My 1990 F150 Cummins

[WRENCH52]

Hi, I've been a lurker on here for a while. I thought I'd show you my vehicle build. I hope to either acquire or most likely build a simple light weight pop up for the back. I like light weight , simplicity and reliability, those were my objectives in this build.

The base vehicle is a 1990 F150 4x4 Super Cab that I bought new. I put close to 190k miles on it before deciding to rebuild it. It originally had the 302.

Specs and build details:

* The truck was totally torn down to the point of cutting the frame cross members off the rails,.
* The C section rails were sand blasted and then boxed and plated with 1/8 plate.
* Cross members were sand blasted and then the frame was reassembled.
* The total frame was hot dip galvanized and then shot with epoxy primer and two pack.
* Cummins 3.9 4BT was totally rebuilt including the VE pump. Holset HX25w6 installed for instant boost, boost controlled to 25 psi. KDP fix. piston lift pump with regulated return to give 10 psi into the VE.
Original hydraulic engine mounts used on fabbed brackets. Dodge IC installed. VE pump turned up, I estimate 175 hp. The electric fuel solenoid shut off is gutted so the engine is shut down with the mechanical shut off on the VE pump from inside the cab
* Original M5R2 5 spd and 1356 TC were rebuilt and used.
* Gear Vendors OD installed giving 8 forward ratios. In reality I don't split 2nd so actually use 7. 1,2,3,3 over,4,5 and 5 over. 5th over gives 1650 rpm at 75 mph.
* Dana 44 solid front axle sourced, rebuilt and installed, 3.5 gears with Eaton Tru-Trac LSD. Moved forward 3/4" to clear front cross member. Fabbed tie rods, track arm and trailing arms. HD coils with Bilstein 5100 shocks. Warn hubs.
* Ford 9" rear sourced and rebuilt, 3.50 gears with Eaton Tru-trac LSD, original leafs with Firestone bags, Bilstein shocks. Explorer discs installed.
* The cab was gutted, floor repaired, door lowers and cab corners replaced. Explorer power seats and console installed.
* Front clip from a 93 was installed along with the windows in the cab extension.
* Fabbed custom aluminum flatbed along with aluminum front and rear bumpers and cab steps. The bed sides are removable. Custom storage boxes.
* Toyo 285/75R16 AT's on ProComp alloys.
* Total fuel capacity 34 gals. The rear tank contents are transferred to the front tank as needed with the stock rear in-tank fuel pump. 4BT lift pump draws from front tank.

I've put about 20k on it since the build, a blast to drive and gets 23 mpg cruising at 75. I did everything except install the new windshield,

 

[pigsammy]

Really good looking truck!
How long did the tear down and build take?

 

[WRENCH52]

Thank you.
I think it was about two years from the time I picked up the 4BT (Frito Lay van} until I first drove it. But there was a divorce in between so that kind of slowed down the schedule a little, Then there was some shakedown work like going to the smaller turbo and getting the VE pump dialed in, the stock belt tensioner bracket bolts sheared off and I heard a thud and saw the tensioner behind me, made a new bracket for it and a few other small items.

I have a lot of pics from the build but they are on an old Win 7 so I have to transfer to this new one. I will try to do that this week.

I have been spending hours on the DIY camper forum, I would really like to build something similar to a FWC Hawk. I realize there is inflation in everything but where does $30-35k go into one of those?

 

[WRENCH52]

Build pics and about 1200 other pics are gone. I had them on Kodak ezshare software when I had an old Kodak digital camera. Now it shows all the files are corrupted, it shows thumbnails for about 20 secs then they turn gray with a jagged line thru it, Bummer. All my off-road bike trips too. I loaded it up with the KLR last w/e and went to the deer camp for work w/e. Was pulling logs for firewood. Took a great ride on the KLR.

 

[dbhost]

Since you mentioned a DIY camper, check out tnttt.com and look for RJ Howell's later model F150 flatbed build. I have an '04 and am planning on swiping some of his ideas and going a bit deeper into the build. (Fully trimming out the iterior to make my lovely wife happy).

I REALLY hate the issues the 5.4L 3V Triton has, and have considered a 4BT swap.It would most likely be a lot easier on your generation truck.

I can't say enough good about your build though. VERY well done. I'd be curious to see how you manage to get through any sort of emissions testing with that sort of swap. Not sure what the regulations on that are... Sounds like you had a good amount of body work to deal with. Something I have never learned. Still need to do that...

 

[WRENCH52]

Thank you. I live in NY state, tax capital of the nation and run by the dumbest people on earth but any vehicle older than 26 model years and any diesel older than 1996 is exempt from emissions testing.
Yes, the body work took a lot of time. Instead of welding the door lowers and cab corners I used 2 part automotive body adhesive and rivets and put the seam under the rub strip, that way I didn't have to worry about any warping, it worked great.
I will check out that link, thanks.