it's both.  And I actually had to replace the heater core a month or so after I got it. 

I'm stumped.
Title: Re: Zombie Ford F-350
Post by: KensAuto on August 07, 2015, 10:17:07 PM
It could be 3 separate things. You know the gauge is bad (or the sending unit...you already proved it).
So, item #2, A/C not working. Is the compressor engaging? If so, is the drier getting cold?
#3, no heat. Both heater hoses should be whatever your temp gauge is reading (190ish). If only one hose is hot then there is a restriction on the other side...the one that's not so hot (I would doubt the core would be plugged already, but who knows). If both hoses are hot, then the air should be hot. The problem would then be in the dash.
Title: Re: Zombie Ford F-350
Post by: husker77c on August 08, 2015, 03:24:19 PM
Yeah I was planning on checking components next but I just find it odd that all three things went out at the same time.
Title: Re: Zombie Ford F-350
Post by: KensAuto on August 08, 2015, 04:51:32 PM
It is strange, but not rare.
Title: Re: Zombie Ford F-350
Post by: Nate on August 09, 2015, 12:01:46 AM
i would say its more a reality than anything.....ken, you know as well as I do that when you start to fix and replace one thing, they get a bit of an attitude and you end up having to fix and replace a few other things before they calm down and be good.
Title: Re: Zombie Ford F-350
Post by: EL TATE on August 10, 2015, 12:41:36 PM
I'm thinkin along the lines of Ken here; sudden loss of functionality on temp guage, ac and heater. sounds electrical in the dash, possibly harness, but if the baffles aren't moving on the heater you're only getting ambient air temp. if there is bad connection to the AC controls, compressor won't kick on, and even if it does kick on, if the truck still thinks your temp control setting is at 70+ it's not going to blow cold air.

Turn the AC on, set the temp controls to coldest setting and look for engagement of the compressor. If no worky, check the electrical at the controls. if it kicks on but no change in temp, look at the climate controls. I had a VW that blew hot air even in the dead of winter with the ac on, compressor spinning, and climate at it's coldest setting. the connection on the back of the control unit was corroded and no longer made contact.
Title: Re: Zombie Ford F-350
Post by: husker77c on August 11, 2015, 06:39:31 PM
Well I've narrowed the AC down a bit.  The compressor clutch isn't engaging so upon researching a bit I checked the low pressure switch on the dryer. Pulled it off and jumped it with a piece of wire and the clutch engaged.  So that narrows it down to either a faulty switch or its low on R134. I'm going to charge it a bit with some cans from autozone to see if it helps. If it doesn't then I know it's the switch.   I'm thinking about taking it to the shop though cause if it's low on r134 then I have a leak somewhere and I've heard horror stories about people putting AC stop leak in them and having to replace pretty much every component in the AC system. I guess it wreaks havoc with the o rings or something.   I thought about buying some gauges and doing it myself but after I get it fixed I would very rarely if ever need the gauges again.  I guess it depends on what a shop would charge.
Title: Re: Zombie Ford F-350
Post by: husker77c on August 17, 2015, 09:10:44 PM
Well the real work begins.

I got my AC fixed, was a low pressure switch combined with low R134.  Its blowing 38* out of the vents so thats good.

Decided to start tearing apart the axles.   My girl goes back to TX for work on Sunday so I figured if I got it started I could finish it after she leaves which leaves me two weeks of evenings to complete other projects.

I came apart relatively easy.  Until I got to the spindle.  Its stuck on like crazy.  Im going to go to Autozone to rent a slide hammer i think unless someone knows an easier way to remove them?

(http://i.imgur.com/8RpS9wz.jpg)

I got one of the races out easily and the other one was moving fairly well but it got kind of late and didn't want to completely neglect my girl and didn't want to annoy my neighbors beating on it.  There is some residue around where the seal was.  Any ideas on what it could be?  Part of it is green like the seal came apart and there is a yellow substance almost looks like old silicone or the like.

(http://i.imgur.com/z1dz5Qj.jpg)

My ball joints aren't as bad as I thought they were, in fact everything that I have taken out has been pretty decent except for the one seal I got to.
I might as well do the ball joints anyway so I know where I stand and I will know everything else is tip top when i get done.
Title: Re: Zombie Ford F-350
Post by: TexasRedNeck on August 17, 2015, 09:45:14 PM
not a dana expert but watching this to learn a few things.

What part of Texas is your girl going to?
Title: Re: Zombie Ford F-350
Post by: Sammconn on August 17, 2015, 10:12:48 PM
I suspect the green is the paint off of the seal. A lot I have done over the years were painted green.
The silicone like substance, not sure, may just be that, reason good question.
Title: Re: Zombie Ford F-350
Post by: KensAuto on August 17, 2015, 10:25:36 PM
I suspect the green is the paint off of the seal. A lot I have done over the years were painted green.
The silicone like substance, not sure, may just be that, reason good question.

Exactly.
Title: Re: Zombie Ford F-350
Post by: husker77c on August 18, 2015, 02:36:16 PM
Well I rained out today due to a flood last night.  It was kind of misting and cloudy so i was super excited to get to work on the Ford all day today.  i went by Autozone and rented all the tools I thought I might need and headed home set for a good day.  I got the spindle off and axle and stub shaft out.

i had to take the axle to a local shop to get the U-joint pressed out but after that I was good to go.

Layed out next to the BEEFY Yukon gear El Tate hooked me up with.

(http://i.imgur.com/dY5III8.jpg)

And with the new Ujoint and new 35 spline stub shaft.

(http://i.imgur.com/gy16N3L.jpg)

Then I set about finishing tearing down the hub and spindle to start building it back up.  Thats when I started really cleaning everything with brake cleaner and looking closely at what I have. 

What I have is a pretty wore out hub and a tore up spindle.


(http://i.imgur.com/FrE9QHg.jpg)

(http://i.imgur.com/IMzog3H.jpg)

(http://i.imgur.com/Er7q9QM.jpg)

Disappointed to say the least, Think I will change the name from Zombie to Money Pit F-350

Talked to El Tate and he gave me a couple options so I have to figure out how I want to proceed.  I need this done as the truck is on blocks in my parking lot.  And I'm actually thinking about ordering two while I'm at it for the other side.  That way I don't have to wait when I get into the other side next week.





Title: Re: Zombie Ford F-350
Post by: Flyin6 on August 18, 2015, 02:55:17 PM
Bro, those are some ugly pics!

All except for Tate's 35 spline axle stubs. I picked them up as well and pounded then into Square D. At least that is going for ya!
Title: Re: Zombie Ford F-350
Post by: Sammconn on August 18, 2015, 02:57:47 PM
That is nasty, and probably explains the silicone.
Title: Re: Zombie Ford F-350
Post by: husker77c on August 18, 2015, 03:09:17 PM
Yeah but like my girl said at least I found out now and not when a bearing decided to let loose and strand me in who knows where.

Tate got me all fixed up with a new spindle and a lead on some new hubs. They were so cheap I did buy two.  Hoping the other spindle is in good shape.

I should thank you Don this forum has saved me a boat load of money on this project thus far.  I'm going to end up with a nicely built axle for about the same price as a stock rebuild when I'm done.   I'm starting to come out of the closet a little bit too........













I have a small obsession with sled pulling.  This front axle will definately serve me well if I decide to go down that road in the future. 

What did you think I was going to say?
Title: Re: Zombie Ford F-350
Post by: Sammconn on August 18, 2015, 03:11:59 PM
Oh yes, going the full blown route that you've chosen is definitely the way to go.

Like you said, you only want to do this once!
Title: Re: Zombie Ford F-350
Post by: Flyin6 on August 18, 2015, 07:53:14 PM
Glad we can be of service

Thanks Tate, I know you're takin' care of the boyz!
Title: Re: Zombie Ford F-350
Post by: OldKooT on August 19, 2015, 04:48:42 PM
Bummer on the damage. But good you caught it ahead of time. For future reference the TTB Dana 50 front spindles and hubs are the same as the Dana 60 Ford stuff.

Title: Re: Zombie Ford F-350
Post by: husker77c on August 23, 2015, 07:59:27 AM
So I'm still waiting on hubs so I decided to go ahead and start on the ball joints.  I got them pressed out and new ones pressed in and now I'm ready to install the knuckle back on the axle.  Do I just put the stud of the ball joint into the C on the axle until I can get the nut started then suck them up with a socket?  I can get my impact on the top nut so can I use the impact to tighten that one which should in theory pull the lower one into position?  Is that the proper way?


Edit:

I just read the insert that comes with the ball joints and they had the torque procedure on them.  I guess that answers my question.  Hand tighten them in the C and then run em down to the torque required.   It's calling for  150# on the lower and 69# on the upper final torque. Am does that sound right?
Title: Re: Zombie Ford F-350
Post by: Flyin6 on August 23, 2015, 10:59:05 AM
Yes, that is correct...not as hard as you may think, will go easy for you I think

I am please that you are 1. Doing this yourself as it empowers you

and

2. That you are posting and documenting it as well for all the other readers who will attempt the same repairs
Title: Re: Zombie Ford F-350
Post by: husker77c on August 23, 2015, 12:56:42 PM
You were right the ball joints went on without a hitch.  A lot easier job than I was expecting, the press I rented made it smooth.

(http://i.imgur.com/2nmdMEg.jpg)

Im ready to install the axles now but is there an axle seal where I'm pointing?

(http://i.imgur.com/TAU2E29.jpg)




 I don't recall one coming out when i took it apart but with the condition of the other stuff it may have needed one but it was missing.  When I pulled the axle I started losing gear oil out of the tube so If I just put the axle back in i'm thinking that gear oil will still want to come out.  I googled info about the seal and apparently there is a seal that they came up with for that area but I sure didn't have one when i took it out.

Title: Re: Zombie Ford F-350
Post by: Flyin6 on August 23, 2015, 01:00:20 PM
I don't believe there is. The seal is inside near the diff
Title: Re: Zombie Ford F-350
Post by: OldKooT on August 23, 2015, 05:40:17 PM
Don nailed it, the seal is inside by the Diff. If the truck is relativity level and it's leaking gear lube out the axle tubes that's not abnormal really. The axle shaft provides the sealing surface, right now there is a 1.5" hole in the middle of the seal due to the missing axle shafts.

Right now would be a good time to make yourself a little "tube scraper" and carefully without pushing debris into the diff area, clean out your axle tubes. I use a half moon shaped piece of metal welded onto a hunk of rod long enough to reach into the tube.

Title: Re: Zombie Ford F-350
Post by: EL TATE on August 24, 2015, 07:03:13 PM
Yes, inner tube seal directly against the bearing cap. Are you leaking now?
Title: Re: Zombie Ford F-350
Post by: husker77c on August 24, 2015, 07:11:26 PM
Small Update.

I put this together as I have parts coming in so It's slower than id like.  It seems that each step only takes me a few minutes but overall its taken me two weeks to get to this point.  I should have everything ready for the other side though when it comes time for that unless a spindle is messed up.  Even if it is though Tate is drop shipping me parts from KY so i get them next day when i order through him.  Just waiting on the new/used hub to show up and I can install and pack the new wheel bearings and drivers side will be complete.  I'm going to replace my rotors and pads as well while I have it apart.   The rotors are pretty wore and they might be able to turn them but for $50 i figure what the heck. I'm already into this for a whole lot of money so whats another fiddy?

Kind of hard to see but here is the depth the rotors are worn.

(http://i.imgur.com/B96DU38.jpg)

Here is the axle installed in the housing waiting for the spindle, with a liberal coating of anti-seize should I ever have to go down this road again I don't want to fight it.

(http://i.imgur.com/dHhjlZo.jpg)



And finally all torqued down and ready to go.
(http://i.imgur.com/DoXB81l.jpg)

And my most recent Amazon order came in, I needed headlight bulbs for the Dodge and some Rage body filler for some final touch ups on the Ford. figured i would throw this on there for good measure.

Old school gun rack for the back window!

(http://i.imgur.com/EJPiqBk.jpg)

It will mostly be used for my hard hat but just figured it would be period correct for this year of truck.
Title: Re: Zombie Ford F-350
Post by: husker77c on August 24, 2015, 07:13:17 PM
Yes, inner tube seal directly against the bearing cap. Are you leaking now?

It leaked for a little bit when I first pulled the axles then stopped.  Its not perfectly level at the moment. 
Title: Re: Zombie Ford F-350
Post by: Dawg25385 on August 24, 2015, 07:13:28 PM
Yessss. The gun rack is legit


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Title: Re: Zombie Ford F-350
Post by: EL TATE on August 24, 2015, 11:09:16 PM
That'll do it.  Glad it was after axle removal
Title: Re: Zombie Ford F-350
Post by: husker77c on August 26, 2015, 07:32:00 PM
I'm spending more time waiting on parts than working on this thing at this point.

I got my new/used hubs in and set to work yesterday after I got home.  The hubs came with the old bearings and races in them so i got to work removing those and I have to say this is the second set I've removed and I am getting quite good at it, by the time I work on the passenger side I expect this to be similar to a NASCAR pit stop.

(http://i.imgur.com/5LGQ6TS.jpg)

Ive had my races chilling in the freezer for the past week so I put the hub into my hub heating oven and prepared to install them.

(http://i.imgur.com/vigmeFI.jpg)

I'm not sure the freezing and heating part even did anything.  When I read about that method I had envisioned the race freely dropping into its seat and then magically expanding to a perfect install.  Not so much, I still had to use the old race and a hammer to get them set in place so I doubt I will do that again.

Then I got out the wheel bearings and prepared to get them packed and installed when I realized I had no wheel studs on the hub.  Figured it wasn't a good idea to be pounding wheel studs in with the bearings in it so I called it quits for the day.

(http://i.imgur.com/gSopEzL.jpg)

Today I woke up went to work then started ordering brake parts.  I got new rotors and a new set of pads and also ordered 8 new wheel studs.  Went in after work to pick them up and I ordered rear studs instead of front and of course they don't have them in stock for the front.  When I asked him how long to get them in he said 4-5 days.  What in this world takes 4-5 days to get?  I would have ordered them from NAPA, but they keep bankers hours and I definitely don't work bankers hours.  Tomorrow Im going to sneak away from work and run to NAPA to see if they have them.  If not at least I know I will have them by the weekend.  Got the rotors and pads though.

(http://i.imgur.com/RzkTeLO.jpg)

I am correct in assuming that if I replace the rotors I should replace the studs?

Title: Re: Zombie Ford F-350
Post by: Flyin6 on August 26, 2015, 09:41:00 PM
Yes, buy new studs

Here's a trick I learned: Buy Dually studs, they are longer!

Just check the shank size to make sure they fit, but you can get a stud nearly 3" long in some instances which allows you to use a thicker lug not, and helps you to get the wheel on a bit more easily as all that sticks out a bit more...Looks cool too!

Check them out on Square D

And some manufacturers used a 1/2" stud

Replace those with 9/16-18 studs and add a ton of strength for essentially no more cost
Title: Re: Zombie Ford F-350
Post by: husker77c on August 28, 2015, 08:05:33 PM
OK need some help.
I got my wheel studs and got the hub on the spindle.
(http://i.imgur.com/aJztUJv.jpg)

I set the bearing preload to 50 lb/ft and backed off a quarter turn. 

Now for the life of me I can't get the lock ring to line up with the stud on the inner nut.
(http://i.imgur.com/b6pGpmF.jpg)

Is there a trick I should know?  how can i be sure that my pre load is still set if I have to keep moving the inner nut around trying to get it to line up?  please tell me there is an easier way besides wiggle the lock in there, pull it out, move nut, repeat until I'm ready to kick something.
Title: Re: Zombie Ford F-350
Post by: Flyin6 on August 28, 2015, 11:25:06 PM
I am not sure what to tell you. That part is a living horror story. Seems you either get it or you don't. Trying moving the nut a bit left and right and accept the preload which is left. That's what I do...
Title: Re: Zombie Ford F-350
Post by: KensAuto on August 29, 2015, 02:17:57 AM
Be sure to try flipping the washer. ...the holes are offset 1/2 of a hole from one side to the other,  then use a 90* pick to feel the pin and to move it if needed.

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Title: Re: Zombie Ford F-350
Post by: Sammconn on August 29, 2015, 11:43:58 AM
Be sure to try flipping the washer. ...the holes are offset 1/2 of a hole from one side to the other.


That I did not know.


You'll get this together. I'm with Don as well, have to sometimes accept what you're left with.
Title: Re: Zombie Ford F-350
Post by: OldKooT on August 29, 2015, 05:09:22 PM
Yeah what Ken said... flipping the washer usually does the trick. I tend to always swap my front 60 axles to 14 Bolt Chevy wheel bearing nuts. That way one socket fits both ends, and they are much easier to deal with.

Just stay at it you'll get it. When you get this running drive a hundred miles or so and re-torque the lugs nuts. New studs = probability of loosing.

Title: Re: Zombie Ford F-350
Post by: husker77c on August 29, 2015, 07:19:56 PM
VICTORY!!!!!!!!!!!

Blind luck got the pin in the lock ring on the second try tonight.

Now for the fun pretty stuff.

More gear from my main man El Tate

(http://i.imgur.com/746f2P7.jpg)

(http://i.imgur.com/IM6bHKE.jpg)

The locking hubs went together super easy and came apart super easy as well.  I had to disassemble them when I forgot to install the spacer.  that minor setback aside.  They are installed and they work!

(http://i.imgur.com/PCYdORy.jpg)

(http://i.imgur.com/4TxKxz0.jpg)

Then the new brake pads and the caliper installed.

(http://i.imgur.com/N4uIRtb.jpg)


i was hoping to get to the other side tomorrow but i have to go in to work for an overnight shift to watch over the hydrostatic testing so I think Im going to take it easy tomorrow and rest up.  One overnight will wreck me for the week but I'm trying to make a hand for the new company so I can continue to work next year.  With the economy as uncertain as it is a man can't really ever turn down work.


Title: Re: Zombie Ford F-350
Post by: Sammconn on August 29, 2015, 07:32:19 PM
Quote
I tend to always swap my front 60 axles to 14 Bolt Chevy wheel bearing nuts.

Says the guy with four sheds, two barns, and a warehouse he has yet to speak of full of axles and parts.

New studs = They're going to be loose.
Title: Re: Zombie Ford F-350
Post by: OldKooT on August 30, 2015, 10:40:55 AM
I actually usually source my 14 bolt bearing retainer nuts from a U pull it yard. I just buy the entire axle for like $45 swipe the nuts, and wheel bearings if good. *bearings are the same as Dana 60frt/rear wheel and diff carrier, and some Dana 70*  I much prefer old serviceable OEM quality bearings to new junk. So if I find a nice axle with said parts I snag it, part it out, toss the housing/hubs/shafts in my iron pile, and motor along happily LoL



Title: Re: Zombie Ford F-350
Post by: JR on August 30, 2015, 01:58:29 PM
Nice write up. Was good to see see all the parts I have getting put on. Tate did me good too and my CC still hurts.

Using Norms idea on the nuts, but doubt I will get the whole axles. Nice thing is I have one axle nut wrench that fits the Dmax rear and the Subs front and rear axles.

How do the hubs work? They are sure purdy.
Title: Re: Zombie Ford F-350
Post by: KensAuto on August 30, 2015, 02:21:27 PM
Congrats on the install. Need a job? lol



Not everyone buys an entire axle to get the nuts. Matter of fact, I think Norm may be the only one!
Title: Re: Zombie Ford F-350
Post by: husker77c on August 30, 2015, 06:18:09 PM
Thanks guys.  I'm already over half way done with the other side.  It goes so much faster after you've done one side.   The hardest thing was the ball joints and even that wasn't that hard. 

The hubs are money.  They have such a positive feel to them.   Dealing with locking hubs growing up they always felt as if they were about to break when you were turning them.  These are firm but smooth if that makes sense. They have a solid click when you engage or disengage them. I've read they can be a little tough to disengage after using them so I will have to see if there is any validity to that claim after they get some use.  I've also heard that the reason people have a hard time disengaging them was due  to people having them in a bind still after using 4wd and due to not enough grease.   I packed a whole bunch of grease in them so that won't be an issue for me. 

Hopefully this thing will be back on the road Tuesday night.  Probably won't be able to take it to work immediately because it will probably need an alignment after I replace all the tie rods and everything.  I have those removed and I assembled the new ones as close as I could to the old ones length so I'm hoping they are close to be able to take it for a test drive to verify function.

After all the running gear work I'm thinking I need some cosmetic work next.   Probably try to paint it next week.
Title: Re: Zombie Ford F-350
Post by: OldKooT on August 31, 2015, 07:13:37 AM
When you get your tie rods all changed out you can just set the toe at about 1/8, and go for a drive. 99% of the time that is about exactly where the toe needs to be.
Title: Re: Zombie Ford F-350
Post by: KensAuto on August 31, 2015, 10:04:16 AM
D
When you get your tie rods all changed out you can just set the toe at about 1/8, and go for a drive. 99% of the time that is about exactly where the toe needs to be.
Ditto
Title: Re: Zombie Ford F-350
Post by: EL TATE on August 31, 2015, 02:28:36 PM
Looking great bud, glad it's all turning out well for you. Yeah, those spindle nut washers suck for sure, got some providence there getting it to work like that.
Title: Re: Zombie Ford F-350
Post by: husker77c on September 07, 2015, 10:45:16 AM
Almost got it.

You guys said above that I should set the toe to 1/8" in?  How do i go about doing that?  Where do I get my baseline?  I assume once i have it at zero then I can jack up both sides of the front end and turn the adjustment sleeve to get the 1/8".  Is it possible to have one side straight and the other side turned out to much?  I have the tire off of one side and its a little hard to tell without the tire on but it looks as if the passenger side is turned more than the drivers side.  I eyeballed the tie rod and drag link and they are within an 1/8" or so of the pieces I took off.  Maybe it will look better when i get the tire on.  If it doesn't then i should be able to leave the one tire on the ground and turn the adjustment sleeve which should bring the other one in correct?  I'm about ready to put the drag link on but I'm thinking I should leave it off until the toe is set correct?  Because it will have to be adjusted depending on where the tie rod sets correct?

some pics

(http://i.imgur.com/o4ny23u.jpg)

(http://i.imgur.com/MPNuKaA.jpg)

(http://i.imgur.com/mB8djMD.jpg)

(http://i.imgur.com/X3mSlvj.jpg)
Title: Re: Zombie Ford F-350
Post by: KensAuto on September 07, 2015, 12:25:48 PM
When I do a front end, I try and put everything back to the same as before, laying parts next to each other for reference, and using a tape measure. Using the tape measure, find a spot on the tire that's consistent (center groove?), and measure across the front, then compare with the back of the tires. It doesn't matter which side you adjust as far as toe is concerned, but it will affect steering wheel position.
Title: Re: Zombie Ford F-350
Post by: husker77c on September 07, 2015, 12:39:37 PM
Yeah I just stumbled through it.   Got my toe pretty close to 1/8" and my steering wheel is just a touch off.  I'm going to mess with the drag link sleeve a bit to see if I can get it straight.
Title: Re: Zombie Ford F-350
Post by: husker77c on September 07, 2015, 02:12:26 PM
Well just took her for a drive.  Feels so much tighter now. My steering wheel is almost upside down when driving straight but other than that it pulls a touch to the left but overall I'm satisfied and feel comfortable taking it back to work.   
Title: Re: Zombie Ford F-350
Post by: TexasRedNeck on September 07, 2015, 05:34:03 PM
Nicely done!  Thanks for the report. I've never owned a straight axle 4wd but I've learned a lot from your experience.


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Title: Re: Zombie Ford F-350
Post by: husker77c on September 07, 2015, 08:06:40 PM
It's really wasn't that bad.  If I could have worked solid on it I could have knocked it out in a weekend.  The first side is where you figure stuff out and the second side you know what to do and what not to do. 

Example. When I was putting the drivers side together I put the studs directly into the hub. Then I tried to put the rotor on and realized that the studs have to go through the rotor and then into the hub.

Another on is the sleeve that you install when putting the locking hubs in.  I didn't see it in the box and the directions said if applicable or something like that so I assumed mine didn't need it.  Then I got out the screw bag and low and behold there were the spacers.  So I had to pull it apart to put them in. 

On that note for anyone installing the Yukon hubs.  When you are putting the gears in and you have to compress the spring while getting the stub shaft splines aligned with the splines on the hub.  Take a small straight pick and push along the outer edge of the gears to move the spring down and line it up behind the gears.  When you're trying to put the gears in the spring will catch between the lip on the hub and the gears and it won't allow it to go in.  If you use the pick to push the spring off of the lip it will slide right in.   The first side I did I fought it forever and it finally went by luck, the second side I fought for about 20 minutes till I tried the pick and it went right in. 

im so glad this is done.  Now I can move on to the more "fun" stuff.  Next weekend I'm hopefully going to be able to install the tool box/fuel tank combo and make a mount for the spare in the bed.   Then I'm going to continue on the interior  because with work it will be a sort of rolling office.  I also have a bunch of old stereo gear laying around that I'm going to put to use and get some better tunes.
Title: Re: Zombie Ford F-350
Post by: Flyin6 on September 07, 2015, 09:44:47 PM
Good work.

Solid project, and you did it yourself

Get it professionally aligned and you're G-T-G
Title: Re: Zombie Ford F-350
Post by: Atkinsmatt on September 07, 2015, 09:53:16 PM
Great work.  Picked up a new trick with the pick there.
Title: Re: Zombie Ford F-350
Post by: husker77c on September 21, 2015, 03:13:55 PM
So figured I would post a little update now that work has slowed down a bit.  Still 7 days a week but at least not 15 hour days.
 

As some of you know from my other thread my daily driver is being bought back by dodge so the ford will become my daily driver so I have some work to do on it to get it 100%

I got my auxiliary fuel tank down to where I'm at and will put it in when I get the chance hopefully sometime this week.

(http://images.tapatalk-cdn.com/15/09/21/88d7341a59b3f7eb8fdb8b4f7022c599.jpg)

(http://images.tapatalk-cdn.com/15/09/21/83e12dc214dadac28e3039ba6573c069.jpg)

I also started gathering up parts for the cummins swap.  I found a guy on a FB group I'm a member of selling motor mounts that had only been used for mock up.  I snatched those up quickly.

(http://images.tapatalk-cdn.com/15/09/21/0f114f6ff99516c652374eb27d709d75.jpg)

I had my buddy who is storing my engine pull the head off and take it to the machine shop. I'm having it decked flat and they are installing O-rings.  I've also started shopping for performance parts for the 12 valve.  From what I've gathered I need to be shooting for 450 HP or so which will give me close to 8-900 ft/lb of torque.  This seems to be the magic number to give the 12 valve similar towing performance to my 2012.

So far I'm looking at

New turbo possibly a 62/65/12 maybe a little bigger.

New injectors. 100hp which are 5x.014 or
7x.010 along with different delivery valves

4k governor springs and 60# exhaust valve springs. 

And then the tuning.  Pull the fuel plate, tune the pump, and bump the timing to somewhere between 16-18 degrees. 

New head bolts,  going to go upgraded bolts versus head studs.  I shouldn't be going over 50 psi so the bolts are much easier since you don't have to ream the block and machine the rocker pedestals. 

Probably going to tear it down and re seal everything and give it a nice coat of paint also.

I'm still researching because I need it to be reliable and if that ends up being too much then I'll have to tone it down. Might mean having to pull the camper a little slower but I'd rather do that than break down. Especially if I'm pulling the trailer trying to get out of dodge because something happened.  I figure I've got about a month and a half or two months before i start the swap.  So I've got time to research and figure it out.

Anyone here have any suggestions or comments on building the engine?


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Title: Re: Zombie Ford F-350
Post by: JR on September 21, 2015, 04:33:37 PM
Looks like a plan. What bolts you looking at? I am thinking along the same lines.
Title: Re: Zombie Ford F-350
Post by: husker77c on September 21, 2015, 04:58:58 PM
http://www.mightydiesel.com/store/product_info.php?cPath=143_734_108&products_id=1011

I'm looking at those.  From what I hear they're not a special bolt just a 12.9 metric bolt.  We could probably do it cheaper if you bought each bolt individually from fastenal or the like but this is a good price for all of them I think. 

My engine guy just sent me these.

(http://images.tapatalk-cdn.com/15/09/21/140fa9a8cdd868e6f0f344862dc7a929.jpg)

(http://images.tapatalk-cdn.com/15/09/21/0048bfe9523ae13ba24aa265c55be775.jpg)

Progress.



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Title: Re: Zombie Ford F-350
Post by: husker77c on September 28, 2015, 07:54:29 PM
Had some fun issues wtih the Ford.  I was driving it at work last week and all of a sudden it wouldn't shut off.  I had to kill it in 5th to get it to shut off.  Started fine but wouldn't stop.  I parked it for a few days and decided to tear into it and see what was wrong and turns out it was dead as a door nail. When I put the cables on it the ABS light was on and the battery light as well.  These lights stayed on even with the ignition off so that was what was draining the battery but I had no clue what was causing it.

Well I started taking it apart and I replaced the key cylinder, which needed it anyway, and the ignition switch.  It starts and stops fine now so one of my problems was solved.  The lights staying on was weird so I started pulling fuses until I pulled one that made the lights go out to figure out what circuit the draw was coming from.  Turns out I had to pull a maxi fuse from under the hood that according to the diagram was not used anyway.  But I pulled it and the lights went out so I'll roll with that until something comes up again.

I figured I might as well start Tearing out all the hacked wiring up wiring and put it back to as close to stock as possible.   I'm also going to wire in some anti theft devices as well.

There was a hard wired trailer brake controller in there and this lovely splice job into the headlight switch.  The controller had wire nuts on it as well.  I guess the PO had something wired in that he only wanted on with the headlights.   

(http://images.tapatalk-cdn.com/15/09/28/e988514889d1258a15ba5f88acf7d6e0.jpg)




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Title: Re: Zombie Ford F-350
Post by: TexasRedNeck on September 28, 2015, 08:15:06 PM
OH, I hate tracing down electrical issues.  Especially after people who have no business with electrical tape and a pair of wire cutters...
Title: Re: Zombie Ford F-350
Post by: OldKooT on September 28, 2015, 08:50:38 PM
I'd suggest you install the Cummins almost stock if possible. I'd then tow with it and see where you feel it lacks. You may find it's not all that bad and just needs some minor tweaking. 

Title: Zombie Ford F-350
Post by: husker77c on September 29, 2015, 07:00:04 AM
I'd suggest you install the Cummins almost stock if possible. I'd then tow with it and see where you feel it lacks. You may find it's not all that bad and just needs some minor tweaking.

I think you're right.  I've been leaning this way for the past few days after adding up parts costs to do what I was planning.  Tune it with the stock setup and see where it lands.   I'm still going to do the head work and upgraded bolts since I have the head off.   I'm just worried because I've never towed with an older diesel.   I've towed with some older gas burners and it was interesting to say the least. Both my 6.7s I've had pull like freight trains so I have visions of going 35 mph up a grade on the interstate. Haha


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Title: Re: Zombie Ford F-350
Post by: EL TATE on September 29, 2015, 10:42:03 AM
my bet is trailer lights with that hack job. Probably ice picked around until he found the lines that were hot with the lights on. Been down that road a time or two and I don't envy you sir.
Title: Re: Zombie Ford F-350
Post by: husker77c on September 30, 2015, 02:51:14 PM
Well I figured out what the fuse I pulled was for.   Glow plugs. The truck was very hard to start these past few months.   It would crank and crank and belch white smoke when it did start.   I replaced the relay shortly after I got the truck and it helped but it still started hard.   Well I think the relay went bad and was drawing current which is why the lights were staying on.  At least that's my theory. 

So I set about fixing it.   I changed the relay and wired in a momentary switch so I have control of how long the glow plugs light before i start it.  Not my first choice by since I pulled the fuse to the system I couldn't get the relay to latch and thought the controller might be at fault so that's why I bypassed it.   

I'm not concerned too much about it because hopefully this just has to get me by till I do the swap.   I hated to spend money on an engine that will only be used for a few more months but from what I've seen with this truck if it doesn't have a fully functioning glow plug system it's dead in the water in the cold. 

So thinking along those lines I went to the parts store and got 8 new motorcraft glow plugs and swapped those out as well.   

The weathers changing up here and I knew if I didn't do this now I would have wished I had at some point.   

Now with a few seconds of heat from the plugs she fires off like a champ. 
(http://images.tapatalk-cdn.com/15/09/30/640d2ec1303ea466d54dcb21bf5230a4.jpg)
(http://images.tapatalk-cdn.com/15/09/30/a2c5c210d7450313cf4afc2e1d9e7a7c.jpg)

All in all took me about an hour to swap the plugs and relay but took me three hours diagnosing it.   

Grrrrrr can't wait to have a Cummins in this thing.


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Title: Re: Zombie Ford F-350
Post by: KensAuto on September 30, 2015, 09:21:23 PM
You're hired!!

Now all you have to do is drive to Az....it was only 106 today....won't need those plugs, you can take them back for a refund!
Title: Re: Zombie Ford F-350
Post by: Flyin6 on September 30, 2015, 09:28:28 PM
106! What, one hundred six feet above sea level?
Title: Re: Zombie Ford F-350
Post by: KensAuto on September 30, 2015, 09:29:53 PM
Yeah, I think summer forgot what day it was supposed to end on.
Title: Re: Zombie Ford F-350
Post by: Flyin6 on September 30, 2015, 09:48:21 PM
Yeah, I think summer forgot what day it was supposed to end on.
Insane!

Drink plenty of water, heck, just drink all the water!
Title: Re: Zombie Ford F-350
Post by: Sammconn on September 30, 2015, 09:58:54 PM
106! YUCK!
I'd say summer forgot to take a hike.
I'm happily around 50, and I'll take that any day over 100+
Title: Re: Zombie Ford F-350
Post by: husker77c on October 01, 2015, 08:50:44 AM
Arizona sounds nice.  I did a job in 02 in Blythe California.  I saw 126 on a flying J sign out there.  I was going to work at 4 AM and my truck was regularly reading 99-100 that early in the morning. 

It's turned up here though. Down right chilly this morning.   Plus we got 4.5" of rain on Tuesday so today is the first day back to work.  Now if this east coast hurricane turns my way we may be shut down longer. 


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Title: Re: Zombie Ford F-350
Post by: KensAuto on October 01, 2015, 10:19:37 AM
That's a bunch of rain!
Title: Re: Zombie Ford F-350
Post by: JR on October 01, 2015, 10:51:14 AM
It was a 112 here just about a week ago, now we have clouds and a little rain.

Blythe, my old weekend hangout area was the Salton sea. Little town there called Thermal. It had the best little mexican food place you ever saw, but was it hot!

Hmm, Blythe, contract job had to be for the prison.
Title: Re: Zombie Ford F-350
Post by: Bigdave_185 on October 01, 2015, 11:16:19 AM
Utah is still hanging onto high temps too.  We hit 90+ yesterday.   With humidity we usually never see. 

Your truck makes me miss the old roll along ford powerstroke models.  They were sweet!


Keeping the early morning rolling, the afternoon hours snoring, the late night hours feeling the powers.
Title: Re: Zombie Ford F-350
Post by: husker77c on October 01, 2015, 11:44:59 AM

It was a 112 here just about a week ago, now we have clouds and a little rain.

Blythe, my old weekend hangout area was the Salton sea. Little town there called Thermal. It had the best little mexican food place you ever saw, but was it hot!

Hmm, Blythe, contract job had to be for the prison.

Actually was a pipeline. Ran from Blythe down to Yuma.  Right past that military training grounds. Chocolate mountain? Maybe?  It's been a long time since I was there.   Drove by several times and saw apaches hovering really close to the ground.

Also my first taste of illegal immigration.  Seeing the water tanks they leave in the desert so people don't die of thirst. 

The Colorado river was awesome though. We covered almost every mile of it from Blythe to Havasu.


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Title: Re: Zombie Ford F-350
Post by: Flyin6 on October 01, 2015, 12:12:48 PM
Yep, Chocolate mountains
Title: Re: Zombie Ford F-350
Post by: JR on October 01, 2015, 07:19:47 PM
Small world, I lived in Yuma when I was young being a military brat. Even had SNOW!!!
Title: Re: Zombie Ford F-350
Post by: Flyin6 on October 01, 2015, 10:51:43 PM
Small world, I lived in Yuma when I was young being a military brat. Even had SNOW!!!
I stayed at the Stardust resort hotel there for 3 months while training with the Marines. A pro baseball team was there as well, doing training camp getting ready for the season. I was always working out and when I'd be outside stretching people would come up to me asking for an autograph...so I signed things...Hooah, not my name!
Title: Re: Zombie Ford F-350
Post by: husker77c on October 03, 2015, 04:50:41 PM

Small world, I lived in Yuma when I was young being a military brat. Even had SNOW!!!
I stayed at the Stardust resort hotel there for 3 months while training with the Marines. A pro baseball team was there as well, doing training camp getting ready for the season. I was always working out and when I'd be outside stretching people would come up to me asking for an autograph...so I signed things...Hooah, not my name!

That's hilarious.   I liked Yuma. I bought a dirt bike out there and we hit Glamis a few times.  It was the dead of summer so we had to quit riding by 10AM or you would roast. 

Did a little work on the ford.

I put my aux fuel tank.  It's not ideal size but since it was close to free I have to use it. 

I can't decide if I want to center the tank in the bed or if I should off set it like this pic and use the space on the side for the spare. 

(http://images.tapatalk-cdn.com/15/10/03/251c52d29209d620175a33be29e2b088.jpg)

Any thoughts?


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Title: Re: Zombie Ford F-350
Post by: TexasRedNeck on October 03, 2015, 05:58:05 PM
Offset
Title: Re: Zombie Ford F-350
Post by: Sammconn on October 03, 2015, 06:09:52 PM
I'd stay offset. Keeps the spare in check, or anything about that size in place if the spare is gone.
Title: Re: Zombie Ford F-350
Post by: Flyin6 on October 03, 2015, 06:43:55 PM
Offset, but to the other side

Too much on the left already. Existing fuel tank, your carcass, (Battery??).
Your center of gravity (CG) is well left of center already, better to use the fuel weight on the right to counteract that
Title: Re: Zombie Ford F-350
Post by: JR on October 03, 2015, 07:00:01 PM
I like the offset too. Great spot for the spare.

I would keep the tank on the side you fill the truck up from. But then again if you need tools, it is much easier to get out and turn than to walk around to the other side.

Funny Don. A buddy and I had the same thing happen up in Santa Rosa many years ago when the Raiders trained there. We didn't sign anything though.
Title: Re: Zombie Ford F-350
Post by: husker77c on October 03, 2015, 07:51:39 PM
I agree with the offset and it does create a perfect spot for the spare. I'm pretty sure I could go up to a 37 and still have room for it in there.   I'll try moving it to the other side tomorow. The only thing that concerns me about that is my view out the rear view.  I have a pump for it that goes in the left side and if I move it to the right then the pump will block what little rear view I have left.


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Title: Re: Zombie Ford F-350
Post by: Bigdave_185 on October 06, 2015, 10:14:55 PM
What side of the tank will you fill up your truck from is also a consideration


Keeping the early morning rolling, the afternoon hours snoring, the late night hours feeling the powers.
Title: Re: Zombie Ford F-350
Post by: husker77c on October 17, 2015, 12:11:41 PM
A little update.  I used my 4wd today for the first time since the front end rebuild.   The grease zerks that came with the upper ball joints were too long and they just barely cleared the stub shafts.  Well I thought they cleared because they sheared completely off.  Not the end of the world but not a good thing either. 

Then while I was climbing up a hill I started hearing a thumping noise.  Naturally my heart dropped to the bottom of my boots thinking I had done something wrong in the rebuild.   Clunk got faster with my speed so I got back to level ground and had a coworker listen while I eased back and forth.   Front drive shaft is making the noise.   The double u joint thing at the transfer case output has a massive amount of play in it.  It's rebuildable but I may just order an entire new shaft.  Without proper tools replacing u joints is a massive pain I've found and I think it will be way easier to just replace the whole thing. 


I also sold my fuel tank so I'm shopping  for a different one.  I can't decide on a 100gal one or the 40 gal.  $80 price difference from big one to small.  Ideally I should get the small one as it will allow me to keep my tool box lower than the bed rails which will be good when I'm pulling my camper. But I really like the idea of thousands of miles of range before refueling.  We'll see.


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Title: Re: Zombie Ford F-350
Post by: KensAuto on October 17, 2015, 12:16:05 PM
Yeah, trying to rebuild those double cardan u-joints in a vise is a b**** if you've never done one before....but it is doable....just try to have an extra set of hands.
Title: Re: Zombie Ford F-350
Post by: EL TATE on October 19, 2015, 12:15:28 PM
Sure the zerks weren't the right size and the stub shaft wasn't oversized?
Title: Re: Zombie Ford F-350
Post by: husker77c on October 19, 2015, 01:21:32 PM

Sure the zerks weren't the right size and the stub shaft wasn't oversized?

Now that you mention it....... Haha


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Title: Re: Zombie Ford F-350
Post by: EL TATE on October 19, 2015, 02:56:32 PM
check your size requirements, but I've got some m6x1 flush mount zerks in TN and KY. I'd be happy to send you some no cost if they'll fit. I don't have the specs on ball joints on their own, just application data, so if you can figure it out, I'll ship 'em.
Title: Re: Zombie Ford F-350
Post by: Flyin6 on October 19, 2015, 07:27:29 PM
check your size requirements, but I've got some m6x1 flush mount zerks in TN and KY. I'd be happy to send you some no cost if they'll fit. I don't have the specs on ball joints on their own, just application data, so if you can figure it out, I'll ship 'em.
That's great customer care there Tater!
Title: Re: Zombie Ford F-350
Post by: husker77c on October 20, 2015, 09:53:16 AM

check your size requirements, but I've got some m6x1 flush mount zerks in TN and KY. I'd be happy to send you some no cost if they'll fit. I don't have the specs on ball joints on their own, just application data, so if you can figure it out, I'll ship 'em.

That is great customer service. 

But to get the broken off zerks out I would have to take the front end all apart again.  There's just no room to get at the bottom of the upper ball joint when it's assembled.  Even apart I think I would have to remove the lower ball joint to get a drill or easy out in there.   

Next spring I will probably tear down the front end and install the reverse shackle kit so I can do it then. 

I've started ordering parts for the cummins swap. So far I've bought

Adapter plate
Clutch kit
Intercooler
Radiator hoses
Tach sender kit
Misc fittings for the power steering.

I've also secured my dads shop in MI.  I hate to drive 12 hours up there to do this but it's really the only option.   If my dad was going to be there it would be awesome to spend time with him but he's been feeling pretty good and they are going to FL for a couple months in November.   But a bright side is it will be just me up there and I will be able to work on the truck non stop.   After I get the truck done my girl and I are going to pull our camper down to where he is at in FL and spend some quality time down there.

I will actually have a place to work with concrete, lights and heat,  I'm going to be spoiled.


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Title: Re: Zombie Ford F-350
Post by: Bigdave_185 on October 20, 2015, 10:16:59 AM
Sounds like a good plan to me


Keeping the early morning rolling, the afternoon hours snoring, the late night hours feeling the powers.
Title: Re: Zombie Ford F-350
Post by: KensAuto on October 20, 2015, 10:19:40 AM
Sounds like a good plan for sure. Just have to be careful when doing a job that size without a set of helping hands around, if something goes sideways.

Make sure to take pics!
Title: Re: Zombie Ford F-350
Post by: EL TATE on October 20, 2015, 10:42:29 AM
He'll have plenty of helping hands Ken, via electronic proxy. Just make sure you have a good internet connection 8)
Title: Re: Zombie Ford F-350
Post by: KensAuto on October 20, 2015, 01:15:19 PM
Yeah, I guess we can call 911 if his foot gets stuck in the turbo...but then i might ask him to start a thread on how that happened.lol
Title: Re: Zombie Ford F-350
Post by: husker77c on November 12, 2015, 09:21:27 AM
Something's happening

(http://images.tapatalk-cdn.com/15/11/12/5ed2c7cf1c5a9a0cfd03969a2c9fe7ef.jpg)


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Title: Re: Zombie Ford F-350
Post by: Bigdave_185 on November 12, 2015, 10:13:03 AM
You going to make dinner? (http://images.tapatalk-cdn.com/15/11/12/91d7db01a34b93a4aba25bb28ded6e73.jpg)


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Title: Re: Zombie Ford F-350
Post by: Flyin6 on November 12, 2015, 10:49:04 AM
Engine/turkey crane

What will they think of next?
Title: Re: Zombie Ford F-350
Post by: JR on November 12, 2015, 11:08:51 AM
Probably free shipping on ebay too,,,,,,,,,,
Title: Re: Zombie Ford F-350
Post by: husker77c on November 13, 2015, 04:46:18 PM
Got a little bit more of that turkey fried

(http://images.tapatalk-cdn.com/15/11/13/554ea0601fcc72bc13128de55e9f2e6a.jpg)

(http://images.tapatalk-cdn.com/15/11/13/b0d378c588e99323a8a7a7f70ce191a4.jpg)

(http://images.tapatalk-cdn.com/15/11/13/05483aba88fb278fcaeff94a8482d508.jpg)


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Title: Re: Zombie Ford F-350
Post by: Bigdave_185 on November 13, 2015, 05:14:44 PM
Gobble gobble gobble


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Title: Re: Zombie Ford F-350
Post by: husker77c on November 15, 2015, 02:38:43 PM
Gobble

(http://images.tapatalk-cdn.com/15/11/15/bd1cf928787b5fe6ad1bf6b69e17396e.jpg)

Gobble

(http://images.tapatalk-cdn.com/15/11/15/b766725dc3cff593112b4f2d9178c574.jpg)

Gobble

(http://images.tapatalk-cdn.com/15/11/15/5c260ae843b790e2e60b31743f4c3c4c.jpg)


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Title: Re: Zombie Ford F-350
Post by: husker77c 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. 

(http://images.tapatalk-cdn.com/15/11/15/69e4490ddb6ebb60c1edf265172c43fd.jpg)

(http://images.tapatalk-cdn.com/15/11/15/6657e9a1351a193d6f98cde39e999aa1.jpg)


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Title: Re: Zombie Ford F-350
Post by: Flyin6 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! ;)
Title: Re: Zombie Ford F-350
Post by: TexasRedNeck on November 15, 2015, 07:04:54 PM
If in doubt, have it decked.
Title: Re: Zombie Ford F-350
Post by: Bigdave_185 on November 15, 2015, 07:32:55 PM
That looks yummy!!


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Title: Re: Zombie Ford F-350
Post by: husker77c 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. 

(http://images.tapatalk-cdn.com/15/11/16/894dac9d64ce540d85c0223ef11c9110.jpg)

(http://images.tapatalk-cdn.com/15/11/16/dcc2c8743a742c5da06b73fdb1c54a60.jpg)


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Title: Re: Zombie Ford F-350
Post by: husker77c on November 18, 2015, 06:58:53 PM
Got some more work done. 

Torqued down with the mighty diesel head bolts.

(http://images.tapatalk-cdn.com/15/11/18/4a63773a86223abff1977d16b8b00856.jpg)

60# valve springs and titanium retainers.

(http://images.tapatalk-cdn.com/15/11/18/869a92f62be70d48de2f502b51c8f941.jpg)

Adapter plate installed. 

(http://images.tapatalk-cdn.com/15/11/18/b95aebac5bcc0405e068ffec96520f51.jpg)

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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Title: Re: Zombie Ford F-350
Post by: husker77c on November 19, 2015, 08:39:35 PM
Almost ready to set in.

(http://images.tapatalk-cdn.com/15/11/19/76b75c886c97a7e390ff3cc972a78982.jpg)

In and bolted down.
(http://images.tapatalk-cdn.com/15/11/19/330046eba950fbcea54e9d0fdc4c52be.jpg)

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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Title: Re: Zombie Ford F-350
Post by: Bigdave_185 on November 19, 2015, 09:21:38 PM
That looks tasty for sure. 


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Title: Zombie Ford F-350
Post by: husker77c 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.
(http://images.tapatalk-cdn.com/15/11/21/aa95cb77d2624107ded655cc00bf23e7.jpg)

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.


(http://images.tapatalk-cdn.com/15/11/21/8373bd6a4aa45df02c53661142b838f8.jpg)
Title: Re: Zombie Ford F-350
Post by: cudakidd53 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.
Title: Re: Zombie Ford F-350
Post by: KensAuto 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 ?...?
Title: Re: Zombie Ford F-350
Post by: husker77c 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.   
(http://images.tapatalk-cdn.com/15/11/21/17a666cef122c80f52d3a07e2c1f68c1.jpg)
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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Title: Re: Zombie Ford F-350
Post by: Flyin6 on November 21, 2015, 05:21:10 PM
You are definitely making progress!
Title: Re: Zombie Ford F-350
Post by: husker77c 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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Title: Re: Zombie Ford F-350
Post by: KensAuto 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.


Title: Re: Zombie Ford F-350
Post by: husker77c 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.

(http://images.tapatalk-cdn.com/15/11/22/39d114c8acdce6386c9388c4eb3f94c4.jpg)

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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Title: Re: Zombie Ford F-350
Post by: husker77c 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.

(http://images.tapatalk-cdn.com/15/11/23/f5d4b11a45158a831a1a346b88592871.jpg)

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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Title: Re: Zombie Ford F-350
Post by: stlaser 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
Title: Re: Zombie Ford F-350
Post by: KensAuto on November 24, 2015, 09:32:38 AM
Yeah, the mount looks great for 50 bones.
Title: Re: Zombie Ford F-350
Post by: JR on November 24, 2015, 12:17:18 PM
What are the measurements on that cooler? I heard the ford fits the GM grill nice.

 

Title: Re: Zombie Ford F-350
Post by: husker77c 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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Title: Re: Zombie Ford F-350
Post by: KensAuto on November 24, 2015, 03:47:38 PM
Man, isn't that the way it goes.
Title: Re: Zombie Ford F-350
Post by: JR 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
Title: Re: Zombie Ford F-350
Post by: husker77c 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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Title: Re: Zombie Ford F-350
Post by: JR 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!!
Title: Re: Zombie Ford F-350
Post by: husker77c on November 29, 2015, 08:33:17 PM
Victory

https://vimeo.com/147274767 (https://vimeo.com/147274767)

Should be able to take it for a drive tomorrow

(http://images.tapatalk-cdn.com/15/11/29/d8013486be1527c14962fe15f87cb07a.jpg)


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Title: Re: Zombie Ford F-350
Post by: KensAuto on November 29, 2015, 08:43:49 PM
Congrats!
Title: Re: Zombie Ford F-350
Post by: TexasRedNeck on November 29, 2015, 08:54:59 PM
Very nice.  A cummins swap that runs!  (stickpoke:Don)
Title: Re: Zombie Ford F-350
Post by: Sammconn on November 29, 2015, 10:32:51 PM
Great job! Congrats!





Oh, how come you were able to do this so fast... 8)
Title: Re: Zombie Ford F-350
Post by: husker77c 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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Title: Re: Zombie Ford F-350
Post by: husker77c on November 30, 2015, 04:41:42 PM
https://vimeo.com/147383728 (https://vimeo.com/147383728)


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Title: Re: Zombie Ford F-350
Post by: stlaser on November 30, 2015, 04:44:48 PM
Congrats
Title: Re: Zombie Ford F-350
Post by: EL TATE on November 30, 2015, 06:57:21 PM
Excellent work there sir.
Title: Re: Zombie Ford F-350
Post by: Sammconn 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.
Title: Re: Zombie Ford F-350
Post by: cudakidd53 on November 30, 2015, 09:50:14 PM
What?  No SMOKE?  I thought those motors smoke a bunch when you first start them........#pokeDon  ::)
Title: Re: Zombie Ford F-350
Post by: Flyin6 on November 30, 2015, 10:22:38 PM
Very nice.  A cummins swap that runs!  (stickpoke:Don)
I feel bad...
Title: Re: Zombie Ford F-350
Post by: Bigdave_185 on December 01, 2015, 11:23:04 AM
That turkey looks like it survived the holiday!!  Congratulations.  Sounds like a dodge


Raising boys into RealMen!!
Title: Re: Zombie Ford F-350
Post by: JR on December 02, 2015, 04:07:56 AM
Ahead of BD and me!
Title: Re: Zombie Ford F-350
Post by: Flyin6 on December 02, 2015, 12:14:39 PM
Ahead of BD and me!
Apparently much farther ahead of me than I once thought!
Title: Re: Zombie Ford F-350
Post by: husker77c 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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Title: Re: Zombie Ford F-350
Post by: TexasRedNeck 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
Title: Re: Zombie Ford F-350
Post by: husker77c 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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Title: Re: Zombie Ford F-350
Post by: EL TATE 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.
Title: Re: Zombie Ford F-350
Post by: husker77c 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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Title: Re: Zombie Ford F-350
Post by: Bigdave_185 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


Raising boys into RealMen!!
Title: Re: Zombie Ford F-350
Post by: husker77c 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. 

(http://uploads.tapatalk-cdn.com/20160201/68f8d6d63b4ac70733354287229c5f5b.jpg)


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Title: Re: Zombie Ford F-350
Post by: husker77c 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.

(http://uploads.tapatalk-cdn.com/20160202/1a87aabb5e99115a63f36a6bcd469aa9.jpg)

(http://uploads.tapatalk-cdn.com/20160202/d2830cfed62c40aacde7dc47051707f0.jpg)

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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Title: Zombie Ford F-350
Post by: husker77c on February 03, 2016, 01:56:03 PM
I'm taking advantage of the 60* temps here in PA. 

I got my boost leak fixed.  Had an ill fitting clamp on the compressor outlet.  A quick drive got me 18# of boost which is right where it should be in a stock configuration. 

I moved on to mounting the rest of my gauges.   I decided to make a fiberglass pod to sit on top of the dash. 

I started by masking off anywhere I didn't want resin going.
(http://uploads.tapatalk-cdn.com/20160203/104bbfde559ddba160be769d1d56e55b.jpg)

Add plastic so it doesn't run
(http://uploads.tapatalk-cdn.com/20160203/403cf519eb6121e0bd685178de1285f7.jpg)

Then draw the rough outline of the size of the base.
(http://uploads.tapatalk-cdn.com/20160203/b1ebfa79bc74228b0679f9f4bfdf3c11.jpg)

Next is laying the resin and mat.  I always seem to be off on the ratio of resin to hardener so it either dries before I get it layed up or takes forever to dry.   I got it pretty close.

I pour some resin on the piece, brush it even then lay the mat on top of that.  Then add more resin to soak into the mat and make sure all the edges stay down. (http://uploads.tapatalk-cdn.com/20160203/216f8f923ba4f805edbcf8327da186ed.jpg)

Then wait

(http://uploads.tapatalk-cdn.com/20160203/14cd1b198b7dcb01472087f14a5fa3cc.jpg)

After it dries pull it off the dash and remove as much tape as you can.  Then cut on the line I made a few steps before.

(http://uploads.tapatalk-cdn.com/20160203/bca458e19ddc1248d5ba36fb9fad89fa.jpg)

Final bottom piece t will need some more trimming but it's close.

 (http://uploads.tapatalk-cdn.com/20160203/b320272eac5082cfa31734709fd4ff2f.jpg)

Now decision time. I can't decide if I want to use 2" PVC for the actual pods or if I want to cut a piece of wood and drill out the gauge holes.  I'm leaning towards the wood that way I can add an indoor outdoor thermometer to the pod.

 (http://uploads.tapatalk-cdn.com/20160203/6b027e6b8c67432b17154388e3cdc859.jpg)

(http://uploads.tapatalk-cdn.com/20160203/c45f3c2a32e1328f990c6f53b499e5d2.jpg)

(http://uploads.tapatalk-cdn.com/20160203/8ed8ce401efeaa7a1baff799bc3f02e7.jpg)




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Title: Re: Zombie Ford F-350
Post by: TexasRedNeck on February 03, 2016, 04:23:27 PM
That's looks like as many gauges and those death traps that Don flew!


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Title: Re: Zombie Ford F-350
Post by: husker77c on February 03, 2016, 04:51:12 PM
Yeah it's a bit obnoxious.  I wish I could put them in the actual instrument bezel but I haven't figured out a way without a complete dash rebuild, which is not high on the priority list.  None of the factory gauges work since the swap so it's all the basic needs to monitor.   

The fuel gauge and speedometer are the only factory gauges that work and there's no way to put them down further below without blocking the fuel gauge or speedo. 
This will work for now.  But a full dash rebuild will come in the future. 


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Title: Re: Zombie Ford F-350
Post by: KensAuto on February 03, 2016, 05:32:06 PM
Cool idea. Simple, check. Effective, check.
Title: Re: Zombie Ford F-350
Post by: husker77c on February 03, 2016, 06:19:08 PM

Cool idea. Simple, check. Effective, check.

Thanks. I'll try to get it finished in the next day or two.  Still have to wrap the whole thing in a t shirt and cover it with resin.  Then  paint it up and wire it.


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Title: Re: Zombie Ford F-350
Post by: Flyin6 on February 03, 2016, 09:31:04 PM
Kinda like it so far...Watching you develop this idea...
Title: Re: Zombie Ford F-350
Post by: husker77c on February 08, 2016, 10:06:34 AM
Had to put the gauge pod on hold to work on running gear before the rain.   

Which way should this muffler go?   Should the opening of the louvers face towards the front of the truck or the back?

(http://uploads.tapatalk-cdn.com/20160208/a4f8fe2b724a2e883883e855889c75f6.jpg)


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Title: Re: Zombie Ford F-350
Post by: Flyin6 on February 08, 2016, 10:31:21 AM
Had to put the gauge pod on hold to work on running gear before the rain.   

Which way should this muffler go?   Should the opening of the louvers face towards the front of the truck or the back?

(http://uploads.tapatalk-cdn.com/20160208/a4f8fe2b724a2e883883e855889c75f6.jpg)


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Ya know, I have placed them facing either direction. When I pulled the thing off afterward, I couldn't see where one direction "Clogged" vs the other. If a muffla' has a directional arrow, OK, that's it, but if not...???
Title: Zombie Ford F-350
Post by: husker77c on February 08, 2016, 01:50:46 PM
I installed it just like the picture with the louver opening facing towards the back of the truck.  A little googling and that was kind of the consensus.  So I got the exhaust as done as it can be right now.  It is sooooo much quieter with the muffler and a 4' straight pipe off the back of the muffler.  It took some experimenting to get my heat and wire speed right when I welded up the few pieces I had to weld but I'm happy with it.

Now if I get the hole in the floor patched up you might be able to carry on a conversation in this beast.

Unfortunately though my front driveshaft isn't going to be long enough.  So I'm going to have to plunk down the money to get it lengthened.  The cardan joint needs rebuilt anyway but I was hoping I could use what I had to get me by until I went back to work.  No such luck.

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Title: Re: Zombie Ford F-350
Post by: husker77c on February 27, 2016, 09:09:53 AM
Well I worked on the truck a bit the last few days.  I took a couple weeks off and got married so now that that whole situation is normalizing I found a little time to tie up more loose ends.

I had to pull the intake off to put a gasket on the intake horn that I forgot so I took the opportunity to do a little tuning of the AFC.

I removed the fuel plate,  I will probably grind the stock plate to a more aggressive profile and re install but I'm going to run it without the plate for awhile till I can get around to that. 
  (http://uploads.tapatalk-cdn.com/20160227/31213c99a9b6cb8f44dea6ed79e7e1ce.jpg)

(http://uploads.tapatalk-cdn.com/20160227/ee6a6aef8630070287b02d7fbd8be8dd.jpg)

(http://uploads.tapatalk-cdn.com/20160227/f6c9da420c5848701f9093b16f89774b.jpg)

Also pulled the AFC apart and loosened some things and tightened some things to start turning up the fuel.  From what I've read it's a painstaking process to get it all set just right so I marked down what I did, number of turns, etc so I can see if it went better or worse. 

Once it warms up a bit I'm going to start it up and go for a drive to see where I'm at.



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Title: Re: Zombie Ford F-350
Post by: TexasRedNeck on February 27, 2016, 09:30:26 AM
Congrats on getting married. Marking down what you did is a good idea.
Title: Re: Zombie Ford F-350
Post by: cudakidd53 on February 27, 2016, 09:56:12 AM
Congrats- marriage is like your AFC, little changes and keep track of what you do and if something isn't working right.....FIX IT!
Title: Re: Zombie Ford F-350
Post by: BobbyB on February 27, 2016, 11:27:27 AM
Congrats on getting married.
Title: Re: Zombie Ford F-350
Post by: Flyin6 on February 27, 2016, 11:48:54 AM
Congratulations!

Marriage advice, since I am the "father time" about this place

Marriage is all about compromise...

You do all the compromising, all the time...and things will work out just fine! ;) ;)

Title: Re: Zombie Ford F-350
Post by: stlaser on February 27, 2016, 01:48:00 PM
What he said ^^^^ Congrats!
Title: Re: Zombie Ford F-350
Post by: cj7ox on February 27, 2016, 01:55:43 PM
Congrats! What BD said, is truth! That, and when in doubt, apologize. You may not know what for, but asking her will just make it worse. LOL!
Title: Re: Zombie Ford F-350
Post by: Sammconn on February 27, 2016, 02:15:09 PM
Congrats. Big D is definitely right!

And the only two words that matter now...Yes Dear.
Title: Re: Zombie Ford F-350
Post by: rpar86 on February 27, 2016, 02:45:21 PM
Something I've heard my in laws say a lot...

Dad: I'm the head...
Mom: I am the neck that turns the head!
Title: Re: Zombie Ford F-350
Post by: husker77c on February 27, 2016, 06:45:51 PM
Thank you everyone.  I will be sure to heed everyone's advice lol.  It was a borderline shotgun wedding. We decided to do it right after New Years.   My dads health is good and I'm still laid off so it worked out.  Small ceremony in San Antonio right on the riverwalk.


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Title: Re: Zombie Ford F-350
Post by: cj7ox on February 29, 2016, 08:59:44 AM
Nice! Congrats, again!
Title: Re: Zombie Ford F-350
Post by: husker77c on February 29, 2016, 12:45:10 PM
Well my "wife", still weird saying that lol, is in TX for work so I took the Ford out to fill it up with diesel and check my mods.  It is a completely different truck.  Builds 30#s of boost and runs like a scalded dog.  If it was an auto I'd say it's close to keeping up with my 6.7.  Crazy that a few tweaks can yield that kind of gain.   My tune is pretty close to perfect too.  A little black smoke when u get on it and a pretty good haze when it's pulling.  From what I've read you want just a light haze when getting on it.  Im Not going to mess with it anymore for now though. I need to concentrate on getting the hole in the floor patched up and getting it to be a livable truck instead of a project.   Going to start driving it a lot more to figure out any bugs. 

On a side note we had a bunch of fuel perks from groceries so I got 30 gallons for free.  I had intentions on filling both tanks and putting some in bed mounted tank but since they shut me off at 30 gallons I'll save that for next time.   


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Title: Re: Zombie Ford F-350
Post by: BobbyB on February 29, 2016, 12:49:09 PM
How's the homemade gauge pod working out?
Title: Re: Zombie Ford F-350
Post by: JR on February 29, 2016, 01:55:23 PM
Congrades on getting married, it will never be the same again,,,,,,,,,,,,,,,,,,, Mine used to like toys, now she doesn't understand at all.

What is you setup? I am stating to get a few pieces based off Norms recommendations but like to hear others.
Title: Re: Zombie Ford F-350
Post by: husker77c on February 29, 2016, 04:23:47 PM

How's the homemade gauge pod working out?

I screwed it up.  When I glued the pvc onto the fiberglass it ended up all crooked.  I need some nail polish remover to remove them from the base and start over.  That's one of my goals for the next few days, get the gauges wired up neatly and permanently installed.   


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Title: Re: Zombie Ford F-350
Post by: BobbyB on February 29, 2016, 04:37:30 PM
I screwed it up.  When I glued the pvc onto the fiberglass it ended up all crooked.  I need some nail polish remover to remove them from the base and start over.  That's one of my goals for the next few days, get the gauges wired up neatly and permanently installed.   

Yay projects.
Title: Zombie Ford F-350
Post by: husker77c on February 29, 2016, 04:37:54 PM
Congrades on getting married, it will never be the same again,,,,,,,,,,,,,,,,,,, Mine used to like toys, now she doesn't understand at all.

What is you setup? I am stating to get a few pieces based off Norms recommendations but like to hear others.

What I've done so far is pull the fuel plate out and turn the smoke screw (pre boost fueling screw) in 3/4 of a turn.  I also have a boost elbow and it's pretty close to being all the way in, fully in would essentially close the wastegate and would allow a few more pounds of boost but from what I've read that's not the best idea.  As is pulling the fuel plate out can have some negative side effects as well. There is a pin inside the pump that can break off because of it.  It's a rare occurrence from what I've read but can happen and it's a $1200 bill when it breaks.
I also slid the AFC fully forward.


I am planning on grinding my fuel plate to a 100 profile and reinstalling it.  I'm also going to mess with the smoke screw to see if I can get the turbo lit a little sooner, it has a touch of lag. I will also play around with the star wheel to see what role that plays in this dance.  I haven't been able to lock down an exact plan from researching online so I'm just going to learn as I go.  I was hoping to find a recipe such as turn smoke screw X amount of turns and spin star wheel Y amount of turns etc but it's just not that simple I'm finding.

I will tell you the few things I've done is amazing.   Truck pulls so much harder.   Pulling the fuel plate and sliding the AFC is good for 100hp from what I've read and I would believe it.   





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Title: Re: Zombie Ford F-350
Post by: husker77c on March 02, 2016, 09:28:43 AM
Well I had a couple beautiful  days so I started something that absolutely should have been put off till a later date lol.  Paint

(http://uploads.tapatalk-cdn.com/20160302/b6afc855f88afdf748b118bf75ac3bb1.jpg)

I started out just painting my mirrors black but I had some leftover spray paint from painting a rifle so I decided to see how it would look.  Then went to lowes and picked up several more cans and figured what the heck I'll see what it looks like. 

I've got some tiger striping from the spray paint but I was never going after the show truck look.   It turned out decent I think. 

I just think the louvers painted black stands out to much on the tan. 
I thought about painting od green but nothing else is green.  Not sure what I'm going to do about that.

 (http://uploads.tapatalk-cdn.com/20160302/71c59ea7aa8eb3b3b6cb54c980380251.jpg)




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Title: Re: Zombie Ford F-350
Post by: BobbyB on March 02, 2016, 09:30:08 AM
I like the black and tan scheme.
Title: Re: Zombie Ford F-350
Post by: JR on March 02, 2016, 10:38:04 AM
100 hp would be good and Norm likes the S300 turbo better so it is all open.

Yep, tan is cool, different.
Title: Re: Zombie Ford F-350
Post by: cj7ox on March 02, 2016, 11:40:07 AM
Looks good to me!
Title: Re: Zombie Ford F-350
Post by: Flyin6 on March 02, 2016, 11:50:37 AM
Tan and black...X2 or X3 or ...
Title: Re: Zombie Ford F-350
Post by: husker77c on March 02, 2016, 01:30:39 PM
Tan it is then. 


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Title: Re: Zombie Ford F-350
Post by: husker77c on March 02, 2016, 01:47:31 PM

100 hp would be good and Norm likes the S300 turbo better so it is all open.

Yep, tan is cool, different.

S300 is a good turbo.  Factory equipment on some Caterpillar engines so you could possibly find a wrecked truck and get a cheap upgrade if you have the patience.  Or buy a new one.  Or I believe a super B is an s300 that's been tuned up.

If I decide to get stupid with my truck I'm going to do an HT3B/HX35 twin setup.  Towing twins is what it's sometimes referred to.  Reliable and late model 6.7 type linear power.  In all honesty though I don't see myself needing that anytime soon.  I'm looking forward to taking the truck as it sits out on the pipeline ROW and see how it does.  It has plenty of power now to run down the highway and as long as it can climb adequately that's all I need.

The next purchase for the truck will probably be some sort of locker for the rear end.  Having to be pulled out of 6" of snow when my 4x4 was out is unacceptable for a truck with this intended purpose.


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Title: Re: Zombie Ford F-350
Post by: JR on March 02, 2016, 05:28:51 PM
I was close to a HX35 but the 300 sounds better. Sounds like you have not touched the injectors at all.

I just wish someone made a better set of head bolts vs studs.
Title: Re: Zombie Ford F-350
Post by: husker77c on March 02, 2016, 06:26:14 PM

I was close to a HX35 but the 300 sounds better. Sounds like you have not touched the injectors at all.

I just wish someone made a better set of head bolts vs studs.

HX35 turbo is good for up to 35ish psi then it starts to blow hot air.  S300 should get you closer to 50#. 45-50 anyway.  At that level from what I've read studs might be good insurance.   With a properly torqued head and good gasket you should be able to run up to 40# with stock bolts. Anything over that and studs might be a good idea.   It's just such a process to stud the engine.  Having to machine parts for them to fit etc.

I was looking at studding but I'm just not gonna turn it up that much right now so I did the mighty diesel head bolts.   And the only reason I did those was because they are the same price as factory cummins bolts and they are a touch stronger.   If I get a garage put up this year I may pull the engine next winter  and rebuild it and I will probably stud it then.   But I'll also do fire rings and such.



My injectors are stock.  I had them pop tested and flowed before I put them back in so I know they're good to go.  They are the largest dodge put into an auto 12 valve and should be good to go for awhile.


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Title: Re: Zombie Ford F-350
Post by: JR on March 02, 2016, 08:40:21 PM
I thought going over 30 and you start looking at studs?

New 35s and 300s all start about $600 from what I am seeing. Finding used 35s is easy.
Title: Re: Zombie Ford F-350
Post by: OldKooT on March 03, 2016, 09:26:59 AM
I run right around 45psi on "Patch" in sustained foot to the firewall running it will tag 48psi and puff a little antifreeze on the windshield. I usually find this a good time to lift off the throttle a bit and turn on the wipers.

So... given that engine has never had a head gasket and is North of 400k miles...I'd say head studs are not required unless you intend to run above 40psi for extended duration's. Those stretchy OEM cummins head bolts keep it sealed fine under 45psi in my trucks anyway.



Title: Re: Zombie Ford F-350
Post by: husker77c on March 03, 2016, 10:07:25 AM
I thought going over 30 and you start looking at studs?

New 35s and 300s all start about $600 from what I am seeing. Finding used 35s is easy.

Yes a used 35 is a dime a dozen, lots of people changing them out for bigger turbos.  They are also popular with the Mitsubishi 4G63 crowd for a larger replacement turbo for their cars.   

Ive read about people running 60# on factory head bolts,   Granted life span is severely shortened, and they don't live hundreds of thousands of miles at that level, but it just shows what is possible. 

I run right around 45psi on "Patch" in sustained foot to the firewall running it will tag 48psi and puff a little antifreeze on the windshield. I usually find this a good time to lift off the throttle a bit and turn on the wipers.

So... given that engine has never had a head gasket and is North of 400k miles...I'd say head studs are not required unless you intend to run above 40psi for extended duration's. Those stretchy OEM cummins head bolts keep it sealed fine under 45psi in my trucks anyway.

How many of those miles did you run 40+psi?  Just curious of longevity.  Do you have an S300?



Title: Re: Zombie Ford F-350
Post by: OldKooT on March 03, 2016, 10:34:51 AM
Patch runs a modified (wheel n gated) OEM turbo. (62mm I think) It would have a S300 on it but I had this Turbo laying around off a different project so I tossed it on there long ago. As for miles... no clue, over 75K I am sure in it's present combination. The head gasket has leaked since the first day I put the Turbo on the truck. It only leaks coolant at full boost, and other than topping off the coolant on occasion if using it hard, I have seen no reason to change it.

I figure for a 400K+ engine I am not going to invest time/money in a head job when I have a few fresher engines laying around waiting for a home. That said it leaks no oil to speak of, has great compression and no blow by....so it may be in there a while yet LoL

Title: Re: Zombie Ford F-350
Post by: JR on March 03, 2016, 10:47:01 AM
I have 2 oem turbos, neither with a WG. I thought about just doing the wheels but a S300w sounds better. Say keep it around 35psi and I will be good.

Extra motors laying around, must be nice.

Title: Re: Zombie Ford F-350
Post by: husker77c on March 03, 2016, 11:27:32 AM

I have 2 oem turbos, neither with a WG. I thought about just doing the wheels but a S300w sounds better. Say keep it around 35psi and I will be good.

Extra motors laying around, must be nice.

No kidding on the spare engines.

I thought about building up the 35 but when u add up a new exhaust housing, upgraded wheel, and the machining to upgrade said wheel you're in it ~$600 already for gains that would still leave you needing more air when you upgrade injectors. 

Your idea of holding back the s300 so it isn't working hard is by far the better plan, power wise and money wise.  That leaves you a ton of headroom for bigger injectors, delivery valves etc in the future.   And you won't run out of air with the bigger turbo.   An S300 will get you into crazy power numbers. 500/1200 isn't out of the question on the high end with that turbo.


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Title: Re: Zombie Ford F-350
Post by: OldKooT on March 03, 2016, 11:36:28 AM
The 62MM S300 on my wife's Ramcharger runs and drives fine with the fuel set at 250HP or 450+ Then again it's also a $1700 Ball bearing turbo. But it's flexibility has always been impressive.

Keep in mind the P pump engines have a different taste in turbos than a VE size wise.


Title: Re: Zombie Ford F-350
Post by: husker77c on March 13, 2016, 06:05:05 PM
I got a few more things done.

Sound deadened and sealed up the front doors and installed my new eBay door panels.

(http://uploads.tapatalk-cdn.com/20160313/769aa54d8afe35137ffcbc514073ddd5.jpg)

(http://uploads.tapatalk-cdn.com/20160313/9474b1de4a0e5030db2dffadeccd2aec.jpg)

(http://uploads.tapatalk-cdn.com/20160313/f7b56b9d71cb83df880165bb0c1c5340.jpg)

I also got the hole in the floor taken care of.  Still have to put the transfer case shifter back in.

(http://uploads.tapatalk-cdn.com/20160313/f5228e1979f72edd190b133db696c00b.jpg)

Also installed some new speakers in the front door.  It's starting to be livable again and not a completely tore down truck.


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Title: Zombie Ford F-350
Post by: husker77c on March 15, 2016, 10:33:22 AM
Time for a fun project.

Bumper/bombproof tow hooks.

Mounts will be out of 1/2x4 flat bar with two 5/8" bolts holding it to the frame.  I may add a third bolt in between but two grade 8 5/8 should be sufficient.

(http://uploads.tapatalk-cdn.com/20160315/145f898294c90a26abdb185583fa4b72.jpg)

These will come through the front plate of the bumper and will be where I attach the shackles. 

Then I will attach the 1/2x4 cross piece to the frame mounts kinda like this. Only on the bottom side.  Then I will probably pick up a prefab winch plate to attach to the cross member.

(http://uploads.tapatalk-cdn.com/20160315/e08f2c99de8954f73359c99fa1176588.jpg)

I'm debating on what to use for the actual bumper.  I've considered a piece of channel iron that I could wittle down and section to give it some bends or just getting some 3/16 plate and building it like Square D.  It will be a lot better going that route but I've never done anything similar and the channel I think would be easier.   

I also don't know what I'm going to eventually do for tires but in case I want to use Hummer tires I scored these on Craigslist.  $25 for a set of rims with three bald tires.  Had to pay $40 to get them dismounted but at least I have options.  And for the price I couldn't pass it up.  16.5 wheels are getting hard to find.

(http://uploads.tapatalk-cdn.com/20160315/dc0c218241035e5af8610399c2e9a53f.jpg)




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Title: Zombie Ford F-350
Post by: husker77c on March 17, 2016, 05:59:45 PM
I got a little done on the winch bumper. 

I decided that by the time I bought the bits and hole saws etc that I would need to drill the mounts that I would be money ahead to have a machine shop do it. I drop them off in the morning to have the holes punched.

(http://uploads.tapatalk-cdn.com/20160317/58919694a659474b049884ffe5f0ddec.jpg)

The back mounts of the winch plate will go like this.  I'm using the factory angle iron bumper mount as a stop for the winch to pull against.  It should be sturdy enough.  Grade 5 bolts are just for mock up.  Once I know what I need I'll go get the grade 8s

(http://uploads.tapatalk-cdn.com/20160317/0b329173efef1d6eb3f49fca227e39f1.jpg)

Then I have some 4" angle iron  going to cut a couple pieces of and run them from the mounts down to the plate kind of where my finger is curled in this pic. I'm going to weld the angle to the mount and bolt it to the plate.  That way the whole mount will drop down from the bottom to add the winch easily (as easy as bench pressing a 100# over my head while simultaneously trying to line up bolts).  Or if I need to replace the winch I don't have to take off the entire bumper.

 (http://uploads.tapatalk-cdn.com/20160317/4dee43108283623ca4ee9d0578f61f0e.jpg)

I also got a quote on the 3/16 plate to finish it. $125 for the steel and I will have about $225 in materials and machine shop labor in it not including a winch obviously.  That will wait till I go back to work.


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Title: Zombie Ford F-350
Post by: husker77c on March 22, 2016, 03:51:11 PM
More progress.  Slow but steady.

Got my mounts from the machine shop.  They tigged in a sleeve for the shackle.  It's speced for a 7/8" shackle.  6.5 ton working load limit on the standard and I think 8.5 ton on the alloy if I think I need more strength.

(http://uploads.tapatalk-cdn.com/20160322/290cbefc0a68e4ea1b1ae3d5b4c6e43a.jpg)

Bolted up

(http://uploads.tapatalk-cdn.com/20160322/fcb7f8765c9fe12dc15aed4da28391fd.jpg)

I also got the angle iron cut and drilled for the winch plate.

 (http://uploads.tapatalk-cdn.com/20160322/4b7fa5d59eed1513a9bd124c9249852a.jpg)

I have been having second thoughts though.  I could just trim my bumper and stick the shackle mounts through the factory bumper and save quite a bit of time and money.   I wouldn't have a winch, but I would have solid recovery points.   I really want to build a bumper and brush guard to save the front end in the event of a deer impact or Prius attack.  Grand scheme it's only a couple hundred bucks and if I don't do it now and I go back to work I won't get it done till next winter.   Have to decide tonight though cause I need to get the plate tomorrow if I'm going to build.   Decisions.

(http://uploads.tapatalk-cdn.com/20160322/d75f774cc1443955861d590b9571ef41.jpg)


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Title: Re: Zombie Ford F-350
Post by: cj7ox on March 22, 2016, 07:52:58 PM
Build it!  :D
Title: Re: Zombie Ford F-350
Post by: JR on March 23, 2016, 12:59:45 AM
Build it!  :D

Ditto, do it now!!
Title: Re: Zombie Ford F-350
Post by: Atkinsmatt on March 23, 2016, 08:42:02 AM
How long do you think it will take for you to say "I wish that I had a winch" if you don't do it now?
Title: Re: Zombie Ford F-350
Post by: Flyin6 on March 23, 2016, 08:44:12 AM
^^^ Three wise men there

I'd take their counsel!
Title: Re: Zombie Ford F-350
Post by: Atkinsmatt on March 23, 2016, 09:02:20 AM
Especially in your work situation, a winch will make you brave so you can get stuck farther from the road.
Title: Re: Zombie Ford F-350
Post by: cj7ox on March 23, 2016, 09:24:06 AM
Especially in your work situation, a winch will make you brave so you can get stuck farther from the road.
But he'll be able to get himself unstuck, too!  8)
Title: Zombie Ford F-350
Post by: husker77c on March 23, 2016, 03:46:22 PM
I think I'm done for the day. 

Center plate fitted.
(http://uploads.tapatalk-cdn.com/20160323/c65f323cfcdf285d5e3dda57dc96e8bf.jpg)

Wing mock up

(http://uploads.tapatalk-cdn.com/20160323/6fa7e66883d85b34dc5e26f0cdd03e46.jpg)

Wing welded
(http://uploads.tapatalk-cdn.com/20160323/a7a8def0038b405472a15cdff25756b6.jpg)

2 wings welded.

 (http://uploads.tapatalk-cdn.com/20160323/7b99306b5c47f6dfce1d58c24dbc59a7.jpg)

(http://uploads.tapatalk-cdn.com/20160323/4600e72aa46fd63a4e5a87f350453685.jpg)

Everything is tacked into place right now.  I'll probably pull it off in the morning and weld it up and start grinding on the front piece.  Then add the top, weld out, grind, then paint. 

Then cap the ends or something.  Not sure what I'm gonna do there yet.  Winging it kind of.

I'm going to do a one piece top and then when it comes time for a winch I'll cut the access I need for the controls. 

If I have enough material I'll start on the brush guard.  If not that can be done added at a later date.   Can't spend anymore money on this truck right now.  Wife is calling it very bad names.




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Title: Re: Zombie Ford F-350
Post by: BobbyB on March 23, 2016, 04:23:58 PM
I like it.
Title: Re: Zombie Ford F-350
Post by: cj7ox on March 23, 2016, 05:11:30 PM

I like it.
x2!


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Title: Re: Zombie Ford F-350
Post by: Sammconn on March 23, 2016, 07:46:01 PM
Good looking start. You won't regret doing it now.
Title: Re: Zombie Ford F-350
Post by: JR on March 23, 2016, 08:47:13 PM
Good start. Don't forget to add some lateral bracing as even that 1/2 plate will not be enough.
Title: Re: Zombie Ford F-350
Post by: swbhobie16 on March 23, 2016, 09:44:18 PM
^^^ Three wise men there

I'd take their counsel!

not claiming to be a wise man, but I vote for a build too (with lots of pics, of course).
Title: Re: Zombie Ford F-350
Post by: husker77c on March 23, 2016, 10:16:36 PM
Good start. Don't forget to add some lateral bracing as even that 1/2 plate will not be enough.

Thanks guys. It came together a lot faster than I thought it would.  I kept the design simple since its my first project of this scale. 

I'm hunting gussets for the lateral bracing now.  I can find straight 90s in a bunch of styles. Those will be perfect for the inside of the tow hooks. But the way I built it the outside will be a bigger angle. Probably somewhere around 110*.  May have to find a plasma table shop to have some cut out.  I could cut my own but I've been eyeing these ones with a biohazard symbol cut in them.  Or the spider webs are cool too....

Edit-  and I just sold my factory bumper for $150. Woo hoo.  This whole thing will cost me around $175. A lot better than the $1000+ they want for aftermarket bumpers.
Title: Zombie Ford F-350
Post by: husker77c on March 24, 2016, 12:55:05 PM
Done again for the day.  Wife's birthday so have to get around for the evening festivities. 

Got the top plates on.  Had to do three pieces because my 10" plate I had wouldn't be deep enough.

Top plate and drivers side.
 (http://uploads.tapatalk-cdn.com/20160324/0207607a16279f0e47fe7ea358e7f1e2.jpg)

Passenger side I ran into a little issue.  I guess I was off on the wing when I cut it cause I had a massive gap. I tacked on a scrap piece on the back and filled it in.  Probably have 3# of wire in this side lol.

(http://uploads.tapatalk-cdn.com/20160324/9e4ed3c09094d7a8649b166ec1bc78c6.jpg)

(http://uploads.tapatalk-cdn.com/20160324/9897c6ea1da7abcded5e0aeb665bc1d8.jpg)

This saw is awesome.  Cut the 3/16 plate like plywood.  I need a new welding hood though.  This pipeliner pancake hood is good for running a long bead one one side of a piece of pipe but it doesn't cover near what I need to cover.  Major arc burn on my forehead haha.  I could use the color though.

(http://uploads.tapatalk-cdn.com/20160324/ade05a574a28d09ec80ad8300a7a963a.jpg)

Wish list should I ever get a shop.

At the very least a plasma cutter. I'd really love a 4'x8' plasma table though

Big welding machine with gas. My little Hobart is great on the 3/16", as long as I don't have a 1/2" gap to fill.   But trying to get penetration on the 1/2" mounts was next to impossible.  My welds ended up looking absolutely horrible where the mounts comes through the bumper.  There not very structural so I'll grind them down and make it look decent they'll hold up fine for dear and parking lot impacts.  I don't plan on ramming through road blocks with this thing.  And it would be better if the bumper caved versus the frame bending.   The power of my machine is definitely limited.


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Title: Re: Zombie Ford F-350
Post by: wyorunner on March 24, 2016, 01:38:37 PM
What saw is that? The double blade thing from HF? Or?


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Title: Re: Zombie Ford F-350
Post by: husker77c on March 24, 2016, 02:06:00 PM
It is a harbor freight metal cutting circular saw.    I just looked on their site and I don't see it anymore.

Blade is a toothed blade

(http://uploads.tapatalk-cdn.com/20160324/ccba5f1b1f75547aef7b04742a24aafa.jpg)

It produces small chips

 (http://uploads.tapatalk-cdn.com/20160324/75995fb772f4dfa237d3c4bc8485f13e.jpg)

I would have probably given up on this project if I had to cut every panel with a cut off wheel and a grinder.  It is seriously just like cutting plywood.


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Title: Re: Zombie Ford F-350
Post by: wyorunner on March 24, 2016, 03:34:14 PM
A couple years back rigid (from homedepot) sold a double blade that was said to be able to cut most things. Metal was what interested me, never bought one and now they don't have em in the store. The bumper on the 4Runner was cut entirely with my angle grinder. Next go round I will be using a sawzall and jigsaw!


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Title: Re: Zombie Ford F-350
Post by: husker77c on March 24, 2016, 04:18:58 PM
I feel your pain brother.   I cut out the winch hole in the front with an angle grinder.  Killed a whole blade with just that.   

I just got back from harbor freight picked up a new welding hood.  I looked for the saw they don't have the exact one I have but they do have a 7" metal cutting circular saw for $60.  It's just physically smaller than mine.  Well worth the money and saved time. I could've knocked this whole bumper out in a day if I wouldn't have only worked half time on it.   With a grinder and wheels it would have taken me at least twice that.  And the cuts wouldn't have been near as nice.


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Title: Re: Zombie Ford F-350
Post by: JR on March 24, 2016, 04:27:44 PM
Are you using the mig with gas or flux core?

Flux core will give you a deeper weld vs gas. In the meantime a good old stick welder will work for those deep welds too and not break the bank. A good bead using 5/32 7011 will yeild a great weld and the flux will roll right off.
Title: Zombie Ford F-350
Post by: husker77c on March 24, 2016, 04:40:26 PM
Are you using the mig with gas or flux core?

Flux core will give you a deeper weld vs gas. In the meantime a good old stick welder will work for those deep welds too and not break the bank. A good bead using 5/32 7011 will yeild a great weld and the flux will roll right off.

Flux core .035.  I don't have the regulator kit for the welder to run gas.   

I only have 4 heat settings and I set it to 4 and wire speed at about 25 out of 100 and I can't get a bead to stick to that 1/2".  I try starting on the 1/2" and running the puddle onto the plate but I can't get a decent puddle to drag down there. I start on the plate and try to bring the puddle up to the 1/2" and I lose the puddle.  So I have a bunch of bird crap welds all stacked on each other.  Looks terrible but it seems solid. Smacked it with a sledge a few times to make sure.   I know it's not penetrated very far into the 1/2" though.  I'll grind it down and I'm going to take it in to the machine shop to have them make me some bracing for the recovery points and I'll see if they can do anything better with it.

I wish I had a stick welder for getting more penetration.  But without a garage or even a shed for tools I just don't have the room.  I could have filled that gap so easy with a few rods.  I'm going to start watching craigslist for a welder and possibly a plasma cutter. 


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Title: Re: Zombie Ford F-350
Post by: JR on March 24, 2016, 05:08:15 PM
Run a good bead on 1/2 plate, then weld to that. I know its done, but should work.
Title: Re: Zombie Ford F-350
Post by: Sammconn on March 24, 2016, 08:05:30 PM
^^x2.
Clean it up with a wheel and it'll clean right up with another pass or two.
Title: Re: Zombie Ford F-350
Post by: husker77c on March 26, 2016, 10:20:18 AM
Well a little update on my welding fiasco.   I ran out of wire yesterday and when I was getting my new hood I picked up a roll of harbor freight flux core.  I be only ever used Hobart brand wire.  Holy cow what a difference.  I'm not a great welder and with my recent experiences I was getting frustrated.   This stuff welds so much smoother than the Hobart

(http://uploads.tapatalk-cdn.com/20160326/bc7f957ac6388491f4759d94672529ab.jpg)

My mount pass through before.

(http://uploads.tapatalk-cdn.com/20160326/002f84f7a5b7413b97427a779dcdaff9.jpg)

And after.
(http://uploads.tapatalk-cdn.com/20160326/2c0b3be155c62238e907a08d820836f2.jpg)

Not the same place but I didn't take a before on that area. 

Still have hours of grinding but it may end up decent after all.

(http://uploads.tapatalk-cdn.com/20160326/661e11f75c5c700a58ff3723b4b2dbfa.jpg)


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Title: Re: Zombie Ford F-350
Post by: husker77c on March 26, 2016, 10:48:54 AM
(http://uploads.tapatalk-cdn.com/20160326/71899944afa5a30bc33a17491daa086e.jpg)

Decided to break out the big gun for grinding.  Almost done now lol


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Title: Re: Zombie Ford F-350
Post by: rcampbell on March 26, 2016, 10:54:43 AM
I'm loving this bumper! Any plan to do a rear bumper as well? I was thinking of doing something very similar to yours on my dodge!
Title: Re: Zombie Ford F-350
Post by: husker77c on March 26, 2016, 11:52:07 AM
Thanks man.  It was a lot easier than I thought it would be.  I've got a ranch hand style pipe bumper on the back that was on the truck when I bought it.  It's held on by one bolt and a 2" weld on each side so I have to either re work it or build a new one.   I've been leaning towards a new one because it would just be easier to incorporate a strong receiver hitch into a new one.   Plus it has a piece in the middle that comes down that I'm always scraping when I have to go up a steep hill for work.

Only pic I have on my phone.

(http://uploads.tapatalk-cdn.com/20160326/6623a2ffb5dbcd23f448a0de09996ea2.jpg)

If I do build one I'm going to do a piece of 2x6 or 2x8 1/4 wall rectangle tubing.   Then pass the mounts through the tubing just like on the front one.  Tie the receiver into the mounts and have rear recovery points like the front. 

Rectangle tube would be easier to incorporate a swing away tire carrier into.
Yeah I've thought about the rear a lot lol.

Doubt the rear gets done anytime soon though.


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Title: Re: Zombie Ford F-350
Post by: JR on March 26, 2016, 12:03:46 PM
Looks much better and the welds are picking up too. Is the wire a diff number or just brand?
Title: Re: Zombie Ford F-350
Post by: husker77c on March 26, 2016, 12:39:39 PM

Looks much better and the welds are picking up too. Is the wire a diff number or just brand?

Just brand. Same .035 flux core.  This HF stuff is much darker color than the Hobart.   The Hobart is silver.  I even double checked to make sure I didn't have non flux core Hobart.  But they are both the same specs.



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Title: Re: Zombie Ford F-350
Post by: Wilbur on March 26, 2016, 01:05:05 PM
I like the progress looking good!
Title: Re: Zombie Ford F-350
Post by: JR on March 26, 2016, 03:28:19 PM
Maybe 035 is to heavy. I am using .023 and about to step up to 030 on my Miller 211, but I run gas too.

I'm getting a couple rolls of 030 solid now and maybe a roll on 035 for heavier welding.
Title: Re: Zombie Ford F-350
Post by: stlaser on March 26, 2016, 04:40:57 PM
I've always had 250 machines or larger & I always run .035 w/ gas from 1/8" up to multi pass heavy plate welds. Place I worked at once had a Lincoln 135 & I ran .035 & gas as well
Title: Re: Zombie Ford F-350
Post by: JR on March 26, 2016, 06:25:07 PM
I just happen to have the 023 or would have gone 030 right off. I do some exhaust and like to minimize the burn through.
Title: Re: Zombie Ford F-350
Post by: OldKooT on March 26, 2016, 08:49:49 PM
That bumper looks great.

I run .030 in my Miller 250 and that has been a nice blend between being able to do sheet metal, and much heavier 1/2" type stuff easily. I do keep a liner and a spool of .035 around for those "special times" LoL



Title: Zombie Ford F-350
Post by: husker77c on March 28, 2016, 10:24:56 AM
Well I blew out the electrical outlet that I was using outside so no progress till an electrician gets here.   It's not a flipped breaker and anything else with AC wiring is out of my skill set so I have to wait till tomorrow to get that fixed. 

In the meantime I'm mocking up my next project. 

This pic is mock up for measurements with some small pieces I had. 

(http://uploads.tapatalk-cdn.com/20160328/4095670852c0e78b367cb3a691cd0967.jpg)


I'm going to up armor the bed rails with 4x4 angle on the sides and 2x3 angle up front.  Going to run the angle the length of the bed and the cross piece in the front.   Then I'm debating welding in a piece along the tool box that will lock the box and fuel tank in place.  It will also give me a mounting point for the hi lift jack.

If I don't ever have to pull my camper with this truck I'm going to build an expedition rack for the back.   Put a large basket up top and maybe carry my spare up there. 

Maybe something like this

(http://uploads.tapatalk-cdn.com/20160328/49bce4c9bd74627c4388c4c226474179.jpg)

I've also entertained the idea of having a canvas tarp made to drape over a rack like that and snap to the rack.  Wouldn't be 100% waterproof or secure but would at least keep my stuff back there fairly dry.

Something like this.

(http://uploads.tapatalk-cdn.com/20160328/257e58c35541471eddcea0a1904dcb39.jpg)

I wish I had done a military trailer as a truck bed back when I replaced the bed on this but oh well. I can work with what I have. 

My girl goes back to TX for work on Wednesday so I will have several full days to work on the truck.   Hope to get bumper finished and painted and bed rails done.  If there is any time left I will see about a grill guard for the bumper. 




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Title: Re: Zombie Ford F-350
Post by: Bear9350 on March 28, 2016, 10:55:41 AM

Just brand. Same .035 flux core.  This HF stuff is much darker color than the Hobart.   The Hobart is silver.  I even double checked to make sure I didn't have non flux core Hobart.  But they are both the same specs.

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How old was the old wire?  If it sat around for a little while some corrosion will start to build up on the first few layers on a spool.  It might take a little while to burn up that wire and then clean all the corrosion out so everything runs good again.  Looking at the pics it does look like you might be able to crank the heat up a bit.  I'm not a very good arm chair welder though.  Would have to be there running and hearing it to give you any decent advice on where your settings should be.

I know I have ran smaller spools of both HF and Hobart wire when I wanted something for a project that required smaller than the .035 I generally run.  I'm always running solid wire though.  I'm not sure what the brand of wire I get from the AirGas dealer is.  I just puck up a couple 44 lb spools when I am running low.  Given the current steel prices I should probable look into stocking up.
Title: Re: Zombie Ford F-350
Post by: husker77c on March 28, 2016, 11:10:12 AM
It was fairly old and the whole spool seemed to be the same way.   My heat is as high as it will go. I have just been running the beads pretty fast on the plate.  I could probably get a hotter bead if I stayed in one place a little while longer before moving. 


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Title: Re: Zombie Ford F-350
Post by: Bear9350 on March 28, 2016, 11:17:16 AM
It was fairly old and the whole spool seemed to be the same way.   My heat is as high as it will go. I have just been running the beads pretty fast on the plate.  I could probably get a hotter bead if I stayed in one place a little while longer before moving. 


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I just went up and read where you said you had it cranked all the way up.  The pickling on that thicker steel can be thick.  If you haven't been I would suggest grinding down to raw steel on those surfaces.  Also, if you have been welding on the truck, taking the bumper off and making horizontal welds instead of vertical will give you more penetration and better control.
Title: Zombie Ford F-350
Post by: husker77c on March 31, 2016, 01:25:16 PM
Well after 3 hours of an electrician here trying to figure out why my outside outlet net belly up we found this stellar wiring job by the previous owner.

(http://uploads.tapatalk-cdn.com/20160331/048ed8c758ad57390fe8ea823ee5454d.jpg)

Fixed up now and the wife's out of town so I started hitting it hard on the ford.  Until it started raining.  Grrrr I need a shop. 

But some progress.

Got one end of the bumper plated.

(http://uploads.tapatalk-cdn.com/20160331/d966d802ce2e0bc3086ec2e7c52620d8.jpg)

I picked up my angle for the bed rails.
(http://uploads.tapatalk-cdn.com/20160331/8f5ff88ceb90fd2e349df42717e0acb9.jpg)
I hit the bottom side with undercoating in a can so I shouldn't have any rust issues where the bed meets the rails. 

I got my jack mount finished.

(http://uploads.tapatalk-cdn.com/20160331/3e60e2f2435c9e3275078239dd1c35c1.jpg)

(http://uploads.tapatalk-cdn.com/20160331/628190efc08214e34889e798ab7cab6c.jpg)
That piece will tie into the bed rails behind the tool box and stiffen everything up lock the tool box and fuel tank into the bed. 

It will go here
(http://uploads.tapatalk-cdn.com/20160331/519fd0537827d9c06ac5dc85c2b8171f.jpg)

Hopefully the rain passes soon so I can get back to work.  I'd like to have all these projects finished by the weekend. 


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Title: Zombie Ford F-350
Post by: husker77c on March 31, 2016, 06:50:43 PM
Well it stopped raining and I got the brace/jack mount fitted and the bed rails on.  They aren't bolted down yet and the piece behind the cab has to go in yet but it's taking shape.

(http://uploads.tapatalk-cdn.com/20160331/e79be5a3f4c32d910cf2c0ce5f402844.jpg)

(http://uploads.tapatalk-cdn.com/20160331/1d5c024f06f21fea8998ec0bc7aee7f8.jpg)
I'm going to paint the rest of the tool box but wanted to get the part behind the brace painted. 

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Title: Re: Zombie Ford F-350
Post by: Flyin6 on March 31, 2016, 08:43:57 PM
I like this project because it's simple, practical, affordable and unlike mine, will probably RUN!
Title: Zombie Ford F-350
Post by: husker77c on March 31, 2016, 09:18:35 PM
I like this project because it's simple, practical, affordable and unlike mine, will probably RUN!

Lol. I have faith that D will run in due time. 

It is affordable. I've got maybe $400 in steel for all these projects.  I tried to scour craigslist for steel but nothing ever came up that was usable to me. 

It is simple because I only have short bursts of time to work on it. Being unemployed means extra wife scrutiny and I have to handle a majority of the household chores while she works.   So I needed to be able to go outside have a quick thing I could do and then get back to whatever else I was doing. 

And practical because it went from a zombie apocalypse truck to a future daily driver.   I'm going to have to sell my 2012 to cover some debt I have from my previous life so the Ford will be pushed into daily driver duties for a year or two, maybe longer.   

I have zero need for a late model truck ever again. I think back to all the money I've wasted keeping up with the oil field Joneses and I want to kick myself.  It's just not necessary.  I'm not getting down on people who do it but that's not a rat race I want to be in anymore.

This truck does 95% of what a late model truck will.  Might not ride as nice or have backup sensors and such but I'll live. 

And I finally got my front driveshaft installed.  I had it lengthened and it was about an inch to long so I had to go get it shortened a bit.  Fits like a champ now and it's fully operational.   I think I'm going to fix my crooked steering wheel tomorrow and take it for a drive to use my fuel perks to put 30 gallons in the auxiliary fuel tank for free.

Also made this little guy for the wasted area on the instrument bezel.  I'm going to wire a starter kill into one of the safety switches along with a second hidden switch for that circuit.  The other safety switch may be an all kill for the other three switches (a la Square D) which will be hooked up to a light bar, and fog lights for the bumper and a third TBD circuit.

(http://uploads.tapatalk-cdn.com/20160401/ec0e0d2631221e9b21da4a618f1106ae.jpg)


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Title: Re: Zombie Ford F-350
Post by: swbhobie16 on March 31, 2016, 10:48:28 PM
going to do something very similar to that for the 715. the truck came with a floor started on the trans tunnel hump.. so to keep it from getting accidentally bumped while driving, going to put another toggle or button somewhere on the dash to complete the ground circuit for the starter relay. figured it's be safest.. and keeping it theft proof.

if it doesn't take a key to start it.. one can't lose the key. hahah
Title: Re: Zombie Ford F-350
Post by: husker77c on April 01, 2016, 08:17:15 AM
Yep.  A starter kill is cheap insurance.   I'm going to wire in an additional relay into the starter circuit.  I used to work at a car stereo shop and one of my best friends is a genius with automotive wiring.   A starter kill relay is pretty basic but if you don't know where that switch is then it will never start or even crank. 

Here's my diagram if anyone wants to do the same.  Wire colors will obviously be different though. 
(http://uploads.tapatalk-cdn.com/20160401/c92f611e429ce71f715498e149debf37.jpg)

Like I said I will have a visible switch on the dash and I'm going to bury one somewhere else that I will switch when I need theft a  deterrent.


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Title: Re: Zombie Ford F-350
Post by: stlaser on April 01, 2016, 09:31:20 AM
That should be a sticky.....
Title: Re: Zombie Ford F-350
Post by: Flyin6 on April 01, 2016, 09:50:13 AM
I just luv this exchange of informations! (Trying to talk like the russian on the phone I spoke to who was faking trying to be someone else...)
Title: Re: Zombie Ford F-350
Post by: JR on April 01, 2016, 12:41:45 PM
Dealing with that in the sub I am flipping. So many wires from the alarm and it turns but no spark or fuel. At least I have another to compare!
Title: Re: Zombie Ford F-350
Post by: husker77c on April 01, 2016, 02:39:45 PM

Dealing with that in the sub I am flipping. So many wires from the alarm and it turns but no spark or fuel. At least I have another to compare!

If the alarm was wired in by a pro then that's more than likely how they set up the starter kill.  But a starter kill in an alarm won't allow it to crank.  They could have wired in the same type of relay on the fuel pump or coils. Just replace the switch in the diagram with the trigger from the alarm brain.   Alarms/remote starts in 90s through 08-09ish were a rats nest of wires especially in multiplex cars.  Wire is a positive trigger on some circuits and negative trigger on others all running through the same wire.  Once everything went to data bus it's a lot simpler wiring to install and remove.   Heck I can even use my factory key fob to run my Viper alarm/remote start on my 2012. 


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Title: Re: Zombie Ford F-350
Post by: JR on April 01, 2016, 02:45:42 PM
This was don by a so called expert and it is a 91. Here some what I have removed;
Title: Re: Zombie Ford F-350
Post by: KensAuto on April 01, 2016, 04:18:07 PM
I would call that^^^^ a cluster-you-know-what.
Title: Re: Zombie Ford F-350
Post by: stlaser on April 01, 2016, 05:09:12 PM
Ouch........ Good luck with that
Title: Zombie Ford F-350
Post by: husker77c on April 01, 2016, 06:12:34 PM
Yikes.  What brand is on the crossovers in the first pic?

91 model. My guess would be it was hard wired to everything.  Parking lights ignition etc. Which means there is absolutely no good way to remove except through trial and error.  Kind of lake the squiggly thing in the alien movies.  You can remove it but it kills the host lol. 

Was it just an alarm or a remote start too?

Edit.  I see they are MB Quart crossovers.  Those are worth a few bucks to someone.   They are bi-amp three way crossovers.  If you want to sell them let me know.  I may be interested.


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Title: Re: Zombie Ford F-350
Post by: JR on April 01, 2016, 08:10:46 PM
Yep, its a mess. I have lights and it turns over, just no run. Nice thing is I have another 91 sitting next to it, but it has power accs.

Sure, they can go, make me an offer. Did you see the old cell phone!
Title: Re: Zombie Ford F-350
Post by: husker77c on April 05, 2016, 05:56:14 PM
Well I've been busy getting the Ford road trip ready.   My dads cancer is back and he has to go back through chemo starting Tuesday so I'm leaving this weekend for MI.  Going to take the Ford and see how she does.  I'm curious about fuel mileage and it's manners on the interstate. 

I fixed my non centered steering wheel from when I rebuilt the front end. 

Installed my oil pressure gauge and changed the oil.   I'm going to have some free time up at dads so I'm taking all my electrical things and I'm going to re wire all the gauges. 

(http://uploads.tapatalk-cdn.com/20160405/6051c99d503f547f6e7152f6dec633a3.jpg)

Cleaned out the bed and tacked on some eye bolts for a makeshift spare tire mount.

(http://uploads.tapatalk-cdn.com/20160405/64db55130a5d302053fd04ba45f5c10f.jpg)

(http://uploads.tapatalk-cdn.com/20160405/6127a0981db698952710ebbd1ae1fc09.jpg)

I painted the bumper the other day and got my 7/8 shackles.  Just put em on for the pic.  I don't want them stolen so I'll keep em in the tool box till I need them. 

(http://uploads.tapatalk-cdn.com/20160405/3a9e2f4be108d219d9689b4e0499c663.jpg)

I have to figure out a license plate bracket or something for the front bumper.  I don't want to drill holes if they aren't going to be in a permanent location.  I may cut a board to bolt to the fair lead holes and mount it to that for the time being.


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Title: Re: Zombie Ford F-350
Post by: JR on April 05, 2016, 06:33:11 PM
Good luck on the road trip and prayers for your father.

Mount the plate on a hinge and tac that to the bumper.
Title: Re: Zombie Ford F-350
Post by: Atkinsmatt on April 06, 2016, 09:10:05 AM
Spring clips mounted to the license plate that clip to the rollers on the sides of the fairlead.
Title: Re: Zombie Ford F-350
Post by: husker77c on April 06, 2016, 09:41:37 AM

Spring clips mounted to the license plate that clip to the rollers on the sides of the fairlead.

That will be the end result but I don't have a winch or fair lead yet.   So I need something temporary that I can use till I get a winch. 


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Title: Re: Zombie Ford F-350
Post by: Atkinsmatt on April 06, 2016, 01:03:38 PM
Put a wood plate inside the hole and screw the plate to it.
Title: Re: Zombie Ford F-350
Post by: husker77c on April 06, 2016, 01:24:39 PM

Put a wood plate inside the hole and screw the plate to it.

That's a good idea. But I welded up a little bracket that should work well. 

Had an Amazon gift card so I got some goodies. 

Plug for the block heater for the bumper.  I'm probably going to run this plug to a junction box somewhere and have this plug split off to run battery heaters and a fuel filter heater. That way I plug one extension cord in and it can run all heating systems.

(http://uploads.tapatalk-cdn.com/20160406/98ba1eaef4ea29e454bb4ad585309ecd.jpg)

Also picked up a 12volt fuel pump.
We exclusively use fill-rite on pipelines and they are stupid reliable.  In fact I've never seen one fail.  This one is a little smaller though because I don't need to fuel heavy equipment with it.   

(http://uploads.tapatalk-cdn.com/20160406/e15310774b13f53e81e1c7d3718d968a.jpg)
I'm setting it up with cam lock fittings to be able to easily disconnect it and configure it to pull from the on board tank or be able to hook up a draw hose from the inlet side and suck out of other tanks.   In case of an emergency I can suck out of  abandoned heavy equipment, tractors, anything really. Get a long enough hose and I would be able to pull from underground tanks at gas stations.  The pump will supposedly pull 15' of head but we'll see.
(http://uploads.tapatalk-cdn.com/20160406/9fe1135658a86cd22d9ad4c6d34b7e04.jpg)

(http://uploads.tapatalk-cdn.com/20160406/a9e7a07ff88d4a08e17079bf4ce41ccf.jpg)

Painted my tool box finally

(http://uploads.tapatalk-cdn.com/20160406/da6a0039412b0005a7149a3e8e3f5c95.jpg)

I welded some tie down points to the bed rails.

(http://uploads.tapatalk-cdn.com/20160406/5c9fba040a0843401a1fb5c187b66928.jpg)

(http://uploads.tapatalk-cdn.com/20160406/4d492470b4fead42e4b503cf24896ef2.jpg)

I'm also thinking I'm going to put a section of E-track I have down each rail for more attachment points.

 (http://uploads.tapatalk-cdn.com/20160406/d1ce5d75138d5ad002bbddf22048bf3a.jpg)




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Title: Re: Zombie Ford F-350
Post by: husker77c on April 06, 2016, 02:56:42 PM
Welded in the E track.   They are made of some crappy metal.  But they should hold up well enough for anything I need to haul. (http://uploads.tapatalk-cdn.com/20160406/8e0f770a0603e35cee6ea7fce90e8604.jpg)

(http://uploads.tapatalk-cdn.com/20160406/1f42b1e13464b8b0ab9cd08c816aa3b3.jpg)


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Title: Re: Zombie Ford F-350
Post by: JR on April 06, 2016, 04:01:24 PM
I had E-tract in a trailer and liked it. Pulled it out when I sold it plan on using in burb. Nice that you can get accs. for it almost anywhere, even HF!
Title: Re: Zombie Ford F-350
Post by: husker77c on April 06, 2016, 07:41:37 PM

I had E-tract in a trailer and liked it. Pulled it out when I sold it plan on using in burb. Nice that you can get accs. for it almost anywhere, even HF!

Yeah it's handy for sure. 

I changed my mind a bit about the fuel pump.  I realized I had better put a filter on the tank in case I run into a batch of bad fuel and it's just a good idea.   

I didn't really have room for one on top of the tank so I went and got some black iron and rigged up a little something. 

(http://uploads.tapatalk-cdn.com/20160406/8b78bf9f671e1e912d1c9e3ae8f1da3d.jpg)

(http://uploads.tapatalk-cdn.com/20160406/4486fa41604453d31df69ddea72e09d0.jpg)

I'll get a filter head and put it on the end of the pipe.  I may run a dual setup like I put on the engine so I can run the same filters on the tank and on the truck.  That way in a pinch I could swap the tank filter with the truck filter to get out of a bind.  And I only have to carry one set of spares. 


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Title: Re: Zombie Ford F-350
Post by: swbhobie16 on April 06, 2016, 09:50:17 PM
I just had 2 of those exact same block heater plugs show up at the doorstep too! seemed all to convenient to not have to fiddle with a plug in the sleet and rain. just flip the cover and go. not that the primary driver would forget, but we are going to run my dads to the driver side. probably behind the door and above the rocker. just so you dang near have to step over it to get in the truck and a less astute person would wonder what's plugged in. hahah. also may run an indicator light inside so you can tell when its energized. just extra precaution. 

and I know from our generators you can get a filter head that'll hold a wix 33357 filter.. which is what's on a PPump cummins. the VE may be 33358 (slightly smaller) and i don't remember right off hand which one you're running. I'm sure a parts store can easily cross reference it for you. I think the filter heads came from a Stone trucks parts, which may be local. but you can find them at any heavy equipment repair store I'm
sure
Title: Zombie Ford F-350
Post by: husker77c on April 06, 2016, 10:45:38 PM
That's a good idea running the plug to the body haha. My girl can't get the clutch all the way in on the truck so I'm the only driver. 

I'm not running a factory filter base.   The guy that pulled my engine didn't get all the banjo fittings and I couldn't find the correct bolts for it anyway.  So I'm running two filter bases on the frame rail and running a separate filter and water separator.   I can use any filter that has a 1" inlet.  I originally built it to run a cat 1R-0750 filter because they are supposed to be a 2 micron filter.  About $30 a pop though.  But that's to be expected with anything painted yellow lol.

Only pic I have in my phone of the bases.

(http://uploads.tapatalk-cdn.com/20160407/78c9c21fc72577c13bc78bb6c58ae593.jpg)


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Title: Re: Zombie Ford F-350
Post by: swbhobie16 on April 07, 2016, 06:25:56 AM
those are pretty sweet. I can't recall right off hand what size the PPump cummins filter nipple is..
wanna say 18/20mm X 1.5. but I could be wrong that might be the oil drain plug. hahah. I'd maybe figure out what thread it was and cross reference it to the white filters and just order a case. should be able to get them for $5-6 a piece and just have a dozen on hand..
Title: Re: Zombie Ford F-350
Post by: husker77c on April 10, 2016, 07:08:23 PM
Finishing up a few loose ends before I leave on the 700 mile trip tomorrow. 

Installed some Chinese spot lights.
(http://uploads.tapatalk-cdn.com/20160410/02aec56d3e683bb25823878ae26ffddb.jpg)

Tacked the mount onto my license plate bracket because I'm not sure what a final living configuration will be. 

Installed my plug for the block heater. 

(http://uploads.tapatalk-cdn.com/20160410/07ba04ad0bb1f4503e0cb629f792a304.jpg)

(http://uploads.tapatalk-cdn.com/20160410/18845d98b7252f86c3f393667e31d04e.jpg)

And I installed my cell phone booster.

I made an antenna mount out of angle iron with room for the booster antenna, a CB antenna and a future 2m set up. May have to ground the mount better so I drilled a small hole for a ground wire in case that becomes and issue. 

(http://uploads.tapatalk-cdn.com/20160410/d72fddb9410a3d6a7c3cda3e90ce5334.jpg)

The booster antenna is obnoxious but it's a life saver in those fringe cell reception areas. 

(http://uploads.tapatalk-cdn.com/20160410/0f22f5760c2dc999ae9ff17aee86a067.jpg)


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Title: Re: Zombie Ford F-350
Post by: stlaser on April 10, 2016, 07:46:03 PM
All looks good! I'm gunna go out on a limb here, the shackle mounts are 1/2"? If you're not on a straight pull I think you may bend those to the side some. I don't think they'll let go just think they might twist a little possibly.
Title: Re: Zombie Ford F-350
Post by: JR on April 10, 2016, 10:15:38 PM
I like the plug. Seen that a couple times on rigs for trickle chargers too. Simple and solid.
Title: Re: Zombie Ford F-350
Post by: husker77c on April 10, 2016, 10:22:47 PM
All looks good! I'm gunna go out on a limb here, the shackle mounts are 1/2"? If you're not on a straight pull I think you may bend those to the side some. I don't think they'll let go just think they might twist a little possibly.

Good eye. Yeah it was suggested before that a side load might tweak them and I would have to agree.  I've been trying to figure out some gussets that look decent and will be strong enough.    I may end up laying a piece of 1/4x3 flat bar all the way across the top of the two mounts to tie them both together.   Plus it could be used as a step to get up on the bumper. 

Yeah I may incorporate a battery tender type thing into the heating/AC side of the truck.  It's never done lol.
Title: Re: Zombie Ford F-350
Post by: JR on April 10, 2016, 10:29:38 PM
Why not just laminate another piece onto them for the thickness you want? Or a piece on each side for the same. Weld that to the bumper face and that solve the possible folding issue.
Title: Re: Zombie Ford F-350
Post by: swbhobie16 on April 11, 2016, 08:05:56 AM
im partial to the step idea myself. would keep them from folding and could provide either overhead or underneath protection for the fog lights.
Title: Re: Zombie Ford F-350
Post by: Bear9350 on April 11, 2016, 08:25:02 AM
Why not just laminate another piece onto them for the thickness you want? Or a piece on each side for the same. Weld that to the bumper face and that solve the possible folding issue.

I was going to suggest the same.  Clean all the paint off there good and grind some bevels on each piece before welding.

I don't think you would need to worry about them tearing at all and I don't think they would bend much unless they were given a good jerk.
Title: Re: Zombie Ford F-350
Post by: husker77c on April 16, 2016, 10:20:12 AM
Well I'm on my way home from MI.  Bad news on the dr visit but we are trying some new things and are hopeful things will improve.   

The truck has done really well.  Rock solid temperature and oil pressure.   Will cruise smooth up to 80mph without much coaxing.  It's sweet spot is around 70. 

It really isn't that terrible in the ride quality department.   It's loud though. After 13 hours in it my ears are humming for a few hours afterwards.  I'd like to address that but not sure what else I could do. 

Fuel economy is good but a little down from what I was hoping.  I'm averaging about 18 mpg.  I was hoping for 20s but for higher speed highway driving its good.  I think with a timing change and some more tuning I can get 20s. 

The larger rear fuel tank is awesome.  I didn't need to fill up at anytime I got fuel but I wanted to calculate mileage.  I'm getting around 350 miles when I fuel up and the gauge reads a couple needles over a half tank so I'll be close to 700 miles off the rear tank and another 350 or so off the front. 

I have approx 500 miles left until I'm home and I don't plan to stop for fuel again. 


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Title: Re: Zombie Ford F-350
Post by: Wilbur on April 16, 2016, 11:28:35 AM
Husker sorry about the news from the doc I hope it turns out ok.

You raise something I was thinking about on the fuel range. Around here Sam's is always the cheapest for fuel and I was considering that if I had the right range if I was planning a road trip I could plan out fuel stops (wife and I are discussing another western road trip in the not so distant future) and only use Sam's (or the gss buddy app which i really like) where I could plan stops way ahead of time based on that. (Gas buddy would be good if I needed fuel very soon and was unsure which station in a 10 mile range or whatever had the beat price but wouldnt tell me to drive another 100 miles bc a place two counties over is $0.20 cheaper or whatever). But I like having that range. I had a K10 back in the 80's with 56 gallon capacity. Loved it for cross country/long road trips.
Title: Re: Zombie Ford F-350
Post by: husker77c on April 16, 2016, 01:17:14 PM
Thank you for that. 

And yes a large fuel tank is great.  For me to stop for fuel its about a 20 min process.  If you don't have to stop for fuel but need to  use facilities a stop at a rest area takes about 5 minutes.  Averaged out over a trip saves a significant amount of time.

That's a good idea to plan for SAMs.  And to have the app as a backup.  You'd need that gas buddy running out west.   I80 through NE and WY it could be 500 miles or more between SAMs clubs.  Grand island NE to Cheyenne would be one gap.  Then Cheyenne to probably Salt Lake City.  I70 through Kansas would be similar. 


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Title: Re: Zombie Ford F-350
Post by: Wilbur on April 16, 2016, 03:28:05 PM
Yeah with a bunch of fuel it could be done though.  With the 56 gals I had I usually only need to fill up when I stopped for the night. I would do CO to MA in 625 (or so) mile per day increments (except for the 1 time I did it nonstop by myself yeesh). I am with you- rather stop for a quick p*** break than to add fuel all the time.
Title: Re: Zombie Ford F-350
Post by: Bigdave_185 on August 18, 2016, 10:03:46 PM
How is the ol ford coming along


Raising boys into RealMen!!
Title: Re: Zombie Ford F-350
Post by: husker77c on September 29, 2016, 11:14:32 PM

 
How is the ol ford coming along


Raising boys into RealMen!!

Haven't been on here in a while.   I've been busy with a new "normal" job.  Turning wrenches on roll off dumpster trucks.   Not oil field money but I'm learning a lot and it's kind of nice to only work m-f and 40 hours a week.  I also started a little side business making kydex holsters and selling them at gun shows around these parts.  Gun shows are few and far between though in the summertime up here it seems but there's one almost every weekend for the next few months so hopefully that takes off a bit. 

 Ford is good.  It's my on again off again daily driver.   I never got the AC hooked up so it's been parked most of the summer due to the heat but now that it's cooling off it will get a lot more miles.  With access to a proper shop now I'm already starting to think about installing a reverse shackle kit and super duty leaves up front and moving up in tire size a little bit.   I'm also entertaining the idea of a service/utility body for it.   I hate that I had to take all my tools to the shop which leaves me with the bare minimum here at home.  A service body would solve that and if we have a truck go down on the road at work I could use that to go render aid (at an additional cost to my boss of course).   And I may try to hire out as a truck mechanic on a pipeline next year and I'll need a service truck for that so it seems like a good idea. 
Title: Re: Zombie Ford F-350
Post by: JR on September 30, 2016, 03:18:52 AM
Glad to see you back around. Funny how life slows you down the harder you work.

Now tell us more about the holsters?
Title: Re: Zombie Ford F-350
Post by: husker77c on September 30, 2016, 07:24:29 AM
So true brother.  I started a thread in the firearm section about them.


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Title: Re: Zombie Ford F-350
Post by: Bigdave_185 on September 30, 2016, 08:16:27 AM
Sounds like a good plan for multiple reasons too.     We need a holder I can screw to my underside of my dash!!!


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Title: Re: Zombie Ford F-350
Post by: husker77c on September 30, 2016, 11:35:50 AM
I could probably work that up.  My new job is in a sketchy part of town so I usually roll with it laying in my lap haha.  But a more permanent solution would be better. 


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Title: Re: Zombie Ford F-350
Post by: Bigdave_185 on September 30, 2016, 04:16:54 PM
I was thinking something that would mount to the side of a center console or the under portion of the steering wheel kind of next to the usual place is people with old non factory installed trailer brake kits go


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Title: Re: Zombie Ford F-350
Post by: husker77c on January 30, 2018, 09:22:50 AM
Well since I stopped in to check on Square D I figured I could post a little update about the Ford. 

I got back into the Pipeline game so money has been better and I have a company truck to drive now so the Ford stayed put for the better part of last year.  However when a co worker offered me more than what my 2012 was worth I ended up selling Great white and I just used my company truck for a daily driver.  However the time is nearing that I will have to pull my camper to a new location.  I tossed around the idea of buying a 2017 Ford but the idea that I spent 10k less on a truck than I did my house didn’t sit right so why not move the Ford into tow pig duties?   

I brought the truck down to my work site and started in fixing things I knew would be needed to make it pull and be safe.   

New rear brakes, rear wheel seals and bearings.   After the front end rebuild and the rear end maintenance my running gear should be good to go.  I addressed some wiring issues as well.

I built a new panel for under the hood (https://uploads.tapatalk-cdn.com/20180130/90abbdf09e37d99ba13d4c8324fe1823.jpg)

I ran 4/0 welding cable over to a big truck battery kill switch and then from the switch to my starter and other accessories.   This allows me to shut off and lock the power to the starter as another form of a theft deterrent.   I also cleaned up my relays for the headlights and such and added 4 more relays for future expansion. 

I also put my Reese fifth wheel hitch in. 

I work with a guy that is pretty good with a 12 valve so after I get it back up and running I’ll have him bump the timing and tune it a bit then see what happens when I tow a 14k fifth wheel. 
 


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Title: Re: Zombie Ford F-350
Post by: Bigdave_185 on January 30, 2018, 10:34:38 AM
Looks good! 


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Title: Re: Zombie Ford F-350
Post by: BobbyB on January 30, 2018, 12:18:38 PM
I was actually wondering yesterday about whatever happened to this truck.
Title: Re: Zombie Ford F-350
Post by: JR on January 30, 2018, 12:20:41 PM
Nice update
Title: Re: Zombie Ford F-350
Post by: husker77c on June 11, 2018, 12:28:13 PM
Time for my once a quarter update.

The Ford failed the 5th wheel test.  I set up for a 5 mile pull from the campground to a shop where we were set up for the winter as a shakedown run.  The truck pulled the camper fine.  It needs more power if I continue to push it into a full time tow pig, so I'm researching twins right now.  However stopping the heavy beast was the problem.  It stopped fine and safely on the shakedown run.  With the trailer brake controller and mostly 30-40 mph through town I had no major hiccups.  However there was about a mile stretch where I was able wind it up to around 55mph.  Then when it came time to stop and turn in to the shop, one again it stopped fine but the brakes were smelling pretty bad and when I parked the rotors were too hot to touch.

I think part of the problem was when I rebuilt the rear brakes over the winter I didn't have them adjusted correctly and all of the stopping power was the front brakes alone.

A couple mechanics at my work adjusted the rear brakes for me but I didn't get a chance to pull it again after that.  An employee I work with let me borrow his duramax dually to haul the camper over to our next job location and I drove the Ford over bobtail after that.

I now have until November or so to figure out what my next plan of attack should be.  I NEED a reliable truck to pull my camper but I can't justify the price tag on most newer trucks right now.  In hindsight I shouldn't have sold my 2012, but I did and now I have to figure out what to do.  So my options are.

1) Continue to build the Ford.  Maybe take it to a shop and make sure the brakes are all up to snuff from a professional.  But if I go that route and it comes time to pull and I find out the brakes are never going to be good enough then Im back to square one, actually worse because Ill have to pull and won't know it won't work until I get under the trailer.

2) Buy a truck.  That can be broke down into to options.  One being buy a later model dually, or pick up a single axle international 4300 or similar and install a fifth wheel on it.  With the weight of my camper to be "legal" I really need an F-450 or F-550, and if Im doing that then an international starts to make sense.  A newer 550 can run from 15k for a work truck model to 100k for a platinum 2018. While an international can be had for around 10 used.

While the zombie Ford won't be "legal" either I seriously doubt I will ever get in trouble for it, but I just have to make sure its safe for me and others on the road.
Title: Re: Zombie Ford F-350
Post by: Bob Smith on June 11, 2018, 12:42:04 PM
Are the trailer brakes set up properly, and  are working as they should. Is the controller one of the newer ones, Prodigy name comes to mind, the newer ones work much better. Hopefully once you get the truck brakes adjusted and the trailer brakes working right you should be in good shape.
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