The F250 to F100 project

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The F250 to F100 project

Post  BigBlockRanger on September 30th 2016, 1:53 pm

This started out as just an EFI460 swap....

We all know how that goes though. This is a truck I bought a few years ago for $500. Jake, my 15y/o decided it would be a cool first car. The original plan was to go with a prerunner look, but the street truck bug bit him hard, so here we are. lol

To answer the obvious question, why not use a 1/2 ton shortbed F100? First of all, we have this truck already. Secondly, they are not as common around here for whatever reason and if we bought a longbed 1/2 ton we'd end up doing most of the same modifications anyway.

Sooooo, here we go. haha


















Tomorrow, I hope to get some holes drilled and have the CV front end partially bolted in.
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Re: The F250 to F100 project

Post  68formalGT on September 30th 2016, 2:38 pm

Cool project!! Looking good!!
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Re: The F250 to F100 project

Post  Mike R on September 30th 2016, 7:15 pm

Nice job! It's a lot of fun watching the kids taking an interest in the hobby and honing their skills and taking pride in their project Very Happy

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Re: The F250 to F100 project

Post  D. Sea on October 1st 2016, 9:23 pm

Too cool

As soon as I get my car back together I'm dragging the 1960 F100 into the shop and my 11year old is going to help me put it back together. It will be a long project but he seems very interested.

Looking forward to your updates
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Re: The F250 to F100 project

Post  68formalGT on October 1st 2016, 11:25 pm

D. Sea wrote:Too cool

As soon as I get my car back together I'm dragging the 1960 F100 into the shop and my 11year old is going to help me put it back together.  It will be a long project but he seems very interested.

Looking forward to your updates

That's cool, I've got one of those too! Mine is pretty rough.
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Re: The F250 to F100 project

Post  BigBlockRanger on October 3rd 2016, 10:42 am

Almost have it all bolted in. The rear bushings were completely toasted, so I had to order some new ones. Stock 460 motor mount towers were trimmed a little so I could weld them to plates that bolt to the CV crossmember. We went about bolting it in a little differently than some. Instead of using the 4 long CV bolts and tubes, we used 8 shorter bolts and bolted to the lower frame rail and frame rail tops separately. We also flipped the upper mounts left to right and that allowed them to span the stock motor mount towers.





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Re: The F250 to F100 project

Post  HorsinAround on October 5th 2016, 8:28 am

Looking forward to seeing it finished.
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Re: The F250 to F100 project

Post  dirt_worker on October 5th 2016, 9:46 am

What a great father son project! Kudos  to you and your son James!
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Re: The F250 to F100 project

Post  BigBlockRanger on October 5th 2016, 4:30 pm

I have the back wheels off the Mustang so I decided to see how they looked on the pickup. It would need a different offset, but I think they look pretty good! Jake is more interested in 18" wheels though. Maybe he'll come around. Haha.






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Re: The F250 to F100 project

Post  FalconEh on October 5th 2016, 11:05 pm

Very Cool, and it will mean so much more participating in the creation and gain invaluable experience too. cheers
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Re: The F250 to F100 project

Post  BigBlockRanger on October 24th 2016, 9:24 am

Front end is almost finished.  Just need the steering shaft, so we went ahead and reinstalled the engine ans trans.


Slipped a 28/10.5 slick under the back for giggles.




Bouncing the front end up and down, I think this thing is gonna ride reeeeeeaaly nice.  It is 6" lower in front and I think it will settle out even lower once the front sheetmetal is on.
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Re: The F250 to F100 project

Post  BigBlockRanger on November 21st 2016, 12:45 pm

Wheels Jake chose. 18x9 fronts 18 x 10 rears.



Steering parts arrived and have been installed. I was surprised that this part of it was really really easy.



Driveshaft also showed up a couple of days ago.

We worked a little this weekend. Jake was fighting a nasty cold so we didn't do a whole lot, but every little bit is progress. We mock-mounted the gas pedal from the 1996 F250 and drilled the hole in the firewall for the throttle cable and connected it. We will need to drill 2 more holes to fully mount the pedal, but it looks like it is going to work very well.

Jake connected the heater hoses, and we were lucky enough that the Crown Vic's power steering lines bolted right up to the '96 F250 pump.

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Re: The F250 to F100 project

Post  Mark Miller on November 22nd 2016, 3:11 am

Looking good keep the pictures coming when you get them!!!! Smile Smile Smile

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Re: The F250 to F100 project

Post  BigBlockRanger on December 6th 2016, 4:36 pm

With the weather becoming colder, we decided it would be a good idea to move it inside to sort wiring and plumb the fuel system.


I started sorting through this mess last night removing some stuff that we don't really need and generally just getting a feel for how everything needs to be routed. 99% of the stuff it needs to run on the engine bay side is still connected. Most of our wiring work will be inside the cab.


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Re: The F250 to F100 project

Post  jasonf on December 7th 2016, 6:18 pm

Cool.

Being that you didn't do a through bolt on the k member are you going to box the frame in at that section?
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Re: The F250 to F100 project

Post  Tomasw on December 7th 2016, 8:39 pm

What year car is the front suspension from?
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Re: The F250 to F100 project

Post  jasonf on December 8th 2016, 8:49 am

Tomasw wrote:What year car is the front suspension from?

2003-2009 are the only ones with the bolt in aluminum k members. The earlier ones are welded steel like most old cars. You can't miss it at the auto wrecker.
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Re: The F250 to F100 project

Post  BigBlockRanger on December 8th 2016, 10:25 am

jasonf wrote:Cool.

Being that you didn't do a through bolt on the k member are you going to box the frame in at that section?

No. It is bolted to the bottom of the rail and the top of the rail. I didn't see any real point in boxing it for 15" when the rest of the frame is not. The remains of the stock crossmember is still welded in there and I'm sure it will provide plenty of additional load spreading to the side and top of the rail. The upper mounts carry no load and really only provide a bit of lateral support for the spring towers.

If we were building a show truck, we probably would done more work to make it pretty.
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Re: The F250 to F100 project

Post  BigBlockRanger on December 12th 2016, 12:11 pm

I took some time to work on it this weekend. We installed the driveshaft, replaced the power steering pump and worked on the fuel system. The stock lines that were connected to the fuel rail were damaged when the previous owner removed it from the donor truck. So we made up some steel lines that run along the back of the engine. The supply line connects to the stock steel line and I'll have to run a line for the return to the surge tank.

I pulled the stock supply line off the rail and was blown away by just how tiny it is! Holy cow I can't believe that little thing could supply enough fuel volume for 8 24# injectors at WOT.... then again, maybe it can't. I dug around my spare parts bin and found a suitable replacement that has a much larger ID.



I've read that the intake tubes have a severe restriction as well, so I decided to have a looky. Yep, each tube has a "trumpet" of sorts that necks down to 1.25"! I don't know what the engineering reason for them is, but they are definitely going away!



I started looking over the wiring diagrams again and I think there are only 3 wires inside the cab that I need to connect to make this thing run..... maybe. lol
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Re: The F250 to F100 project

Post  BigBlockRanger on December 19th 2016, 4:44 pm

Saturday was a good day to be inside. It was single digits outside, but the garage stayed decently warm. As a result, we got a lot of stuff done!

-> Oil pressure gauge plumbed.
-> Water temp gauge plumbed.
-> Fuel system 99% plumbed - just need surge tank to fuel tank return line plumbed.
-> Failure prone oil cooler removed.
-> Messy wiring cleaned up.
-> Carrier bearing mount cut out.
-> Air hose "trumpets" cut off.
-> Good times with Jake.

I also noticed that someone removed the timing pointer from this engine sometime in it's life so we will have to grab the one off the old motor.

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Re: The F250 to F100 project

Post  BigBlockRanger on December 29th 2016, 5:56 pm

Got the tires mounted and balanced. I couldn't stand it and had to go bolt on at least a couple of them.

Front fit fine. Rears touch the inner fender well. I expected that they would. We had already planned to trim/mini-tub the wheel wells so everything will work right. Had we used a 9" from a dentside truck, we would have had plenty of room on the inside. But, outside edge room likely would have been really tight. The fender lip would have had to be trimmed considerably.





I compared the wiring diagrams last night and it is surprising how many wire colors are the same between the two.

The firewall connector has 76 wires. Of which, only 4 are necessary for it to run and 3 to report what it's doing (water temp, oil pressure, and tach).



I happened to notice that the fuel rail looked cockeyed and upon further inspection realized the o-ring of one of the injectors was pinched. Can't believe it didn't leak. Pulled the rail and the injectors on that side and they didn't look so good. The pintle caps are really gunked up with varnish. Can't imagine the inside of the injector looks much better. I watched some DIY injector cleaning vids, so I am going to give it a whirl.



My goal for this weekend is to at least have crank and fuel pressure, but I keep finding more stuff to monkey with while the front end is off! Trying very hard not to get caught up in project creep!!!
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Re: The F250 to F100 project

Post  BigBlockRanger on January 9th 2017, 11:56 am

Chipping away at it still.

-> Installed the fuel pump inertia switch out of the '96 truck's dash and wired up the fuel pumps.
-> Plumbed the surge tank's return line to the fuel tank.
-> Front hub replaced
-> Front brake rotors replaced
-> Injectors cleaned, new o-rings installed and injectors reinstalled
-> Oil changed
-> Battery connected - No smoke!
-> Transmission cooler lines looped
-> Wiring (after some head scratching) finished up
-> Flange bearing added to end of steering column (replaces stock plastic bushing)

We are very very close to having a running truck. I had a few head scratching moments with the wiring. A couple of the wire colors in my harness did not match the diagram I have. It seems the location of the wire in the connector trumps the color of the wire. Once I figured that out, everything almost fell into place. I say almost because Ford chose to locate grounds in some bizarre locations in the harness. They are just poking out of the harness in random places and are nowhere near what they are grounding. After I grounded everything, key on, low pressure fuel pump primes, and we have crank with the key!

But, we do not have fuel pressure yet because the old high pressure pump is inop. It is an old one I took off the Ranger many moons ago. I figured it would work, but it will not run, so it will need to be swapped out. I may just put a Walbro 255 on it instead of a Ford pump.

The other issue we ran into is the driver's side brake caliper is a leaker. It needs to be replaced or to be rebuilt. The passenger caliper had brand new pads but the driver's only had 1 really worn out pad! I think that horked up the piston seals because they were waaaaaay out of the bores.

Cleaning the injectors was pretty easy. I took a tire valvestem, jammed it over the injector inlet, drilled a tiny hole in the cap, poked the red carb cleaner straw through, pressurized the injector and cycled it with a 12v source until it sprayed a nice pattern. Worked awesome.

Chawed injector o-rings. There were a lot! Glad we decided to R&R them!


Flange bearing on end of column.


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Re: The F250 to F100 project

Post  BigBlockRanger on January 16th 2017, 4:16 pm

We made good progress this weekend.

- mounted gauges - plates still need some work and will probably be painted black
- gauge lights wired
- radio wired
- tach installed
- inner tie rod replaced
- new brake pads and new driver's side caliper installed (old one was chewed up from not having a brake pad in it)
- inner bed fenders cut out for tire clearance - mini-tubs

Jake putting the finishing touches on the brakes.







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Re: The F250 to F100 project

Post  Doug Rahn on January 17th 2017, 11:33 am

Very cool, looking forward to seeing the finished project. I can't tell from the photos, but where you cut and spliced the frame rails did you weld on fish plates where the splice is? If not I would highly recommend doing it.
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Re: The F250 to F100 project

Post  jasonf on January 17th 2017, 12:37 pm

Doug Rahn wrote:Very cool, looking forward to seeing the finished project. I can't tell from the photos, but where you cut and spliced the frame rails did you weld on fish plates where the splice is? If not I would highly recommend doing it.

Doug this just uses the aluminum cradle from a crown vic and it practically bolts right into the F150 frame (with a bit of work). It is not a welded subframe like you typically have seen in the past.
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