2009 F550/1989 Dodge Hybrid

[upnthetrees]

Long time lurker finally with something to share, still hugely in progress and will likely be another half year till it is capable of working and playing, but thought I would start a build thread to show what I have accomplished so far.

Am pretty positive there will not be another truck like this one. Basically, I am taking a 2009 F550 ZF6 4x4 and dropping a 1989 Cummins and body on top. Behind the cab will be a Hiab and tilting flat deck for work, riding on super singles for play and adventure.

Found a heavy duty mechanics rat bagged bush service truck that had a blown 6.4, rebuilt rear end, replaced transmission and worn out everything else, and towed it home to sit for a few months while I collected pieces.


Friend gave me a good deal on a low mileage 12 valve from an 89, and I proceeded to take it apart. Will get all the fixings, o-rings, studs, springs, tuned pump and injectors to support 450hp by Giles, he351cw/hx55w towing compounds.



Out she comes



The only reason why I bought this truck is for this little gem I liberated. Picture doesn’t do it justice, but the rust was bad where the service body had trapped 11 years of dirt and water. Luckily the frame is thick and everything is in good order after some time behind a pressure washer. Fuel tank and skid plate where the worst.



Good deal on an old Hiab 550-1. Will make some extendable out riggers to make it a bit more useable.



Front axle free



And rear axle



New brake system



Temporary shelter for sand blasting and paint.

 

[upnthetrees]

Good friend came out with his industrial blaster and went to work.



Sprayed some rust primer. Amazing what a blast job and paint can do to make everything look new again!




Sealed up and ready for a coat of epoxy.



Ended up having to get a frost fighter and baked the epoxy, was too cool here to have it cure properly, bit of a mess about, but it is the price I pay for doing this outside in the fall. All turned out real well.





Brought all the little pieces to my friends and sand blasted them myself this time. And I learned the hard way to be very careful where you point the nozzle. Been picking sand out now for a couple weeks.



But, got it done

 

[upnthetrees]

Little parts finished and waiting for topcoat



Got my head back from the machine shop



And had a day of decent weather to finally get the polyurethane top coat on the frame.



And that is currently where I stand right now. Am just working on getting the axles and all the small stuff ready for the final top coat, than I can start putting everything back together again.

Will be a couple weeks likely before that gets done though, as I need to prepare the shop to hold some heat so it can cure properly.

After the topcoat cures, I have pretty well everything I need to get the engine and drivetrain put back together and ready for paint, and the adapters are all waiting to nest it on to the chassis.

Then comes the real fun part of putting the old 1st gen dodge body in place and shoe horning everything to fit. The front rad support will need to be custom modified for the ford fan and radiator and newer dodge intercooler, and the fenders will need massive trimming to fit the 42” tires with no lift. Which comes to the part that am sure no one has done, stretched 1st gen dually fenders on the front fenders to cover the 92” track width.

 

[Jacobm]

You're a mad man.

I dig it.

 

[Overdrive]

Wow, amazing! The Ford cab in the first pic looks like it's in good shape, why are you going with the Dodge cab instead?

 

[upnthetrees]

Wow, amazing! The Ford cab in the first pic looks like it's in good shape, why are you going with the Dodge cab instead?

At first it was mostly because I like the style of the old dodge trucks, and previous to disassembling the ford I was also partial to having more space to work with in the engine bay, as well as the idea of as little electrical as possible. After taking it all apart, the reason is now mostly because of having more space to work with, and as little electrical as possible. ?

I like simplicity, and just want a work/play truck I can work on with basic hand tools, on the side of the road or in the bush if need be.

 

[charlieaarons]

A ZF-6! I am impressed. Add a 2.7 reduction box/NP205, lockers, maybe 335 singles - perfect. Get the gear ratio just right for whatever tires. If you get big singles, reconcile yourself to 60-68 mph even on interstates.

 

[upnthetrees]

A ZF-6! I am impressed. Add a 2.7 reduction box/NP205, lockers, maybe 335 singles - perfect. Get the gear ratio just right for whatever tires. If you get big singles, reconcile yourself to 60-68 mph even on interstates.

Np271 is already 2.72:1 reduction, and for sake of simple and cost, will stick with the chain driven 271.

Rolling chassis is basically staying the same, just a complete restoration. Down the road I will likely do a Jana76 (70 ring/pinion stuffed in a 60 housing) front with an electric locker, and leave the rear limited slip.

Tires will be the 335 G275’s which are rated for 80mph. With 4:88’s and .72 6th gear, 80mph will see me at 2200rpm, highway cruising around 60mph at 1650rpm. The Cummins gets best mileage cruising around 15-1600rpm. Am happy to stay around 60-68 anyhow.

 

[GPurcell01]

This build will be wholly awesome. Have you figured out what wheels you will pair with those G275's? Pretty cool you're going with Goodyear and not the typical Continental like most super singles.

 

[upnthetrees]

This build will be wholly awesome. Have you figured out what wheels you will pair with those G275's? Pretty cool you're going with Goodyear and not the typical Continental like most super singles.

From what I hear the continentals are loud and have poor tread life, and while I don’t plan on doing over 65mph often, it is nice to have the piece of mind that I can if I need/want to.

Am still chewing on what to do about wheels. There is a member on here doing runs of one piece aluminum wheels that look good, but quite the price tag. Am not really too keen to use steel, tires are heavy enough as it is. Stazworks makes an aluminum wheel as well, but not one piece.

At this point by the time I am ready for wheels and tires, I figure there will be more options. Other issues is shipping right now is silly across the boarder, so with any luck that shet show will calm down in a few months…though am not hopeful…

 

[GPurcell01]

From what I hear the continentals are load and have poor tread life, and while I don’t plan on doing over 65mph often, it is nice to have the piece of mind that I can if I need/want to.

Am still chewing on what to do about wheels. There is a member on here doing runs of one piece aluminum wheels that look good, but quite the price tag. Am not really too keen to use steel, tires are heavy enough as it is. Stazworks makes an aluminum wheel as well, but not one piece.

At this point by the time I am ready for wheels and tires, I figure there will be more options. Other issues is shipping right now is silly across the boarder, so with any luck that shet show will calm down in a few months…though am not hopeful…

Have you checked out DBL Design? They make really nice 3 piece aluminum forged wheels that are beadlocks. They also make a 1 piece steel wheel if you don't want the multi-piece like Stazworks.

I hear ya - everything is silly right now.

 

[upnthetrees]

Have you checked out DBL Design? They make really nice 3 piece aluminum forged wheels that are beadlocks. They also make a 1 piece steel wheel if you don't want the multi-piece like Stazworks.

I hear ya - everything is silly right now.

In the end the price will reflect what finds its way under the truck, which even has used aluminum MRAP wheels looking tempting, only issue is having a precision adapter made. A company here in Canada makes adapters, but they are laser cut which will not make for a well balanced wheel. However, 1/4 of the price has me seriously considering it.

 

[vovka1]

wow this is a cool build

 

[upnthetrees]

wow this is a cool build

And it just got far more affordable with your inspiration!

 

[gtbensley]

I cant wait to see more progress on this. Well done