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jthrash’s 91.5 w250 build

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Old 10-04-2018, 08:02 AM
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After 25 years or undercoating rigs in the harsh climate of VT, I have learned that thinner oils applied more often work better than thicker, waxy undercoats as the salt and water will eventually get under the stuff and rot it out.

I usually use bar and chain oil thinned down with diesel fuel, as it soaks into the cracks and seams well. It needs to be re applied every year though. That is what works best for me.
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Old 10-05-2018, 11:12 AM
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Originally Posted by oliver foster
I usually do several trucks at the same time, then have a fire where I burn the dribble soaked cardboard and my old jeans and sweatshirt at the same time after. I then grab a beer and hit the shower.
Sounds like a job for my wife, haha.
Old 10-05-2018, 11:56 AM
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Originally Posted by bannerd
Sounds like a job for my wife, haha.
THAT is a good wife!
Old 02-19-2019, 09:24 PM
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update... dana 80

been busy with other things lately but i’m starting the next phase of my build, over the weekend i bought a Disc brake Dana 80 with 3:55 gears from a front end crashed 01 six speed dodge, as well as MC and hydroboost unit. unfortunately the trans was spoken for. i steam washed the axle and took it the brakes off. my guess is rotors, calipers, pads etc have low miles they are in great shape. i’m going to throw fresh ebrake shoes and hardware in it, and paint everything with a fresh coat of black and run it! i bought a D80 swap kit from ruffstuff. hanging shouldn’t be an issue, possible driveshaft shortening. the confusing part for me will be the hydroboost conversion with the gen1 powesteering pimp... may buy a 24v pump if it bolts to a 91.5 vacuum pump as it’s outfitted with extra ports for HB. we will see! pics to come. hoping it doesn’t look super goofy being about 4 inches wider than a d70.
Old 02-21-2019, 03:22 PM
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Do a search for Hydroboost....there are several threads, mine included that show what we did and how things are plumbed. I started with a 2nd Gen HB PS pump but burned it up by not bleeding properly, so tossed the OEM 1st gen unit back in and has been working great for the last 3-4 years.
Old 04-14-2019, 06:42 PM
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Progress

Disc Dana 80 is in! Bed is off, frame is painted, hydroboost swap is complete using 2nd gen parts. Adjustable proportioning valve install also. Brakes are fantastic. Also, made some new tank straps as mine were getting thin, and freshened up the fuel lines to the sending unit and retaped the wiring harness with some fresh friction tape

Unit was shortened about 6 inches to clear pipe


(I’m not a painter)

Heavy duty straps I made


Used aftermarket perches for adjustability
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Old 04-15-2019, 01:54 AM
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Looks great...well done!! I have thought of doing the Dana 80 swap as well one day, but if I do I think I will run duallies and a flat deck.
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