90 F150 Cummins

[52wrench]

A few pics of my project. As it was before surgery, setting up the mounts for the Cummins 3.9L diesel from a Frito Lay van, after total diassembly of the frame, boxing and plating and hot dip galvanizing, reassembled with 9" rear, solid Dana 44 front, epoxy and urethane over the hot dip, it will last forever.

[52wrench]

Seven lbs of wire later. Had to totally gut the corners, made new running board extensions and support structure from 16 ga.

[52wrench]

I used Fusor panel adhesive and rivets to eliminate any possibility of warping.

[Mooch]

Looks nice but why a 3.9 Cummins ? Not much power there for your truck . Not knocking it just wonder why .


Mooch

[52wrench]

They've got plenty of power. 130HP stock, turn up the fueling on the pump along with a turbo off a 6 cyl and 175 hp is no problem and with torque close to 400 lb-ft @ 1700-1800 rpm. Plus high 20's mpg. Much better than the gutless 302 that was in it that was 165 HP but no torque to speak of unless you wound the p&* out of it. Plus I'll have 9 forward gears with the Gear Vendors overdrive.

Steve

[Len]

Nice looking work. Are those rivets holding that patch panel in place? If so can you post a closeup of one of the rivets and the tool that is used to install them? I'm not a big rivet fan because welding works so well but I'd like to see if you have any problems after the vehicle is on the road for a year or two.

[52wrench]

The backing strip and new panel were bonded with Fusor adhesive so that is really what's holding it. The rivets are just 1/8" steel pop rivets to act as a clamp while the Fusor cures. I made a dimpler out of a vice grips so the head is below the surface. I cut an access hole on the inner panel so I have access to the back of the patch and slopped it with epoxy with a brush. Then after all the painting is done I'm going to spray CP90 inside all the enclosed spaces. Its an oil like rust preventative that coats the panel and seeps into any cracks but does not harden like undercoating. I also drilled drain holes in case any water gets in there but it shouldn't. The factory had like foam rubber on the rocker panel extension that just held moisture, suppose it was for noise control.

[Mooch]

They've got plenty of power. 130HP stock, turn up the fueling on the pump along with a turbo off a 6 cyl and 175 hp is no problem and with torque close to 400 lb-ft @ 1700-1800 rpm. Plus high 20's mpg. Much better than the gutless 302 that was in it that was 165 HP but no torque to speak of unless you wound the p&* out of it. Plus I'll have 9 forward gears with the Gear Vendors overdrive.

Steve

I believe HP rating was with a turbo on the later 3.9L/4BT cummins.

I would look for a turbo off of a 3.9 engine. It is an interesting swap which has been done many times . I would really like to hear what the top speed is when you're done . I know the MPG will be good as some guys have said 27 to 33 MPG .

Looking forward to some pictures when you get to the engine part .

Mooch

[52wrench]

That is correct, that's what I have, 3.9L 4BTA, turbo, air/air intercooler. The stock 4BT turbo's are too small for turned up pump, plus they have huge exhaust housings which causes lots of lag. I've got an HE 351 off a 04.5 Dodge Cummins, has the 9cm2 exhaust housing and 60mm compressor. Lots of guys run these or an HY35. Top speed is not a concern, it will do 80-85 no problem, that's all I need. Running 3.50 gears with 33's, will be turning 1730 r's @ 75 in double over, right in the torque peak. If I tow anything, which will be a snow sled trailer at most, I'll run 4th over which is 2020 r's @ 70. Engine will be governed to 3200 r's. Will be able to split the gears with the GV overdrive.

[Mooch]

Sounds really neat . 80 is about all I ever push my power stroke also .

What nine speed trans are you using ? Have you an idea just how much this total package is going to cost ? Good luck and don't forget the pictures .

Mooch

[52wrench]

Its just the 5 speed that came in the truck with a Gear Vendors overdrive unit on the back of the transfer case. The OD can't be used until 20 mph so can only be used on 2-5 so I've got 1st, 2nd, 2nd over, 3rd, 3rd over, etc. OD can't be used in 4WD either but that's not a problem. I haven't totaled it up (afraid to) but i'm thinking it will be $10K or so by the time I'm done. Yeah, I know, crazy to spend that much money on an old Ford and I'll never get it back except in self satisfaction. It will make a real nice rig for the light weight camper I want to put on it though and no electronics to go wrong out in the boonies. Some guys play golf, I waste my money in my shop.

[Mooch]

Its just the 5 speed that came in the truck with a Gear Vendors overdrive unit on the back of the transfer case. The OD can't be used until 20 mph so can only be used on 2-5 so I've got 1st, 2nd, 2nd over, 3rd, 3rd over, etc. OD can't be used in 4WD either but that's not a problem. I haven't totaled it up (afraid to) but i'm thinking it will be $10K or so by the time I'm done. Yeah, I know, crazy to spend that much money on an old Ford and I'll never get it back except in self satisfaction. It will make a real nice rig for the light weight camper I want to put on it though and no electronics to go wrong out in the boonies. Some guys play golf, I waste my money in my shop.

I had it figured out at about 12,000 with new parts . Not really bad when you think about it . You will have a truck for many years to come if you choose to keep it .
I would love to have all the money I have wasted on various projects that didn't pan out . The ones that do make up for those that don't.

Good luck with your project.

Mooch

[52wrench]

Thanks. It could very well be close to 12 by the time I'm done. Remembered I need 5 new BFG 33x10.50 TA KO's, there's another grand right there. Just got in from doing the last of the 2K on the cab, now to start on the doors. They need new outside bottoms, maybe inner's too unless I can salvage them. I'm using a front clip off a 93 that needs very little metal work, a few minor dents so shouldn't be too bad. The core support is real bad though, may just build a new center section to hold the rad. that came out of the van and weld the wings on to it for the headlamps and quarter supports. I'll post more pics as progress continues.

Steve

[MeanGreen]

Cool. I've got a 93 and a 97 Ford F350 crewcab. Both are diesels...one's the 7.3IDI and the other is the 7.3 PSD. I say spend the money on the older trucks! I looked at a new 09 Ford and fell over.....58K for XLT Lariat.
Besides...real trucks are built not bought! My 93 will eventually have a 12V Cummins!
Post more pics please!!!
Jerry

[52wrench]

Starting to look like a truck again. Cab's painted, came out better than I expected. A little peel on the roof, may not worry about it since you can't see it. Working on the turbo setup right now.