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84F350
01-03-2011, 11:22 PM
After wheeling my 1977 F-150 for a few years at Gilbert, Appleton, AVF, Dresser and Rochester, it was time to start on a new truck.

http://forum.mn4wda.com/attachment.php?attachmentid=56

I started making a list of changes I wanted in a new truck so I could gather parts while limping the old truck along.

Old
Carburated 460
3.55:1
Rear Lincoln Locked
NP205
Skyjacker 6" lift
Disk/Drum

New
-Fuel Injection or Propane
-Lower gears
-Lockers or LS Front & Rear
-Doubler
-More flexible suspension
-Four wheel disk brakes
-Reliabliity

Initially I bought a 89 F-superduty with a 460EFI 5spd to build the truck on, but after working on the truck, I decided I wanted more interior space and the truck was going to end up too heavy with the F-superduty frame.

http://forum.mn4wda.com/attachment.php?attachmentid=88

After a little more searching, I came across the donor for the new wheeler.
A 1995 F-150 2wd 300EFI E4OD

http://forum.mn4wda.com/attachment.php?attachmentid=79

The truck was a little ruff around the edges and missing some items, but the price was right.
Looking back I should have found a rust free Texas truck to start with.

84F350
01-03-2011, 11:43 PM
The next step was to strip the truck down to its bare frame to get rid of the 2wd drive suspension, motor, transmission and rust.

Disassembly begins.
http://forum.mn4wda.com/attachment.php?attachmentid=64

Deciding on the wheelbase. Stock is 139" and I wanted something shorter than the long box of the 77 at 133" The tires are set at 125" wb to clear the cab. The tires are 40" boggers for the rear and TSL's for the front.
http://forum.mn4wda.com/attachment.php?attachmentid=66

Project continues.
http://forum.mn4wda.com/attachment.php?attachmentid=68

Body gone, suspension and rear axle next.
http://forum.mn4wda.com/attachment.php?attachmentid=83

84F350
01-03-2011, 11:45 PM
2wd suspension gone.
http://forum.mn4wda.com/attachment.php?attachmentid=71

Excess frame and 8.8" axle removed.
http://forum.mn4wda.com/attachment.php?attachmentid=73

Frame off to get sandblasted.
http://forum.mn4wda.com/attachment.php?attachmentid=67

Some new parts: Cage extended radius arms, coils and shocks.
http://forum.mn4wda.com/attachment.php?attachmentid=74

84F350
01-04-2011, 12:11 AM
With the frame back. It was time to prime it to keep the rust down.
http://forum.mn4wda.com/attachment.php?attachmentid=87

First components installed was a ruff stuff shackle flip, differential cover, 63" Chevy 1/2ton rear springs, Dana 70 with rear disks, 5.13's and a powerlock.
http://forum.mn4wda.com/attachment.php?attachmentid=86

Front suspension installed with 6" lift variable rate coil springs, 77 F-150 coil towers, Cage radius arms, track bar and a Ford Dana 60 with 5.13's, powerlock and 35 spline outers.
http://forum.mn4wda.com/attachment.php?attachmentid=62

460 EFI and 5 spd installed with factory Ford mounts and a temporary transmission mount.
http://forum.mn4wda.com/attachment.php?attachmentid=81

84F350
01-04-2011, 12:21 AM
While working on the rest of the truck, I decided to install a doubler now instead of later, which would have required a new crossmember and driveshafts. After searching around, I decided to go with Offroad Designs 203-205 doubler along with their tripple stick setup.

Doubler assembled and ready for installation.
http://forum.mn4wda.com/attachment.php?attachmentid=59

Doubler mounted in the frame. The front crossmember doubles as a driveshaft loop.
http://forum.mn4wda.com/attachment.php?attachmentid=70 http://forum.mn4wda.com/attachment.php?attachmentid=82

Tripple stick levers installed. (The rear mounts were being painted in this picture)
http://forum.mn4wda.com/attachment.php?attachmentid=60

84F350
01-04-2011, 12:39 AM
After installing the new drivetrain and crossmembers, the updated fuel lines from a 95 460 were installed and the rear electrical before the cab was dropped back onto the frame.
http://forum.mn4wda.com/attachment.php?attachmentid=69

The column, F-superduty hydroboost, shocks (with F-250/F-350 mounts), front clip and engine harness were installed.
http://forum.mn4wda.com/attachment.php?attachmentid=77

Inside, the cab was kept mostly stock, the stick pedals and column were added and floor was modified for the triple stick and 5 spd.
http://forum.mn4wda.com/attachment.php?attachmentid=84

All of those modifications bring us up to today. The truck still has some small gremlins to take care of to get it to run with the newer body style, but with out a heated shop to work in, progress has been slow. Current priorities are to get it running and modify the front fenders for suspension travel and turning.
http://forum.mn4wda.com/attachment.php?attachmentid=65

Future plans include hydraulic assist steering, onboard air, rock-sliders (maybe boat side), custom bumpers with 2" receivers and D-rings, and shortened bed or flatbed.
As for most projects, I don't think this one will ever end, but hopefully will be out enjoying the trails this year working the bugs out.

mn4wheeler
01-04-2011, 10:32 PM
cool buildup.that is going to be sweet when you get it done.

bruce
01-05-2011, 11:54 AM
Nice write on the build. See you out there this year.

bigE
01-05-2011, 09:30 PM
Looking good so far.

MNtal
01-27-2011, 08:41 PM
Looking good keep up the progress...

84F350
02-03-2011, 03:04 PM
Thanks everyone,
Not much has been done on the truck lately, just a little work on the rear end.
As soon as the weather warms up, the work on the truck will continue.
Current plan is to still have it ready for the spring convention.

84F350
05-02-2011, 10:48 PM
After some last minute wrenching on Clifford Friday night, it made its wheeling debut Saturday morning.
I was very impressed with how the truck worked. The suspension flexed very well and the doubler and 5 speed made a nice combination for wheeling and crawling.
The only obstacles that gave the truck any issues where the ones that were too tight for it to fit.
Its wheelbase and larger tires allowed it to go over obstacles with ease that built Jeeps on 35's were having problems.

I am already working on a new list of things to change and modify down the road. Some of the items are:
-Shorten and reinstall the box
-Build bumpers and sliders
-Trim the front fenders more
-Add rear shocks
-Rebuild the powerlocks or install a detroit in the rear
-Add front bumpstops
-New exhaust
-Upgraded Steering components
-etc...

Truth be told, I doubt it will ever be finished.

Pictures from the Spring Convention:
http://forum.mn4wda.com/attachment.php?attachmentid=117&d=1304394418
http://forum.mn4wda.com/attachment.php?attachmentid=118&d=1304394559

84F350
05-10-2011, 06:00 PM
After looking over the truck some more, I noticed my drag link started looking like a U. Now the question is do I bend it back and reinforce it, change the steering to something beefier, add assist or go full hydro? I still would like to keep the truck streetable and I might have a problem running the full hydro with my hydroboost brakes.

MNtal
05-24-2011, 07:49 PM
Full hydro with a double ended ram and never look back...

84F350
06-23-2011, 10:41 PM
Does the the full hydro with a double ended ram behave its self at higher speeds?

The steering survived its first wheeling trip to Gilbert over Memorial weekend. Only damage was the drivers cab floor by the door.
Rock sliders are still needed and it is still a work in progress.

During Saturday and Sunday the truck performed excellent at Gilbert. The rebuilt rear powerlock took a little while to start working and then worked great. The front one needs a rebuild or switch to a selectable. The brakes lock up the truck immediately and steering had no issues.
The item that impressed me the most was the doubler, it worked great. The truck had no problems crawling over the rocks with no throttle.
The truck never needed a strap or winch. The only spot that gave it trouble was the top of Ski Jump. If the front limited slip would have worked, the top would not have been a problem.
Granted I probably did not take it on the hardest trails.
I think we went on: High Voltage, Upper Money Talks, Ski Jump, Leaf Lake Loop, Sauna Rocks, Rock Crawl, and quite a few more.
The trucks biggest drawback is it width.


Still to do:
-modify box and reinstall
-Bumpers front and rear
-Winch in front bumper
-Rock sliders
-Skid plates
-And the list goes on.