Little truck rehab

[fabiodriven]

This will probably be somewhat long winded which should be expected I guess. I've been a little OCD about this project so I don't want to miss anything.

My truck is a 99 Ford Super Duty, 2wd with a 7.3 diesel and a six speed. It's a four door and has an eight foot bed.

I got the truck in 2011 with about 187k on the clock. Since then it's been on many, many trips with at least a heavy camper in the back if not a trailer as well. I've taken this truck to Trikefest three times. It has almost 226k on it now and it was due for a freshening. The drive train has always been solid as a rock and the body was extremely good for this area of the country. It definitely came from another part of the country. The beds on the Super Duty's are known to break some of the welded joints as well as rot out really fast up here. My bed wasn't rotted at all, but the seams had been broken and then welded by a rookie (who thought he was doing me a favor) so they broke again a year later. Not only that, but the scale on the frame was building up and I really wanted to address it. Then some dame drove into my driver's side dually fender and broke it and the insurance company found me half at fault (which was total bullshit) which only left me with $400 to replace the fender. That wasn't going to cut it. My buddy had been badgering me about some flat be he knew about with tool boxes for $200, so I figured that was the way to go. I had been getting bored with the truck anyways and it would only take me four days at the most, right? :lol:

The first thing we did was pull the bed off. I sold the bed for $600 so that gave me an even $1k to play with. I couldn't have done this without the help of a fellow vet and neighbor of mine who was more than gracious enough to let me use his heated garage, welder, and we were even able to borrow a plasma cutter. Prior to bringing the truck in the garage, we had a freak warm streak where it was about 55 degrees for about 3 days in January. I used my descaler (pneumatic needle scaler) out in my driveway and hit it hard with the descaler and a hammer for the big stuff. I wish I had taken pictures of the amount of scale on this frame. Nothing was rotted though, just covered in scale. I drove around for about a week with no bed and a set of magnetic tow truck lights plugged into my trailer outlet. There were two days when I couldn't drive it as the paint dried. Originally I was just going to paint the back half of the frame, but while the bed was off we did a set of ball joints on the driver's side and a parking brake cable. During that time I couldn't ignore the scale on the rest of the frame, so back under I went to clean and paint the entire frame of the truck as well as some key body areas under the cab. The frame had been bead blasted and painted already, but there was no deck on it and no provisions for lighting. I bought a step bit for my drill to aid in the vast quantity of different sized holes we would have to drill but I found out really fast that drilling this body is a big deal. It came off of a 34 Ford and the metal is really thick. Not only that, but I'm inclined to think it might be "real steel" from back in the day and therefor harder to drill. Just a theory. The body ruined my $40 step bit as soon as I touched it and it laughed at the die grinder. We were forced to plasma cut all of the light holes out which was the plan for the bigger lights, but the button LED markers only require a 3/4" hole and the drill would have been ideal for that. We had to weld 3/4 washers on the inside of the body to have a nice, clean mounting hole after cutting the body with the plasma cutter. I built the entire wiring harness by myself and shrink wrapped everything.

Once the paint on the truck was dry and the body was ready, we moved it on to the truck. I wasn't sure how I was going to mount it when we first installed it. I looked at my trailer receiver and there was at least a foot and a half between the bottom of the body and the top of the receiver. Where my truck is 2wd it's lower anyways so my trailer hitch was always too low. This was a good opportunity to bring it up. Even still, a filler panel was going to be required. I ended up using pressure treated 4x4's trimmed accordingly between the frame and the body and U bolts to clamp the two together. The mounts for the mud flaps weren't going to work so I had to fabricate new ones. I cut the trailer receiver down 3" and welded it back together. I also added some gussets to it. I cut that hitch apart last year before Trikefest and welded it back together and it has been fine, so I am confident in my work. We have a 44" extension that goes into that receiver to reach out under the camper so the leverage makes a heavy load even heavier on that hitch. We roll fast and heavy so it has to hold.

Mounting the deck and tool boxes wasn't hard, it all fell into place. I added an external 2 gallon tank to the on board air system and put a visor over the windshield (which went slightly awry, fingers crossed it doesn't leak) and I also added a removable exhaust stack for when the camper is on the truck. I cut and fabricated the existing exhaust and then added some pieces I bought. The truck, trailer, and camper are now entirely LED externally, except for the HID headlights and front indicators on the truck. All LED's are clear or smoke lens with the appropriate color in the LED itself. Top license plate bolts on both plates are LED license plate lights. Windshield is brand new as well.

All in all it did cost me a couple of bucks in the end, but I don't know how much. I'd say no more than $200 or so. I am very happy with it and have some more to do, but this is the gist of it. I was waiting for a nice day when I could wash it, but that doesn't appear to be happening any time soon. I'll take some better pictures of the underneath and stuff when the weather breaks. Regardless of my situation, my truck is key. It is an absolute necessity for both work and play. If I lost my house, I'd still have my truck. The pictures are chronological. It's no secret that I've had a rough time over the last year or so. This is the first time I've been able to truly get off my arse and so something productive rather than just going through the motions. Something happened right around the time I started this project so I've had a lot to keep my mind occupied and feeling something other than miserable. For about two weeks I was working on this like a full time job, from the time I got up until the time I went to bed. Sometimes past 11pm. There was an additional week of some small fine tuning so it took roughly three weeks. Thanks for looking.

http://i146.photobucket.com/albums/r275/fabiodriven/Trikefest%202011/Trikefest2011LaurelIndiana070.jpg (http://s146.photobucket.com/user/fabiodriven/media/Trikefest%202011/Trikefest2011LaurelIndiana070.jpg.html)

http://i146.photobucket.com/albums/r275/fabiodriven/100_4320_zps020464d1.jpg (http://s146.photobucket.com/user/fabiodriven/media/100_4320_zps020464d1.jpg.html)

http://i146.photobucket.com/albums/r275/fabiodriven/477563_3536380649135_1260904462_33411391_108548185 7_o.jpg (http://s146.photobucket.com/user/fabiodriven/media/477563_3536380649135_1260904462_33411391_108548185 7_o.jpg.html)

http://i146.photobucket.com/albums/r275/fabiodriven/484179_4773643579935_679567091_n_zps9867dc89.jpg (http://s146.photobucket.com/user/fabiodriven/media/484179_4773643579935_679567091_n_zps9867dc89.jpg.h tml)

http://i146.photobucket.com/albums/r275/fabiodriven/IMG_20120425_172339.jpg (http://s146.photobucket.com/user/fabiodriven/media/IMG_20120425_172339.jpg.html)

http://i146.photobucket.com/albums/r275/fabiodriven/IMAG0454_zps19b7f791.jpg (http://s146.photobucket.com/user/fabiodriven/media/IMAG0454_zps19b7f791.jpg.html)

This is my buddy who helped me and let me use his garage.

http://i146.photobucket.com/albums/r275/fabiodriven/IMAG0455_zpsbdc668e5.jpg (http://s146.photobucket.com/user/fabiodriven/media/IMAG0455_zpsbdc668e5.jpg.html)

http://i146.photobucket.com/albums/r275/fabiodriven/IMAG0456_zps26397059.jpg (http://s146.photobucket.com/user/fabiodriven/media/IMAG0456_zps26397059.jpg.html)

http://i146.photobucket.com/albums/r275/fabiodriven/IMAG0508_zps30ffc6b4.jpg (http://s146.photobucket.com/user/fabiodriven/media/IMAG0508_zps30ffc6b4.jpg.html)

http://i146.photobucket.com/albums/r275/fabiodriven/IMAG0509_zps8aca05c5.jpg (http://s146.photobucket.com/user/fabiodriven/media/IMAG0509_zps8aca05c5.jpg.html)

http://i146.photobucket.com/albums/r275/fabiodriven/IMAG0510_zps574b38a7.jpg (http://s146.photobucket.com/user/fabiodriven/media/IMAG0510_zps574b38a7.jpg.html)

[briano]

I like it. I've always thought a big dually should have a flatbed on it.

[trike savior]

looks good. i agree those beds make any truck look better. does the camper still go on without any modifications? i am sure the tool boxes have to come off. what about the exhaust stack?

[fabiodriven]

The tool boxes will stay where they are with the camper in. The exhaust stack is removable.

[DohcBikes]

Very nice. I like the single short off center stack and the two tone. Whered ya get the air horns? What are you running for the on board air system, and how's it working for you?

[Big Mike]

Looks good man, great job. Everyone's going flatbed. My truck is flatted, my father's truck, and now yours. Mine is about 80% done, and will be 100% once the warmer weather gets here again.

[fabiodriven]

Very nice. I like the single short off center stack and the two tone. Whered ya get the air horns? What are you running for the on board air system, and how's it working for you?

The original air system came with the compressor, horns, and a one gallon tank. The first time I installed it, both the horns and the compressor were mounted under the truck in the elements. The horns weren't loud down there and the compressor died after two weeks both because it was a cheapie and because of it being in the elements. The second version used the tank and horns from the ebay kit, but I mounted the new Viair compressor and the tank in the cab behind the back seat. We then moved the horns from under the truck and switched it from an electric solenoid activation to a manual pull lanyard that hangs from the ceiling. The Viair pump goes to 160 psi as opposed to the 120 psi the Ebay kit did. I could easily empty the one gallon tank on a long horn blast, but I pull the horn a lot longer than most people. I bought the new Viair tank which is two gallons and added it to the loop including the old tank so that brings it to three gallons total capacity. I've only been running it for two days like that and the compressor takes a while to fill it up. If the compressor ends up taking too long, I can take the one gallon tank out of the loop for a total of two gallons. Once this compressor goes, I'll get a bigger one. The Ebay horns are excessively loud even if you're expecting them. I hope they stay together because I really like the way they sound a lot. I've had people literally pull off of the roadway and stop near railroad crossings when I hit my horns.

[El Camexican]

It great that your engine is only half way through its life. A friend of mine turned the odometer past 500,000 this year on his 99. It’s been stolen, gone through half dozen clutches and as many tail-gates, but the only engine work was a set of heads two years ago. The wrench said the lower innards still look like new.

[jays375]

Fabio you been rolling some coal!Never figured you for a single black stack type guy.Lol.Where did you find that old of a flatbed?What did you use for decking?

[wisconsinite]

I've got a big old crew cab chevy dually with a flatbed. After 6 months you will wonder how you ever hauled anything without it.

[fabiodriven]

That's right Mexinadian, these engines regularly hit half a million. The only mods to mine are a K&N filter in the factory air box and a straight pipe. It came to me that way and all I've done is put a bigger straight pipe on it. Other than that all I've done are fuel filters and oil changes. It always starts no matter how cold it is out and I don't plug it in. I might make a video of it cold starting, it's pretty impressive. I stand out there every day no matter how cold out it is just to hear it. It starts out with a really powerful, lumpy idle and plenty of smoke. After about 2 minutes or so, it kicks up to its high idle and has a flap in the exhaust that closes limiting the exhaust flow and thus helping to warm the engine. It literally sounds like a jet taking off and I realize there are people on this forum who will never witness this because it's just never cold enough out where you live. Once I put the stack on, it projects the jet engine sound so much it's almost absurd. I can only imagine what the neighbors think. I've had friends run over to my truck lunging for the ignition to shut it off because they thought it was going to explode, haha. People in public places get all fired up, especially while I'm fueling.

No coal rolling jays. I have a programmer but don't have the extra dough to shell out for some programs right now. I've had people breathing down my neck about that for over a year. Apparently I'm not going to believe the difference.

[hatc200x1]

Nice looking truck! I can agree with the jet engine sound, its crazy! I actually didnt know what it did or why my 7.3 did it until now. Haha

[fabiodriven]

Here's the cold start video I made this morning. It was about 20 degrees out. We regularly get down to the single digits here, and the colder it is outside the more dramatic the startup. It's going to come up under my buddy's You Tube account because I had problems uploading it. The high idle kicks up at around 2:30. Sorry, I don't know how to edit.

http://www.youtube.com/watch?v=uKMzt34q24c

[ezmoney1979]

Loud forkin diesel a-holes............glad we're not neighbors:beer

[El Camexican]

Pretty cool! Your's starts a lot better than this poor guy's does. Watch the whole thing.

http://www.youtube.com/watch?v=oPYKs9Jn45M

[DohcBikes]

Dude. That is effing AWESOME. Sounds purrfect to me.....

[fabiodriven]

That guy held the starter on for way too long.

[big specht]

You need to throw that k/n away if you want it to last. I can almost guarantee that thing it letting dirt past. I put a custom burnt TS chip on mine I like it , it was a big differance from stock they suck to drive stock. Hope fully I will have mine at TF this year, (Its alot nice ride than that old dodge I always drive)I need to put a flat bed on mine and a leveling kit a straight pipe and a bigger tranny cooler.

[fabiodriven]

You need to throw that k/n away if you want it to last. I can almost guarantee that thing it letting dirt past.

It's funny you say that. We've had some pretty in depth discussions here on 3ww about K&N's, and I was never a fan. I remember learning a lot about them in the last debate we had and had come to the conclusion I would use them for road going vehicles, but not off road. I don't remember what the deciding factor was there, but I remember coming to that conclusion.

[trike savior]

one of my college professors said, " you guys and the dang K&N filters, of course they flow more cause they don't catch nothin". (he was from OK) He was one of the smartest men I've ever known around vehicles. He taught powertrain management and invented some of the most clever electrical bugs I've ever had the pleasure of tracking down.

However, I still use K&N filters on my vehicles. The oil in them is what catches the dirt. if you run them too long without re-oiling you will be sucking dirt/ dust in the motor

My brother in law recently asked for an FIPK kit for his Yukon which was still under warranty. I told him he needed to check if it would void his warranty, which it did not, but I had recently heard that some manufacturers were blaming the oil in these filters for contaminating the Mass Air Flow sensors and not covering the bill. He showed me K&N has an article on their site saying that was BS.

[tri again]

Nice job Fab. Glad you had a warm place to work.
We had some place near wuss ta where we could rent heated garage space to work on cars.
Think it was called the briarpatch, tool rentals and expert advice to boot.
I remember reaching up to grab a frame rail to pull myself under one of those and a chunk of something like beef jerky came off in my hand. Glad you got the frame redressed.

My uncle was whining about some sort of water? filter? on his that was never changed and it rotted between 2 cylinders? Good to change antifreeze too or sacrificial zinc anode for that reason.
Maybe it doesn't even have one?
Yeah, whatever gets them to half a mil sounds good. Stock filter in the airbox?

Glad you got a happy truck. Sure makes a difference, doesn't it.

What's the programming comment? Some different engine control chip?

[tri again]

Pretty cool! Your's starts a lot better than this poor guy's does. Watch the whole thing.

http://www.youtube.com/watch?v=oPYKs9Jn45M

Someone drove the 89 F250 across the field, shut it off and handed the keys to dad.
About 15 min later, smoke poured out from under the hood.
Fender mounted solenoid got stuck and turned the starter shaft blue.

Imagine if it was parked in a garage and left overnight?

[Dirtcrasher]

It's funny you say that. We've had some pretty in depth discussions here on 3ww about K&N's, and I was never a fan. I remember learning a lot about them in the last debate we had and had come to the conclusion I would use them for road going vehicles, but not off road. I don't remember what the deciding factor was there, but I remember coming to that conclusion.


I agree 100% and do not run them; I run UNI filters with spray on filter oil..........

[big specht]

It's funny you say that. We've had some pretty in depth discussions here on 3ww about K&N's, and I was never a fan. I remember learning a lot about them in the last debate we had and had come to the conclusion I would use them for road going vehicles, but not off road. I don't remember what the deciding factor was there, but I remember coming to that conclusion.

I worked at a ford dealer on diesels for 13 years and I've seen more than one truck with dirt in the filter housing cause those k/n's didnt stop. And make sure your filter housing is sealed up good

[ATC-Eric]

I worked at a ford dealer on diesels for 13 years and I've seen more than one truck with dirt in the filter housing cause those k/n's didnt stop. And make sure your filter housing is sealed up good

I used to run a motorcycle shop, and couldn't begin to count how many machines were toast because of a K&N.

[plastikosmd]

Whoa

Nice truck!!!
Love the camper too.