1977 Ford Crewcab 4X4 with Cummins power (hopefully)

[DavidWhite]

Thx for the pix. Keep-em comming.

 

[KellyClark]

figured out how to make the f250 box work, just trim the corners off the plastic fan blade. the front crossmember is fabricated and the motor is permanently mounted. the 1" body spacer made room to move the motor back about 2-3 inches, which made room for the radiator. looks like the '97 Powerstroke intercooler will fit perfectly around the radiator, just have to cut holes in the radiator support. I'll have to trim the back of the grill and relocate the hood latch to make room for the intercooler.



i bought a new TPS from Dodge, which I can mount anywhere. The hydro-boost from the CUCV fit nicely, only had to cut off the top 2" of the bracket (which was useless anyways) and drill two holes in the firewall.



i sprayed the firewall with three coats of Quietcar. it dries a dark gray and looks similar to bedliner. its soft and scratches/mars easily. i'm going to spray the hood, inner fenders, floor and roof with it later.



Still have to fabricate a transfer case crossmember and hang it from the frame. I bought 1410 yokes and u-joints for all the axles and the transfer case from Off Road Design in Colorado. I'm buying a 14 bolt with a locker and disc brakes from a buddy. as soon as it's all in, i can measure for the driveshafts.



will post more pics soon.

 

[KellyClark]

Cut holes in the radiator support for the '97 Powerstroke intercooler, which fits nicely. We had to clearance the back of the grill, and grill shell.



Hung the divorced NP205 with crossmembers made from 1 3/4" tubing. It's mocked up and ready to be measured for driveshafts.



Pictures show the CUCV hydroboost, motor crossmember, and transmission/transfercase crossmembers.

 

[KellyClark]

Can anyone help me out with the wiring? I have the ECU, and the entire engine wiring harness. I have been led to believe that only eight wires are required to run the engine, but I'm going to need some help on this one. I would like to run an Edge Juice with Attitude, but will it run without the PCM? ANY help would be greatly appreciated.



Thank you



Kelly

 

[KellyClark]

Started fabbing the 4" exhaust. Surprisingly, no one makes a kit for a 1977 Ford with a 04 Cummins . I bought some straight 4" aluminized tubing, a couple of mandrel bends, a 4" down pipe for an '04 Dodge, and a cat-back system for a '05 Ford Powerstroke. Should get me pretty close.



Still trying to find someone who can help me with the wiring



The pics show the Michelin XZL 11. 00 16 tires mounted on 16X8 Unique series 241 chrome wheels (couldn't find any 16" slot mags :{ ), intercooler plumbing made from stock Ford and Dodge pieces, and the intake tubing built from 4" aluminum tubing and rubber elbows. Ray tig-welded a flat piece of aluminum to the tubing to mount the air flow sensor. Just have to clamp on a K&N and build a box to shield the engine heat. We cut a big hole in the radiator support to let cold air into the intake area. Had to relocate the battery to the other side.

 

[Sea01Cummer]

Looking good keep the pictures cummin, showing detailed pictures and info on problems you are having will only help others.



Steve

 

[KellyClark]

the pics show the hole I cut in the passenger side floor board to clear the 4" down pipe, the clearance of the fan to the steering box (we cut off the corner of the tips of each blade), and the power steering pump bracket Ray fabbed to relocate the pump.



I'm leaving for the US Army Special Forces Assesment and Selections course on 10/11/06, and won't return until 11/09/06, so I'll have to take a break for a while. I was hoping to get this thing running by now, but there are so many little obstacles that eat up a lot of time.



I'll post more when I get back. "De Oppresso Liber"

 

[ScottWA]

1977 ford crewcab highboy

some photos of my 77 crewcab conversion with a 2003 dodge motor trans and t case.

 

[ScottWA]

more pics

mock up and firewall mods as well as dash mod

 

[ScottWA]

1977 ford crewcab highboy

more pics of the conversion

 

[ScottWA]

1977 ford crewcab highboy

more photos to completion

 

[Sea01Cummer]

Very Nice!!! Do you have any pics of the dash conversion complete???



Steve

 

[KellyClark]

ScottWA; WOW! Your truck is awesome! Thanks for the pics. Can you help me out with wiring? Did you use the wiring harness out of the 2003 Dodge?

 

[ScottWA]

Yes sir I used the whole harness from fron to back. It made it easier for one but also if needs help it has the diagnostic port.

 

[Moab4x4]

Nice Truck

Thanks for the ideas guys!

I have too have a 77 High Boy Crew that has been in the family since new. (this can be read that it is now worn out and tired) I am trying to decide to rebuild my old 93 cummins engine and do the conversion or to go with a (gasp!) 429 gasser.

If I go Cummins, do I keep the Ford Dana 60's in 4. 10 or replace them with the 92 Dodge D60 front D70 rear in 3. 54?

I am curious how the frames on these old Fords handle the Cummins weight and torque. Stress cracks?

Keep the pictures coming!

Thanks,

Ken

 

[Kiohio]

Moab- I have had quite a few Ford F150 thru F350 4x4's in the 73 to 79 years.

They are all much heavier built than the 89 Dodge W250 I have now.

I doubt you'd have any problems with strength.

Especially since you don't have rust to worry about.



KO

 

[Kiohio]

Scott- That is absolutely beautiful.

That's my dream truck!!





KO

 

[Ten_Bucks]

That red Ford turned out awesome! Do you have any pics of the finished dash swap?



Scott

 

[KellyClark]

Moab4x4,

I would definitely go with the cummins. 429's suck gas like its going out of style. My mildly built 460 averaged 6 mpg. I would also keep the Ford D60 in the front, but ditch the rear D60 for a 14 bolt. The Ford front D60 is the most highly sought after axle around. Also, if you plan to run some bigger tires, you won't want the tall gears.



Oh, by the way, I'm still looking for some help with the wiring :{

 

[Scot]

Moab: I have 23K miles on mine and have yet to see any cracks or problems. I have not pulled over about 8K but have had 2 yds of road base in it several times. If what others say is true, I am putting down >400 hp.



ScottWA. Tell me more about your fuel tank setup.