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Discussion Starter #1
So a little late but in order to keep a log of the work we do on it, better late than never! Our plan was to build a hunting rig to use up here in Alaska as well as an overall exploration rig as well as a project for my brother, dad and I to do together. We are no strangers to large projects and we wanted to be able to start pushing further back into the hunting grounds so it made sense.

So we started with a 99 SD CC f250 v10. The truck came with tires 47x21.5 and was pretty roughly cut to just get them on it in order to store the vehicle. Rims that were on the vehicle were obs lug pattern so would need to correct that. Truck came with the 05+ SD d60 and 10.5 rear. As well as the lift kit and a whole slew of other parts. Plan was to put the 4 link lift on, 05+ axle. Hydro assist, recenter the rims, rebuild the trans, time sert the engine, misc maintenance, tube bumpers and roof rack, and places to store lots of hunting and camping gear.



from when we first went to go buy it


tow truck driver was loading it and popped the bead on the rear pass tire. he was cool with taking still though and went for it


seemed sketchy to us haha



47s vs 35s haha
 

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Discussion Starter #2
so first step was to get it inside and start thawing it out and assessing where its at.




got a spare set of smaller tires to make moving around easier

original dana 50 and leaf springs

time to go, dana 60 and 4 link on the way

more cutting

old suspension cut out and new dana s60 slid in place with the coils. just a mock up but more to make us feel like we are making progress
 

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So the truck came with quite a few parts, including a Rize 8" lift 4 link long travel kit. However it came off a wrecked truck so we had to resection the damaged arm.

the bent section of arm cut out and new gusset plates cut for the sides

started to weld it in

all welded up

the old bent section of arm

some paint and should work great


so the rims that came on it wer for an obs f250 and used adapters. Definitely wanted to omit the adapters so we got some pressed h1 centers that we will install into the rims to convert to the newer sd bolt pattern. more on this later

the old dana 50 removed

playing with the new axle a bit
 

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so since the lift was meant for an 05+ truck we had to do some figuring out on the upper link brackets since we didnt have the factory radius arm brackets the 05+ trucks do. We used the 4 link calculator on here to find the best position for the upper link mount and then designed a simple bracket and cut them on the plasma table.

the lower link brackets from the kit

lower links installed breifly


also installed the spring towers. most holes were in the 99 frame, only needed to drill 2 or so on each side.

also decided we were going to need some much larger jack stands so these were purchased

 

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Discussion Starter #5
continuing


cutting the plates on the cnc plasma I built. still some tweaking to do but fun to be able to use it


links mounted



on with the front suspension
 

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so the next thing we needed to address before continuing on the front suspension is the steering. The plan was to run a steering assist ram, so needed to tap the factor box and install it before we installed the lift drag link crossmember.



steering box tap locations

tossed the hydro ram up there to see what spacing we were working with


new braided brake lines



new brake lines, suspension starting to come together
 

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Discussion Starter #7
front lift on, now to wrap up steering components


used a hydroboost pump and added AN fittings

first load of tubing in!

tossed the big tires on to see how she looked.



ended up just getting the psc dana60 ram mount vs fabbing our own. saved time and was a nice piece


 

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Discussion Starter #8
wanted a little break from the suspension work so moved onto the front bumper fab. started by plasma cutting some frame horn adapters and then the tube work fun could begin




went with Runva winches, so far have been really pleased with them and the only ones we could get shipped up in a decent time. Partially covid and partially because no one wants to ship big winches up here and we had a small time frame so they were chosen. one for front and rear.

C channel welded to mounts

first tube to be bent

will trim out later
 

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Discussion Starter #9
tube work continues







the trickiest bends were these small bars for the fairlead mounting


 

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Discussion Starter #11
now moving onto the rear bumper and recentering the rims



new h1 centers will fit into the existing wheel hoops

so we made an adapter to mount to the rear of the existing wheel center, with the updated bolt pattern on the backside we put studs through so we could mount the new wheel center behind the old one. install and weld. then plasma cut out the original front one and it will keep everything square and true

the adpater we made for recentering

the first one we did. you can see the original wheel center we kind of roughly plasma cut out and the new one behind it. everntually we will laser cut some beauty rings to cover it.



starting the tubing on the rear

 

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Discussion Starter #12
so I guess I dont have pics, but the rear is lifted using small blocks and a shackle flip. we also decided we needed more storage for hunting and camping gear so tossed a cargo box on the rear camper shell we found.




we also decided the truck would be too heavy for the half ton to tow. so we got a 18 350 and a 40.5 goosneck to haul it around.

tows the truck and trailer great!
 

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so now was the trickiest part of the project to date. The original trans was on its way out. so we planned to rebuild one to throw in there, no big deal have done this type of stuff many times. Planned on stage 1 upgrades, shift kits etc. So we got another 4r100 and rebuilt it and through it in....

thats where we ran into problems. it would shift super hard from park into reverse, like it was locking up the converter and would kill the engine. And so there is our screwup after many phone calls and searching. it turns out the 4r100 that was in the truck was no pwm, and the one we rebuilt and installed was pwm. These early trucks seem to be a bit tricky as to deciphering which is which, without checking the solenoid packs and pump. So at this point we found out we either needed to swap the new transmissions pump and solenoid pack to the non pwm set, or get an aftermarket trans controller. We opted for the later but still decided to pul the trans to verify its okay after our little mishap. Turns out inside looks great, although the torque converter we got was incorrect for the truck and had damaged the pump stator. literally was grinding it down, so much for local parts store getting the parts right. But it happens, so we replace the pump stator while the trans is back out and also get a new TC. We reinstall the trans again and use a US shift controller and no issues and shifts great, the US shift is an amazing unit and their customer service was excellent to deal with. Eventually we will be using our cruise control buttons on the steering wheel for paddle shifters as the kit allows



trans rebuilt and ready to roll

the solenoid pack in question, this is what showed us the truck had a non pwm trans to start with so this is where we isolated the problem. Didnt know to look here originally


the damage the bad TC caused
 

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Discussion Starter #14
Trans installed, and working great now after the debacle. Time for a little driveway fun and then onto the roof rack fab!













 

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Discussion Starter #15
roof rack fab continued. setup to mount our gmrs antenna, hi lift and misc led lights


added tie down gussets at every joint

added tie down gussets at every joint






 

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Discussion Starter #16
fabbed a quick mount for the trans controller, then also started adding some switch panels we laser cut and wiring things up. All accessories are run off a blue seas fuse block and its supplied by an ignition triggered 120 amp relay.




winch wiring and disconnect added





 

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Discussion Starter #17
so now time for a test run before hunting, time frame is getting tight.







also fabbed up a game pole that uses the winch for lifting.
 

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Discussion Starter #18
one thing for sure after the test run. we needed an easier way to get in, as well as the trans temps getting higher than we would prefer. So we are still on 3.73 gears which is obviously not ideal, but just running the truck in 4 low and it does fine. Will eventually change the gearing but for now, dont have time. Installed a large Derale trans cooler and that completey solved trans temps, the stock cooler also absolutely blows.

some quick tube steps.

 

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Discussion Starter #20
no moose or caribou this year, but had a blast even still. Cant wait to get it out on other trips and adventures, came out a side by side light haha. It got pretty jacked up and left it up on the mountain to deal with later as we had to get out of there.




 
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