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Old 08-21-2008, 10:11 PM   #1 (permalink)
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96 F150 Build...

Well, after my old truck slowly started to let go, we went and picked up the new project.

Here it is in all its glory.



Anyway, the build will take a short time, and will be my DD until i can find a gas-getter. It is replacing this:



The list:
1996 OBDII 5.8L
E4OD
1356
HP Dana 60 Front
Ford 10.25 Rear
39.5 Boggers
5.38s, welded rear, open front (for now)...

We picked up the rolled over 96 F150 for 900 bucks tonight, 111,000 miles on the clock. It was an older couple's truck, she rolled it and sold it to her son. From there, i bought it, and towed it back to our shop. This weekend i will be swapping a cab onto the 96's frame, and going from there... Should be driveable i the next couple weeks.

The axles: We scored an early 90s F350 for right over 600 bucks. It has a HP dana 60, and the 10.25 i will be running. More pics tomarrow... it started getting dark tonight. BTW, my old truck is being parted out in the classified sections...

The outcome: Im looking for a more "useable" rig, on the rocks, mud, and trails. It will be fully loaded, as the donar truck is an Eddie Bauer. My old truck was underpowered, under geared, and too had much tire. I could use it on the rocks, but feared breaking it. I will be doing an "almost flat bottom" (the most i can with factory rails). Ill load pics tomarrow.

So buildup total so far: $1500
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1996 F150 - Supercharged 5.8L, E4OD, Vortech S-trim, PSD Intercooler, 15 psi , 1356, Dana 60, 10.25, 5.13 gears, welded rear diff, 14" Air/Coilovers. Check it out:

Build thread:
Here

The un-named buggy - 2.3L, lotsa tube, and FJ80s.
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Old 08-22-2008, 08:03 AM   #2 (permalink)
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yep another new project - but i get a good hood out of it, so im good

a pic of the donor truck for the 60 and 10.25 - the rest is going to be parted out in the classifieds, a 6.9, zf, 1356, and a clean body -











the rear will stay leafs for now and get a radius arm up front with some super flex coils - going to get a cab this weekend - then i might get him to help me with my rig - bastered
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build up of the truggy
/forum/ford/544813-update-pics.html
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Old 08-22-2008, 12:52 PM   #3 (permalink)
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Looks like a good builder, what you need to do shortly after you get this one going is locate a tow rig, that fucker is only gonna be street legal for so long if I have my way about it

:Edit: I love the shirt :Edit:
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Old 08-22-2008, 03:17 PM   #4 (permalink)
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YA - i tried to get him fix the 96 and use it as a dd / tow rig and let me fix the green beast and turn it into a trail only rig. but we didnt have any luck finding a cheap good newer body cab ( they want over 600 at the dismantlers ) and the local u pull it didnt have any of this body style.

so he is ripping the 96 apart tonight and is going to transplant his body to that frame - but it will have the 96 interior and dash - plus the working AC

ill get some pics later this weekend
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build up of the truggy
http://www.pirate4x4.com/forum/showthread.php?t=544813
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Old 08-22-2008, 11:18 PM   #5 (permalink)
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Really, at this point in time i do not have a place for:

A tow rig
A crawler thats not street legal
A trailer.


And im getting tired of parking at dans house.


For the updates. I just got home after grabbing a quick bite to eat... The green truck is ready to lose its body, and the white one is almost ready...

With the help of Carl (new guy at work), he helped me rip off the front clip of the green truck before he had to leave. Anyway, I got the dash ripped out of both trucks, and im ready to cut and weld the patch panel off the 96 to make the dash bolt up. Pics!:

The naked green machine:




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1996 F150 - Supercharged 5.8L, E4OD, Vortech S-trim, PSD Intercooler, 15 psi , 1356, Dana 60, 10.25, 5.13 gears, welded rear diff, 14" Air/Coilovers. Check it out:

Build thread:
Here

The un-named buggy - 2.3L, lotsa tube, and FJ80s.
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Old 08-22-2008, 11:22 PM   #6 (permalink)
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And the 96. Its really clean, lower miles, and full power (everything...). The cabs are diffrent for dash mounts, so a couple pics are compairing the floor/firewalls to see what i had to change. Check it out:

The purdy 96:





and the 96's computer: its got the port, good to go!
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1996 F150 - Supercharged 5.8L, E4OD, Vortech S-trim, PSD Intercooler, 15 psi , 1356, Dana 60, 10.25, 5.13 gears, welded rear diff, 14" Air/Coilovers. Check it out:

Build thread:
Here

The un-named buggy - 2.3L, lotsa tube, and FJ80s.
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Old 08-22-2008, 11:28 PM   #7 (permalink)
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And the cabs:

89 cab:


96 cab:


89:



and the 96:



If you look close, you can see on the white 96 cab where i used a black marker to show the cut line. its hard to see. when its out, ill take pics. I had to stop with the cutting early because we are one block away from the police station. A couple cars slowed down as the drove by, and i decided it was time to clean up.

Ill be headed out tomarrow morning for anyother full day. I should have some help to swap the cab. After that, it should fly back together.
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1996 F150 - Supercharged 5.8L, E4OD, Vortech S-trim, PSD Intercooler, 15 psi , 1356, Dana 60, 10.25, 5.13 gears, welded rear diff, 14" Air/Coilovers. Check it out:

Build thread:
Here

The un-named buggy - 2.3L, lotsa tube, and FJ80s.
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Old 08-23-2008, 10:39 PM   #8 (permalink)
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Well, having some help today we got a little bit done:

Both cabs are empty, and we got the heater/ac unit swapped onto my old cab. On a great note, the heater box mount is identical between both body styles. Got all that swapped over really quick. The problem was the firewall by the driver's feet (which we could have hacked, and might fit, but i decided to cut, and weld in the section off the 96. Anyway, pics:

Mike choppin up the carpet...


Cab is off!


My poor truck...



Cleanin it up...


Tearin into the clean one...

It was REALLY clean... its a shame...





I need to finish welding in the section, then throw the cab up. The dash is close enough to bolt up, but the bottom mounts needed to be chopped off the 96 to go on the 89. Anyway, with some paint you will never know its not a 96.
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1996 F150 - Supercharged 5.8L, E4OD, Vortech S-trim, PSD Intercooler, 15 psi , 1356, Dana 60, 10.25, 5.13 gears, welded rear diff, 14" Air/Coilovers. Check it out:

Build thread:
Here

The un-named buggy - 2.3L, lotsa tube, and FJ80s.
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Old 08-23-2008, 10:43 PM   #9 (permalink)
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AC swapped over:



Cab comin off...



Carl being... well carl...


Anyway, motor is really clean. no leaks, just what it lost in the roll...




old cab is going on tomarrow morning. Hoping to have it swapped over, ready to start tomarrow night.

total, i have 1500 bucks, and lunch for 3 into it. Im going to do a tune up while the fenders are off. total of about 8 hours into them...
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1996 F150 - Supercharged 5.8L, E4OD, Vortech S-trim, PSD Intercooler, 15 psi , 1356, Dana 60, 10.25, 5.13 gears, welded rear diff, 14" Air/Coilovers. Check it out:

Build thread:
Here

The un-named buggy - 2.3L, lotsa tube, and FJ80s.
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Old 08-23-2008, 10:43 PM   #10 (permalink)
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lookin good.
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Old 08-23-2008, 10:55 PM   #11 (permalink)
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Quote:
Originally Posted by T151Rex View Post
lookin good.
thanks. its sad to see to dead trucks. hopefully it all goes smooth back together.
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1996 F150 - Supercharged 5.8L, E4OD, Vortech S-trim, PSD Intercooler, 15 psi , 1356, Dana 60, 10.25, 5.13 gears, welded rear diff, 14" Air/Coilovers. Check it out:

Build thread:
Here

The un-named buggy - 2.3L, lotsa tube, and FJ80s.
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Old 08-24-2008, 09:54 AM   #12 (permalink)
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Sweet build. Im liking the look of the green truck the way it was. That grille/hood gaurd is
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Old 08-24-2008, 10:33 PM   #13 (permalink)
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Quote:
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Sweet build. Im liking the look of the green truck the way it was. That grille/hood gaurd is
i also liked the gaurd. So, ill be making a very similar one for this. Thanks for the good words.

Today went by quick. I got there early, and burned in the patch panel (until we ran out of gas...) Anyway, once carl showed up and mike, id say we kicked ass on getting it back together.

We started with a blank frame. By 10, the cab was back on (somehow i did it alone, and im not sure how..).

Let the pics speak;
Once i finished welding, i put a undercoating on the cab:



And then bam! it was back to looking like a truck:


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1996 F150 - Supercharged 5.8L, E4OD, Vortech S-trim, PSD Intercooler, 15 psi , 1356, Dana 60, 10.25, 5.13 gears, welded rear diff, 14" Air/Coilovers. Check it out:

Build thread:
Here

The un-named buggy - 2.3L, lotsa tube, and FJ80s.
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Old 08-24-2008, 10:34 PM   #14 (permalink)
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While i was waiting for a hand on the dash, i did some interior work:
Carpet install:




Carl finally showed up to throw the dash in. He needed his beauty sleep.

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1996 F150 - Supercharged 5.8L, E4OD, Vortech S-trim, PSD Intercooler, 15 psi , 1356, Dana 60, 10.25, 5.13 gears, welded rear diff, 14" Air/Coilovers. Check it out:

Build thread:
Here

The un-named buggy - 2.3L, lotsa tube, and FJ80s.
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Old 08-24-2008, 10:36 PM   #15 (permalink)
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And before nightfall, it looks like a truck again. Its getting new doors, so body lines are not an issue yet (but for a rolled truck, its damn close already.)







and what mike has been doing the last 3 days...
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1996 F150 - Supercharged 5.8L, E4OD, Vortech S-trim, PSD Intercooler, 15 psi , 1356, Dana 60, 10.25, 5.13 gears, welded rear diff, 14" Air/Coilovers. Check it out:

Build thread:
Here

The un-named buggy - 2.3L, lotsa tube, and FJ80s.
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Old 08-25-2008, 07:39 AM   #16 (permalink)
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WTF? I'm gone for 4 days and this shit happens?
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94 F-150 Stepside. BGTL 12" lift, 1-tons, 39" 'roks
95 F-150 6" of lift, SAS 35" BFG's
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Old 08-25-2008, 07:53 AM   #17 (permalink)
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Quote:
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WTF? I'm gone for 4 days and this shit happens?
yup, and i even left the body lift off for you.
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1996 F150 - Supercharged 5.8L, E4OD, Vortech S-trim, PSD Intercooler, 15 psi , 1356, Dana 60, 10.25, 5.13 gears, welded rear diff, 14" Air/Coilovers. Check it out:

Build thread:
Here

The un-named buggy - 2.3L, lotsa tube, and FJ80s.
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Old 08-25-2008, 11:50 AM   #18 (permalink)
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MEh, I like this style front end better anyways. Save that bumper, those fuckers are hard to find. (a clean vented one) And I still can't believe you went auto

You should sell me your lift and radius arms though.
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Old 08-25-2008, 12:14 PM   #19 (permalink)
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Quote:
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MEh, I like this style front end better anyways. Save that bumper, those fuckers are hard to find. (a clean vented one) And I still can't believe you went auto

You should sell me your lift and radius arms though.
im still looking for options on a stick tranny. If i can find a computer/tuner to not throw a light (cali smog) ill throw a zf in her. For now, its cheap and works until i can figure it out.

Plus, its OBDII so i can tune it, and it gives me a shitload more options. Im going 10.25 to keep the factory speedo too. The truck needs cats (prev. owner sold them ) but after that, ill get the vin worked out and smogged. start drivin this bitch.
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1996 F150 - Supercharged 5.8L, E4OD, Vortech S-trim, PSD Intercooler, 15 psi , 1356, Dana 60, 10.25, 5.13 gears, welded rear diff, 14" Air/Coilovers. Check it out:

Build thread:
Here

The un-named buggy - 2.3L, lotsa tube, and FJ80s.
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Old 08-26-2008, 11:35 PM   #20 (permalink)
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Well, i got my old flex-a-lites mounted to the radiator, and ditched the factory fan. Helped a bunch with throttle response. Other than that nothing new... Ill snap a couple pics as i go. Over the next couple days im going to rip out the inner fenders, skid plates, that kinda factory b.s.

Its also getting a full tune up, belt, idler pulley, and im going to swap my saginaw pump onto it this week. After that, ill be ordering some 6" superflex's for the front, and buyin some heims.

I cant wait to lift it. It looks so small.

I also decided that I will be pushing the front axle forward. I love having the protection of the bumper, but hated the approach angle. Somewhere around 2" forward. Also, im going to be redesigning the rock slider for this build. I really liked the old one but i want more of a flat belly. Im going to photoshop a couple pics soon...
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1996 F150 - Supercharged 5.8L, E4OD, Vortech S-trim, PSD Intercooler, 15 psi , 1356, Dana 60, 10.25, 5.13 gears, welded rear diff, 14" Air/Coilovers. Check it out:

Build thread:
Here

The un-named buggy - 2.3L, lotsa tube, and FJ80s.

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Old 08-29-2008, 09:45 PM   #21 (permalink)
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Well, got the saginaw pump swaped over from the 6 to the 8. Bolted right up, used the high pressure hose off of the 6. (I had to buy a new hose, for a early model (IE 1987). Diffrent threads on the pump.

Anyway, decided on using the pulley off of the 6 also. It is about 3/8" smaller than the 5.8s pulley, getting the pump to spin a little faster at idle. Im hoping this will help the idle/turn problems i would get on pavement. It would turn with one finger on the dirt at idle, but on the pavement i would have to do a "high idle" to get them to turn.

Now, it spins one finger and it spins FAST. Should do OK with 40s until i can do an assist setup. Pics:

The pump.

The electric fans.

The lack of inner fenders.

The cleaned motor.


I need to make some small brackets to hold wires, vac lines, that type of thing. I also charged the AC. More updates this weekend.
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1996 F150 - Supercharged 5.8L, E4OD, Vortech S-trim, PSD Intercooler, 15 psi , 1356, Dana 60, 10.25, 5.13 gears, welded rear diff, 14" Air/Coilovers. Check it out:

Build thread:
Here

The un-named buggy - 2.3L, lotsa tube, and FJ80s.
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Old 08-30-2008, 04:37 PM   #22 (permalink)
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wow - you suck


i just realized that you have the gay lower radiator hose too - dont fuck it up - its dealer only


and hurry up, you need to start driving me to lunch
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build up of the truggy
http://www.pirate4x4.com/forum/showthread.php?t=544813
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Old 08-30-2008, 05:13 PM   #23 (permalink)
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Quote:
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wow - you suck


i just realized that you have the gay lower radiator hose too - dont fuck it up - its dealer only


and hurry up, you need to start driving me to lunch
eh, i may just save my cash, throw a Kenne Bell on it and wheel it as is.
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1996 F150 - Supercharged 5.8L, E4OD, Vortech S-trim, PSD Intercooler, 15 psi , 1356, Dana 60, 10.25, 5.13 gears, welded rear diff, 14" Air/Coilovers. Check it out:

Build thread:
Here

The un-named buggy - 2.3L, lotsa tube, and FJ80s.
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Old 08-30-2008, 09:14 PM   #24 (permalink)
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ya - then give it to me so i can blow up my high mileage 5.8 and build a stroker. then you can have it back - maybe
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build up of the truggy
http://www.pirate4x4.com/forum/showthread.php?t=544813
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Old 09-01-2008, 08:31 PM   #25 (permalink)
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well, updates for the end of the weekend:

I sanded one front fender, lower valance, cowl and primered them...

Also, finished most of the interior work. Mounted both seats, plastic A-and-B pillar covers, speakers... bla bla bla. Chopped off the unneeded parts; spare tire mount, skid plates, factory exhaust. Its coming together nice.

Also did a tune-up. had factory wires, cap, rotor, and fuel filter. Also threw my MSD TFI coil off of my old truck, along with the drop in K&N filter. I need to buy cats, and a muffler and then i can go get it all legal.

Edit for pics:





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1996 F150 - Supercharged 5.8L, E4OD, Vortech S-trim, PSD Intercooler, 15 psi , 1356, Dana 60, 10.25, 5.13 gears, welded rear diff, 14" Air/Coilovers. Check it out:

Build thread:
Here

The un-named buggy - 2.3L, lotsa tube, and FJ80s.

Last edited by svt150j49; 09-01-2008 at 08:33 PM.
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