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1994 F350 crew, shortened frame, w a 93 Cummins, NV4500, gear vendors and NP205
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Hi guys, I'm new to posting but have enjoyed reading a lot of posts on this forum. I finally got a chance to take pictures of my project. I'm in Vail, AZ which is close to Tucson, AZ.
Basically I'm trying to make a truck that me, my fiance and family can tow 6-10K, drive on a regular basis, be very reliable and get great mileage. I'm not looking for a lot of power, the engine has the HTT compressor wheel and housing, 4" exhaust and a custom fuel pin. I'm happy with its performance and I was getting ~21 mpg in the 93 2wd without a lockup converter. I'm hoping the conversion to manual and the gear vendors will allow similar mileage even with the added weight. I also really need 4wd since our move to Vail, I can't tow a trailer up a steep hill on our driveway without full throttle smokey launches. It will be nice to be able to click into 4 low and cruise up the driveway. Here is the truck as I purchased it, 460 gasser, almost 200K miles, 4.10 gears. I picked it up for $3500 in Phoenix, but it had a gear vendors installed in it. Just clean enough to use on a regular basis. Attachment 57529 First order is to cut the frame down. I can't stand how long these trucks are for daily driving. I'm going to shorten the bed and frame 20" to make the bed the same as most chevy short bed. Attachment 57530 Attachment 57531 Attachment 57532 Attachment 57533 Welding prep to get full penetration... Attachment 57534 Attachment 57535 Attachment 57536 Plate welded in opposite direction as initial cut, rosette welded opposite sides of cut, but left sides unwelded. Attachment 57537 Attachment 57538 |
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Out with that nasty old 460 and e40d, the thing got 10 mpg driving back from phoenix, haha
Attachment 57519 Attachment 57520 The NV4500 I got a killer deal on, $650 and it came with engine plate, flywheel, shifter, starter and all hardware. Came out of a 2002, but it was 2wd. Although I'm running a divorced t-case, I am putting a gear vendors on the back of the NV4500 so I need the trans as short as possible. The idea is that I can use the gearvendors in low range to combat the weak link of backing up a hill causing the clutch to burn up in the gear vendors. This way in low range the gear vendors has 1/2 the load versus being mounted after the t-case... Attachment 57521 Attachment 57522 Old 2wd shaft and new 4wd shaft with updated split thrust washer to fix the 5th gear problem... Permanently I hope... Attachment 57523 Fretting of old 5th gear trying to work it's way off... Attachment 57524 Cast iron tailhousing from standard transmission, I checked bearing for center it was dead on. Attachment 57525 Attachment 57526 Attachment 57521 Attachment 57528 |
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Preload set right at .002
Attachment 57509 Attachment 57510 Attachment 57511 Attachment 57512 Attachment 57513 Gear vendors disassembled, **** thing has pitted gears in the annulus, going to have to get a rebuilt one... Still way cheaper than buying a new unit. Attachment 57514 Gear vendors rebuilt unit installed, I had to drill and tap the adapter myself so the unit would sit flat, wasn't too bad though. Attachment 57515 Valair 13" clutch, I hope it lasts for a long time. I'm not going to be very hard on it. Attachment 57516 Time to get that Cummins out, poor old dodge, I loved that truck but it just doesn't fit the bill anymore. At least it's heart will go with me many more places. Attachment 57517 Attachment 57518 |
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So I pulled the oil pan off to re-seal it and found a busted plastic piston cooling squirter. Got some billet aluminum ones on the way, but the crank has to come out. Bummer, gonna set me back a week.
Attachment 57499 Time to start working on the motor mounts. I used ones from a 24 valve on accident- the holes are cast back further on those engines so these are far forward on the 12 valve. It actually ended up working really well, putting the mounts right in the middle of the crossmember. It was a lot more work but I like how they turned out. The p/s pump is really close but it does clear. Attachment 57500 Attachment 57501 Attachment 57502 Attachment 57503 Gusseting while trying to stay clear of a/c compressor Attachment 57504 Attachment 57505 Attachment 57506 Engine and dynamat installed, going to have to come back out to fix oil nozzle but I have to keep moving forward... Attachment 57507 Meanwhile finishing up helping a customer restore a 1974 FJ40 TLC. Had the truck down to the frame, powdercoated just about everything steel, rebuilt the entire drivetrain- most all mechanical work I did. I don't do body work though! Attachment 57508 |
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Time to mount the transmission. Many many thanks to Ballistic Fabrication - Manufacturers of Precision Offroad Fabrication Supplies for the laser cut parts. The crossmember was for a superduty that I cut up and modified. Great guys, Allen the engineer can do just about anything you want for a reasonable price.
Attachment 57489 Attachment 57490 Attachment 57491 Attachment 57492 Attachment 57493 Attachment 57494 Trans looks like it was meant to fit in there! Attachment 57495 Time to mount up the divorced 205, I will be taking everything back out to finish welding and rebuild the 205. Also that pesky oil nozzle keeps haunting me... Attachment 57496 Attachment 57497 Attachment 57498 |
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Laser cut frame plates, beautiful stuff.
Attachment 57479 Attachment 57480 Attachment 57481 Attachment 57482 Attachment 57483 Pilot shaft will be ~8.5" long! Rear driveshaft 45", front 62. haha. Attachment 57484 Strange place for a T-case. Attachment 57485 I had to ditch the front tank, so I got the spectra FD26 I believe, the 38 gallon one for the rear that allows the spare tire to be used. I had to make a new pickup, return and modify the sending unit quite a bit. Attachment 57486 Attachment 57487 Attachment 57488 |
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Monsterous tig weld, haha
Attachment 57473 Turbo flipped, waiting on a spacer and a rebuild kit. Going to rebuild everything I can afford to do, trying to make this a low maintenance truck... Attachment 57474 I was able to just heat up and bend/twist the drain pipe a few times to get it so it workes with the flipped turbo. I have some softwall oil hose on the way to connect the 2... Attachment 57475 I pulled the dodge engine last friday (10 days ago), progress seems to be happening quickly! I have to get this thing out of my shop because I have more landcruisers on the way, they will slow progress down substantially. One is getting a Mercedes 6 cylinder turbo diesel, the other already has a brazillian 4 cylinder IHC engine. The rest are just pics that my fiance or I took over the last couple weeks... Sensors for the ferd: Attachment 57476 Adjusting valves: Attachment 57477 5th gear nut tool that ballistic is going to copy so guys like us don't have to spend $50 on a cheap plasma cut POS. Attachment 57478 |
Really nice work!!!
I like that year ford and with the shortbed and cummins it is going to be a great machine!!! |
Thanks! I hope it does everything I want well. It's not getting big tires or anything like that. It should look like a stock F350 aside from the short bed :cool:
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Great write up! Looking forward to seeing it all shortened up!
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super clean build! amazed the 460 got 10 mpg WITH a gear vendors... omg.
Great truck for the family, OBS fords will have parts for the next 50 years, unlike first gen dodges. |
Thanks guys, I'm totally overwhelmed by the project and work right now it's great to have some positive reinforcement. I am hoping it turns out well, we're hoping to drive it to Alaska or the northeast next summer :)
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Looks great! Are you gonna try too shorten the bed you have or try to find a normal shortbed in that body style?
Sent from my DROID2 using Tapatalk 2 |
Originally Posted by bryson711
(Post 3108941)
Looks great! Are you gonna try too shorten the bed you have or try to find a normal shortbed in that body style?
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I made some more progress, I had a couple customers cars come in that slowed things down but still moving forward. Motivation is lacking at times, I need a **** vacation from wrenching...
I rebuilt the starter, vacuum pump, turbo and re-sealed the p/s pump. I sealed what I could on the p/s pump but a special puller is needed to remove the drive dog/hub and I don't see anyone that sells it. I think most just buy a rebuilt pump but I'd rather do it myself. I have trust issues, haha Attachment 57372 Attachment 57373 Attachment 57374 Attachment 57375 Attachment 57376 Attachment 57377 Tore the NP205 down and ordered the bearings and seals needed to rebuild that. Attachment 57378 Attachment 57379 Replaced the body mounts with Poly ones, I hope I don't regret it... The OEM ones were really blow out and new Ford ones were ~$500, at cost + 10%! These were $50 so I'll try it. If you do this, make a puller out of some 3" exhaust tube, I don't know how else you could do it.. Lots online about how to, even the poly instructions had a note on it... Attachment 57380 |
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I also tore the engine down to replace the plastic oil nozzles with the billet aluminum ones, then found that I need a camshaft The rest of the engine looks really good but I'm going to put new bearings in since the old ones are out.
Attachment 57365 Attachment 57366 Attachment 57367 Attachment 57368 Attachment 57369 Attachment 57370 Soon it should be drivable, I keep saying that but it looks like at least a week off... Attachment 57371 |
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More progress:
NP205 rebuilt and converted to twin stick: Attachment 57245 Attachment 57246 Camshaft installed, went with a Colt stage III, I think it might run a bit differently! Attachment 57247 Attachment 57248 Engine and trans installed until it drives, not coming back out again! :party018: I hope. Attachment 57249 Attachment 57250 Clutch hydraulics installed, I used a Ford master cylinder and a 2000 dodge slave/master- removed dodge master and replaced with Ford master. Was fairly straight forward, press roll pin out, switch units out. Be sure to bench bleed the master first. Attachment 57251 Attachment 57252 |
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Pedals converted from auto to manual:
Attachment 57236 Turbo flipped, spaced, drain hose finished: Attachment 57237 Attachment 57238 I installed the starter with the spacer for the 13" flywheel, I had to flatten out the spacer it was 20 thou off on one side. I had to grind out the inside a bit so it would fit over the starter too. Annoying... Attachment 57239 Throttle all sorted out, I used a combination of custom and factory parts. The factory ford sheath is definitely the best for the ford body... Attachment 57240 Attachment 57241 New ford sending units installed, coolant and oil (Hint, go to local hardware store): Attachment 57242 Attachment 57243 Started working on the a/c compressor. I bought a new unit for a 94 because my clutch hub bearing was bad, and converting to R134; then used the rear cap/manifold off a John Deere tractor. Bought a lot of fittings/hose at nostalgic air parts, used them for TLC's in the past: Attachment 57244 I'll update as it progresses, probably 3/4 finished now 3 weeks after taking the engine out of the dodge... |
Beautiful work
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A/C Cap
Do you have the part number off the JD cap you used ? so and using this cap do you still have to notch the cross member ? thanks trucks looking good
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Yes, I got it here: http://www.nostalgicairparts.com/air...ad-back-22.php
They also have all the fittings you need. I had to re-locate the heater return bung as well, I made a return pipe and put it in the lower rad hose then plugged off the one that got in the way of the a/c fittings on the block. I don't think you'd have to notch the crossmember with this depending on your mounting location, I still did but mine is mounted awfully low... |
Looks great buddy , I just finished a 84 suburban cummins conversion , I see you retained the original fuel tank ... was that a diesel tank I know there can be a problem with gasoline tanks having zinc coatings reacting with the diesel .
look forward to seeing more ... great build ! |
Thanks, it's not the original tank, it's from a cab and chassis (I believe) and is 38 gallons instead of 19. It's made by Spectra and is specifically rated for diesel or gasoline- I read about the zinc/diesel meltdown and realized I had to replace it with something, got lucky finding the bigger one for not a whole lot more money...
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Well it's been a while since an update. I've been driving it, getting better with each drive and haven't had too many issues. The divorced t-case has proven to be quite difficult to setup, the driveline angles need to be perfect or **** close... I also fought with a bent input shaft in the NP205, worn out output shaft causing play and an improperly machined 1410 sterling 10.25 yoke.
Attachment 56720 Attachment 56721 Attachment 56722 Lower radiator hose proved to be the tightest and worst. Don't know if I would have used the 1st gen rad again if I had the choice... Attachment 56723 Heater pipe I made because the fitting on the engine was in the way of the a/c hoses Attachment 56724 Attachment 56725 Intercooler plumbing modifications Attachment 56726 The battery cable on the dodge was resting on the frame, that was a close one! Attachment 56727 I had to relocate the battery to the drivers side Attachment 56728 |
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I then took the entire wiring harness apart and deleted all the gasser stuff. Then integrated the cummins into the factory harness, the old fuel pump relay is now the starter relay, ECU relay is now the gear vendors relay etc...
Attachment 56710 Attachment 56711 Attachment 56712 Attachment 56713 Attachment 56714 gasser engine ECU is not even hooked up anymore, and everything works! Still need to hook cruise up. Attachment 56715 Various shots of details... Details, details... Attachment 56716 Lower radiator hose, what a pain that was. Attachment 56717 4" downpipe wrapped, a/c box double insulated. Attachment 56718 Used the first gen intake for now Attachment 56719 |
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8" pilot shaft to t-case
Attachment 56701 38 gallon tank with spare mounted, the spare hangs a bit low but works for now.. Attachment 56702 Exhaust pics, I bought a stainless system for a powerstroke of the same era, but ended up having to modify it completely... Attachment 56703 Muffler from dodge, I love this muffler! Attachment 56704 Various exhaust mounts, etc Attachment 56705 Attachment 56706 Manifold is now upside down but egt probe still works Attachment 56707 Attachment 56708 Attachment 56709 |
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Seats and center console stolen from dodge, most every good part that was on the dodge went into this truck. I feel better about doing what I did knowing a lot of the parts are going onto the new truck.
Attachment 56692 Attachment 56693 Attachment 56694 Attachment 56695 Shifter boot and ring are off an older kenworth, fit really nicely. Attachment 56696 Attachment 56697 Attachment 56698 Added traction bars, and working on the rear diff right now. Pinion bearings are running hot... Attachment 56699 Attachment 56700 |
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Bed on for now, I'll pull off for finishing touches but I love the new length. Surprised they didn't make these trucks this length.
Attachment 56687 Found some proper alcoa's in a junkyard for $200, I also bought F250 lift blocks for the back and lowered the rear of the truck 2" Attachment 56688 It runs amazingly well, I have had 2 mileage estimates both combined hwy/city and had a 20.3 and a 22.7 Really happy with it so far, but still a fair amount of details to finish up. Attachment 56689 Attachment 56690 Here's a pic before the new wheels and dodge tires Attachment 56691 |
Im absolutely in love with your truck i got a 96 f2 ext shortbed i wanna drop a Cummins in my 460 god bless the power is killing my wallet lol
Sent from my EVO using Xparent SkyBlue Tapatalk 2 |
Originally Posted by Peterbilt_379
(Post 3127352)
Im absolutely in love with your truck i got a 96 f2 ext shortbed i wanna drop a Cummins in my 460 god bless the power is killing my wallet lol
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Hey guys, I made a video of the truck as a 10,000 mile 1 year since swap celebration.
I didn't mention the mileage, but I've been getting 18.5-19.5 city/hwy combined with the truck weighing in at 7500 lbs. About 14-15 towing 8000 lbs. |
I think that you have my favorite Ford/cummins conversion Sir!! Excellent job! This is an excellent real world rig.
Your motor-mount saddles in the factory cross-member are super clean. nice work! :cheers: |
Wow is all I have to say, probably the cleanest well done conversion I have seen.
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great work!. I have been agonizing over what transmission I am going to run in my Excursion conversion. You may have just helped me solve that. I prefer manual transmissions. Although I do admit that 5 speed ford auto sound like a nice tranny. I did not want the hassle of programing that trans controler. I had been wondering how easy it would be to adapt the hydraulic clutch. You were just able to remove the roll pin and put the dodge hose right into the ford master cylinder right onto the dodge hydraulic hose? That is awesome. I don't suppose you or anyone else would know if the Master from a 99 and up would fit the same way. I guess I will just have to go parts hunting, If I ever get time off and get home from the oilfields.
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Hey guys, been a while since an update on the truck and progress. Still driving daily, and drove it to Alaska finally! Truck did really well, other than adding a few quarts of oil it didn't have any other issues on the 8000 mile trek.
Attachment 49118 Attachment 49119 I did some modifications to prepare for the trip, I built a flatbed with integrated toolboxes which was probably the largest change: Attachment 49120 Attachment 49121 Attachment 49122 Attachment 49123 Attachment 49124 Attachment 49125 Attachment 49126 Attachment 49127 |
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Attachment 49110
Attachment 49111 Attachment 49112 Swapped out the old Recaros for some 2008 BMW M6 seats, they match better than stock seats lol: Attachment 49113 Attachment 49114 Removed the rear seat for a storage box for the trip and so our dog had a place to lie: Attachment 49115 Added a huge 1750 CCA Odyssey battery (still single battery, but even 2 optimas would be 2000 CCA minus battery cable loss). 10.5 Diff cover: Attachment 49116 Attachment 49117 |
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Added Disc Brakes to the rear using RuffStuff specialties adapters, made a hydraulic cable actuated parking brake and added a proportioning valve:
Attachment 49101 Attachment 49102 Attachment 49103 Attachment 49104 Attachment 49105 Swapped out the H1C turbo for an HE351CW off a 2007 cummins: Attachment 49106 Attachment 49107 Attachment 49108 Attachment 49109 |
Sweet build up and that looks like you had a great trip to AK!
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We did! Albeit, we only had 30 days off work and I can say it's not enough to really experience it. It was basically routine, drive all day, get to a camp, sleep, repeat...
Oliver, we have a lot of cars, but I think you have an addiction :cool: haha |
Originally Posted by 93D250
(Post 3311116)
Oliver, we have a lot of cars, but I think you have an addiction :cool: haha "Hello, My name is Oliver. I am addicted to Mopars" Admitting it is half the battle right? Great I got that off my chest…Now my daughter and I are headed to the the shop to work on Mopars...[coffee] |
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