'90 f150 build

52wrench

New member
Here's a few pics of my build that has been going on for 2 years now. Bought the truck new and started this @ 190,000 miles. My objective is light weight but tough, simple (no ECM's), fuel efficient, aluminum flat bed with FWC eventually. You can see what the salt does to vehicles here near Buffalo, NY. Totally disassembled the frame, blasted and had it hot dip galvanized, reassembled and painted with epoxy and SS urethane. Cummins 4BT with HE341 turbo, intercooler, 9" rear, D44 solid front, 4" lift necessary with the SAS, Eaton Tru-Trac LS frt and rear, 3.50 gears with the M5R2 5spd for now, BW1356 transfer and a GV overdrive to give 9 forward gears. Explorer rear disc conversion. With 3.50's and 33X10.5-15 it will be turning 1620 @70 in double over or 1740 in 4th over @55. Boxed the frame, totally rebuilt the cab, just finishing up exhaust and fuel tank installs.
 

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52wrench

New member
more pics

Cab was a lot of work. Put about 7 lbs mig wire into it. Tried to put more pics up but it wouldn't let me, what's up with that?
 

52wrench

New member
Had to resize one image.
 

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52wrench

New member
About where I am now but just made final install of turbo today after the powder coater. Next is reseal the injection pump and install, make new PS lines to hydroboost and box, start on front clip, finish interior, start flatbed. Need to get this done this summer. Getting psyched to get it on the road.
 

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dirty Bakers

Conservative
Wow you should have had a cab shipped in from AZ and galvanized dipped it. I will be watching this build you are on the right track.
 

52wrench

New member
I forgot I had started a thread on here. After almost 2 -1/2 years of on and off work since I started this thread the truck is 99% done. I got it inspected and aligned last week and am getting the bed deck Linexed tomorrow. I still have to fabricate the running boards or sliders or tube steps, whatever you want to call them. They will be aluminum like the front and rear bumpers. I've only driven the truck about 10 miles and have been taking it easy until I get it broken in but I can tell it will be a fun vehicle to drive.
 

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52wrench

New member
A couple more
 

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seanpistol

Explorer
90 with a 93 front clip? did you swap out the rear double windows as well?

I used to drive a 90 7.3L IDI 4x4, always thought it would look cool with the rear windows from the 92 and newer body style.
 

52wrench

New member
Hi. Stock these engines were set to 105 HP with no intercooler. With an IC, better turbo and turned up pump with stock injectors they have been dyno'd at 180- 190 HP and close to 400 ft-lbs at under 2000 rpm. I haven't touched my pump adjustment yet until I get the engine broken in. There are a lot of similar swaps that get 25 mpg plus, some claim they get 30+ but that is with 2wd I think. In double over I'll be turning 1650 rpm at 70, that is in the sweet spot on the torque curve so I'm hoping to do pretty good. Not sure on weight but suspect around 5000, I have to haul some demo mat'l to a landfill in a couple weeks so will find out then as they bill you by net weight. On the front clip swap, yes, I also swapped the rear side windows, never did like the look of the split windows. This project took about three times as long as planned and cost about 2X as much but I'm happy with the results but glad it's done! Looking forward to putting some miles on it now. Hopefully in a few years a FWC will be sitting on the back. I have more pics of flatbed construction, front end fabwork, etc if anyone is interested.
 

Shiryas

Adventurer
52wrench,

Kudos on a job well done. I do not envy your task of removing all of those frame rivets, they are a daunting task.

What did you use to reassemble the frame after the pieces were hot dipped? (The picture looks like nuts and bolts)

Cheers, Chris
 

njtacoma

Explorer
Great looking truck. I like the newer style windows as well.

My wife was told many years ago by another friend/project widow to "triple the time and double the money every time." It has been pretty accurate so fart.

I really like the front bumper, looks smooth from the side, but aggressive from the front.
 

52wrench

New member
Thank you for the compliments. Yes, removing all the rivets was a real joy. It was a combintaion of torch, plasma, grinder, chisel, punch, a BFH and some persuasion words. All of the holes were then drilled out to 1/2" in three steps using progressively larger bits so that the final bolt fit was very tight. The bolts are all black oxide Gr.8 flange bolts along with GR 8 flange lock nuts, the kind with mechanical interference, not the nylon insert type. Each bolt was then torqued to spec. The frame was held in alignment diagonally using the factory alignment pins on the frame as the cross members were installed then final torqued when it was all together. I did not galvanize the front crossmember under the engine, I did a lot of research on galvanizing and had some concerns with possible warping because of the three dimensional shape. Evidently I got it right because the alignment shop checked the rear wheel alignment and it was spot on. The front caster and camber was also right on so the toe was the only needed adjustment. Went to the Linex place this am and they had run out of product?? So much for inventory control, they said call tomorrow to see if it came in. Going for a ride now to put some miles on the rig. Had a leak on the PS system, looks like a hose end just needed to be snugged up. Keeping my fingers crossed..

Steve
 

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