My 1990 W250 Regular Cab - History and Modifications - WARNING: LOTS of Pics!!

[RSchwarzli]

November 2012:


Also a change as of fall 2012, the truck will no longer serve Daily Driver status. Well, at least during the winter! The truck developed a small patch of rust start on the passenger’s A pillar as well as the drivers drip rail. With that scare of my baby starting to rust away, the truck was taken off the winter driver status and a winter beater was located. These issues were repaired during November 2012 by a Chrysler body shop ad it was painted from the pin stripe up.


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Random pics from 2012:


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So, you think I am done with the mods right? Do I really need to ask you that question anymore? LOL I think it is clear to you now that I have a bad sickness and is the reason for my being a hermit in a garage.

 

[RSchwarzli]

May 2013:


I am tired of the haze I have and the EGT’s are still a bit warm for my liking at times. And I still blow a lot of soot even though I am still stock injectors (9 mm not the 91+ 7mm) and only have timing set at 1.79 mm lift. And now that I have a real transmission capable of some more juice…. So research was done on a Super HX40 (not to be confused with a HX40…..totally different turbo…) designed for Cummins engines up to 10 liters. Spec for the one I got is a 60 inducer and I am running a 16 WG housing with 7 blade intake wheel. Although I have read conflicting reports, I believe the turbo is a 60/65/16. Boost is Holset spec’d for may of 52 psi and is actually a hybrid for spool up lag set somewhere between a HX35 and a HX40 (more info here: http://www.myholsetturbo.com/40appnotes.html ) . Well, after some monkeying around, a new turbo found its way into the truck. A resonator also finally found its way under the truck to muffle the pipes a bit as they are right behind my head and with more towing happening than in the past (and the fact that I am getting older and I want to hear when I am 90…. )


Also so everyone is aware, there is two Super HX40 part numbers for Dodge Rams. Only one of them actually works though!! LOL I know this as I ordered the wrong one despite what the Holset chart shows: http://www.myholsetturbo.com/images/holsetpartnumbers_2008.pdf


4027888 is what I ordered and it did not fit as the WG housing is in the wrong position. Truth be told, I cant see it working on any Dodge application but what do I know? I am just a dumb farm kid. It is a vertical vs 90 deg style. So what you need to order if you want one is 4031450. My cousin changed his order once we determined the PN issue and his bolted right in. Mine not so much….

Mine going in, the 888 number. You can see where the WG actuator hits the oil drain and almost the oil filter. I had to adjust the turbo arm to make it work. I would normally have sent it back but as it was trailer season and I had a job to haul 13,000 lbs of trailer and roofing supplies 400 miles the following morning; dad lent a hand and we got creative so I could make the delivery on time. Nothing like working under pressure! That morning that I departed on the drive was the first time I had actually started the truck with the new turbo on. After a quick 50 mile break in, I was on the road with the now loaded trailer. I did allow 100-150 miles before I tromped on it to allow proper break in.


Here is all three turbos that have lived in this truck: The factory 18cm H1C, the HX35 that used the 18 CM H1C non WG snail, and the new HX Super 40:

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You can see the new 40 is a bit taller:


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So, the HX35 comes out….


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Downpipe gets modified with a 4” adapter as the H1C was a 3.5”


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And now the test fitting and mods:


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Spacer block:


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[RSchwarzli]

June 2013:


Once again, it was the TDR Cummins gathering and we were back at the Cummins Engine Plant (CMEP) in Indianapolis. The truck again made the bi-annual trip down there. These are some pics from the event in no particular order:

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The red truck you see here is D001, the Dodge/Cummins prototype truck that Cummins recently restored.
The blue truck is the first Dodge/Cummins Ram off the assy line.


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And yes, the engineers were there at Cummins including Troy Simonson, John Keele, and Chris Wilkens. So I had them all sign my dashboard!


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Here Troy (head of the Dodge side of the project) tests the driver’s seat and observes the aircraft like cockpit of my truck:


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[RSchwarzli]

July 2013:


98 F ambient. Super humid. 7% grade 3 miles long. AC on full. 20,000 GCW. 72 MPH. 36 PSI @ WOT. Running 5th over (.78 OD of Gear Vendors on direct 1:1). Coolant. Progresses half way up hill…. 235 F coolant. EGT 1400.


So remember said turbo upgrade? Well seems my small little aftermarket intercooler can’t handle the volume of the Super 40 and is heat soaking! And with more power from the turbo, the rad is also heat soaking. For the first 1 minute it is fine but after that I need to let off. I replayed this heat soaking concert multiple times this summer while towing. Totally unacceptable. I am basically making more power with this new turbo but can’t use it!! This sucks like an angry Shop Vac set on full!!


So, parts have been ordered and now that the truck is down in the winter anyways, progression will begin shortly on a 2ng gen rad, IC, IC piping, Horton Fan, and cold air intake install on the truck. Also fabrication of a 5th wheel hidden rail system under the bed will also take place.


November 2013:


Yes, I know I need to be working on the crew cab. But I must have the 90 as priority as it must be on the road come May so it can haul the bacon home! So that will get first dibs over the crew sadly. And as the flat deck trailer will potentially be changing to a 5th wheel/gooseneck come spring, that will mean I have no way to tow it if this hitch doesn’t go in. That also means I can’t haul the crew cab to the shops it will need to go to get completed in the spring.


The hitch:


Progress has begun on the 1990 with the hitch taking the first efforts. The bed was removed from the frame so measurements could be taken and fabrication could begin.


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I started off with a 1994-02 Reese hidden hitch kit and then basically hacked it to pieces.


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See, the gen 2 frame rail section where the hitch mounts is flat compared to the gen 1. So I had to cut the rails where it meets the frame C at a 10 deg angle but still low enough the hitch rails wont contact the bed floor. You can see the assembled hitch rails sitting at an angle when assembled as the instructions show. Also it sits above the top of the socket.


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And cleaned the crud off the frame I was surprised to find that the frame was not rusted (minus surface rust) and even some original paint is there!



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Before removing the bed I measured my distance between the frame and the bed floor so I rigged up this little test to ensure that I would fit. As long as the rails fit between this angle iron and frame, I am golden.



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They fit!!




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But that resulted in very skinny rail ends. Too weak for use. So the reinforcing began with a 2”x1.25” solid block of steel welded into the frame.




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Then cut on the ends to match the 10 deg slope on each of the 4 corners.



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[RSchwarzli]

And finally plunge cut to allow room for the hitch leg locking pucks to drop into. To give you an idea of time, each of these holes took 1.5 hours to plunge cut to correct depth! My thanks to a friend who assisted with that. As I needed to get this frame out before the Christmas holidays I was 1 week before deadline so he assisted with ensuring it got out in time. And yes it makes a mess!


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Then a test fit was done to ensure the slope was correct:


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Pucks now fit in after the plunge cutting:



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Hitch test also passed:



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Now that the hitch fits, its time to make this a bit more solid. So in went some reinforcements that will also help keep spacing:



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And the end plates were welded on:



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Resulting in this fine specimen of steel:



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And for good measure to ensure I don’t ever get a crack at the weakest point, some 3/8”x1” steel strips were welded in.



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And the external frame frame C channel reinforcing pieces that will further support this frame assy by taking weight off the hitch frames C ear by supporting directly under the hitch legs. When I install it will make more sense!



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And how it looked when I picked it up on December 23rd:


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That now brings us current as of December 27, 2013. In total, there is 60 hours into this hitch and it still sits on the floor there for me to finish the frame holes and then clean up and paint the stripped section of frame.



And for what it is worth, this is 14,000 words, 55 pages in Word, and has taken 3 full days to find the pics, upload them, and type this all with my two fingers.

 

[JHumphries]

Remind me to stop giving you crap about being so slow on the crew! :--)
I knew you had done 'a few things' to the 90, but I didn't realize it was this intense.
Also, AMAZING writeup and parts list for the 5600 swap. I'm probably going to copy it all for future reference in case the thread ever disappears.
Keep wining the battle, you're doing a great job!

 

[Joseph Donnelly]

Thanks for filling us in on your excellent work.

I know you now know about every bolt and nut, every component. You have established a real bond with your Rams, and are sure you are immune to New Ram Disease. Hah! I have been there, done that. Do no, repeat do not, ever sit in or <gasp> drive a 2013-2014 or I swear you will get a severe case of New Ram Disease and it will cost you $50,000 to cure it, and you will have to search out good homes who will adopt your older Rams! You have been warned! LOL

 

[S.Morris]

That is impressive and all I can say is do it now cause you won't have that much ambition in a few years (and you just might ride in a 13 and get lazy LOL)

I have a friend who has a 72 kingcab 4x4 350 dually, It has a large JD engine out of a combine in it. Engine comes back into cab so that the doghouse of a dodge van gives a factory look to the interior,,,,if it were a van. It uses a 6spd direct allison and a direct/OD/UD box behind that to the 3.07 gear D80. (4x4 is not functional, no tcase). It is truly a showpiece and will lay black dually tracks on the road from 0-80mph top end. It is not quite as quiet as a 13 though.lol

It has never been dynoed but injection system was tuned at pittsburgh diesel. According to the 80yr old builder/owner this thing will out pull any truck he has ever incountered on his winter snowbird trips to Arizona from Ottawa. I'm sure you would love to see it,he attends local carshows with it in the summer. Sorry I don't have any pics.

 

[Shadrach]

I'm not sure what your winter beater is but try and leave it stock. :-laf Nice write up. Thanks for the update. I can relate to a lot of what you have done, especially the transmission swap as we did a Getrag to G56 on my buddies 93 W350 ( which started out life as a W250 ) I can see that mod coming up with the big hitch installed :-laf We also swapped out the NV5600 from my 03 and also installed a G56- I went from heavy weight to light weight. I will have to show my buddy your version of the t case mount as he used the G56 mount but it is designed for the t case to be hanging off the other side, so it has been giving him some issues. David

 

[RSchwarzli]

Remind me to stop giving you crap about being so slow on the crew! :--)
I knew you had done 'a few things' to the 90, but I didn't realize it was this intense.
Also, AMAZING writeup and parts list for the 5600 swap. I'm probably going to copy it all for future reference in case the thread ever disappears.
Keep wining the battle, you're doing a great job!

LOL Go ahead and give me crap all you want on the crew. Helps keep me motivated. lmao But I did feel this thread would help the understanding.

Yeah, the 90 got out of control as all my auto related stuff tends to get. I can't help it. I have it bad.

Glad the 5600 sections helps. That section took a while so glad it is going to good use.

Thanks for filling us in on your excellent work.

I know you now know about every bolt and nut, every component. You have established a real bond with your Rams, and are sure you are immune to New Ram Disease. Hah! I have been there, done that. Do no, repeat do not, ever sit in or <gasp> drive a 2013-2014 or I swear you will get a severe case of New Ram Disease and it will cost you $50,000 to cure it, and you will have to search out good homes who will adopt your older Rams! You have been warned! LOL

Glad you enjoyed the read Joe!

Yes, I know the trucks like the back of my hand and I cannot see myself parting with either of them for a long time. However I do appreciate the warning on the New Truck Disease. I will be mindful to avoid them however I don't see that bothering me too much. I have driven a few 2013 3500s and spend a lot of time behind the wheel of dads 08 Mega and I have to say, they still dont hold a candle to my first gens. I will tow with my 90 any day of the week and given the choice between his truck and mine, I got with mine every time. For some reason I just don't mind the covered lawnchair on a roller skate feeling. Linda like it actually.

Sorry to hear you are looking for a new home for your baby. That has got to be tough. I am sure if I had to sell mine it would kill me literally.

That is impressive and all I can say is do it now cause you won't have that much ambition in a few years (and you just might ride in a 13 and get lazy LOL)

I have a friend who has a 72 kingcab 4x4 350 dually, It has a large JD engine out of a combine in it. Engine comes back into cab so that the doghouse of a dodge van gives a factory look to the interior,,,,if it were a van. It uses a 6spd direct allison and a direct/OD/UD box behind that to the 3.07 gear D80. (4x4 is not functional, no tcase). It is truly a showpiece and will lay black dually tracks on the road from 0-80mph top end. It is not quite as quiet as a 13 though.lol

It has never been dynoed but injection system was tuned at pittsburgh diesel. According to the 80yr old builder/owner this thing will out pull any truck he has ever incountered on his winter snowbird trips to Arizona from Ottawa. I'm sure you would love to see it,he attends local carshows with it in the summer. Sorry I don't have any pics.

Good advice. Hoping that within the next year or two both trucks are done as far as big stuff goes. I dont mind changing small things over time as it keeps me connected with the trucks but good advice for sure!

Sounds like one hell of a truck too!

I'm not sure what your winter beater is but try and leave it stock. :-laf Nice write up. Thanks for the update. I can relate to a lot of what you have done, especially the transmission swap as we did a Getrag to G56 on my buddies 93 W350 ( which started out life as a W250 ) I can see that mod coming up with the big hitch installed :-laf We also swapped out the NV5600 from my 03 and also installed a G56- I went from heavy weight to light weight. I will have to show my buddy your version of the t case mount as he used the G56 mount but it is designed for the t case to be hanging off the other side, so it has been giving him some issues. David

LOL You dont want to know what my daily is now. It is only asking for time and money being invested into it down the road.

Yes, you have a very good idea what is involved with those 6 speed swaps.

Yes, your buddy needs to swap to a 205 and it will hang on the correct side! (Not incorrect side like those trucks that followed! )

 

[crazzywolfie]

that is a pretty nice looking truck. i have done a few mods to my truck but don't think i would ever go that crazy on it. i am pretty happy with my 727/3.23 in my 81 and 518/3.55 in my 93RC. i mainly do smaller mods that don't stop me from driving my truck like installing a overhead console, upgrading some of the lights and adding lights where i think they should be. also putting things on relays is a big thing for me. i like using a relay wherever i think they are needed.

 

[RSchwarzli]

that is a pretty nice looking truck. i have done a few mods to my truck but don't think i would ever go that crazy on it. i am pretty happy with my 727/3.23 in my 81 and 518/3.55 in my 93RC. i mainly do smaller mods that don't stop me from driving my truck like installing a overhead console, upgrading some of the lights and adding lights where i think they should be. also putting things on relays is a big thing for me. i like using a relay wherever i think they are needed.

Welcome to the funny farm crazzy! And from Ontario yet too! Slick! On behalf of another Ontarian, welcome!

Thanks for the kind words. And yes. There was a time I said the same thing and all I did was small basic things. However, if you really like your truck, and you are a little far gone, there will come a certain point in time that you are faced with some real choices.... Love not logic will dictate the answer!

 

[AClayton]

http://www.youtube.com/watch?feature=player_detailpage&v=WtpEpUaG8sM
Do this mod next!!!

 

[crazzywolfie]

thanks. as long as i can spin my tires i am happy. i just wish i had more money to throw at my 81. my ramcharger has been sucking me dry and i haven't even been driving it that much lately. lent it to my sister because she needs a vehicle. eventually the engine/transmission out of my ramcharger is going to go into my 81.

what part of Ontario are you from?

 

[JHumphries]

http://www.youtube.com/watch?feature=player_detailpage&v=WtpEpUaG8sM
Do this mod next!!!

That thing sounds AWESOME!

 

[RSchwarzli]

http://www.youtube.com/watch?feature=player_detailpage&v=WtpEpUaG8sM
Do this mod next!!!

Yes. I have been watching them for 2 years. Waiting for them to start selling the compression brakes. So far no luck.

what part of Ontario are you from?

GTA

 

[RSchwarzli]

Update time! Hitch is done!


So now that I have the hitch back, it’s a matter of installing and final adjusting. So it was added back onto the frame for post powder coating inspection. The frame was also painted in the area that the oil coating was removed from:


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And the support blocks that help transfer weight into the frame C were added:


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And then I had a problem. I had the factory brake line interfere with the location of the support bracket on the drivers rear. So I tried to bend it but didn’t suspect it would fare well. It didn’t. So I fabricated a new brake line that deflects around the bracket:


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So the shocks were now installed in the frame (remember I removed the old shock crossmember for hitch frame clearance?) and they lined up amazingly well.


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And then it was time to put the box back on! Observe the nice close tolerances!
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That meant the last item on the list was to lower the bed and drill the holes in the floor (the nerve racking part!). So with a buddy on hand, the measuring was done twice and the cutting once. Once cut, the top end mounts were installed and bolted in. Then the bed mat was installed and holes cut into it as well.


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This is the final result of the nice clean install:




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[crazzywolfie]

looks good. nice and clean. so did you blow any brake likes when you went to bleed the brakes after replace that small piece? i find replacing 1 brake line usually turns into replacing almost all the brake lines.

 

[Grizzly]

Wow, I'm impressed! Great work.

grizzly

 

[RSchwarzli]

looks good. nice and clean. so did you blow any brake likes when you went to bleed the brakes after replace that small piece? i find replacing 1 brake line usually turns into replacing almost all the brake lines.

No. I messed with no other lines and had no leaks. I will however monitor the area to see how things progress and if any leaks develop.

Wow, I'm impressed! Great work.

grizzly

Thanks Grizz!