notes and thoughts on grafting a 92-97 front clip onto a 80-86 truck.

towcat

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This last couple of weeks I grafted a front clip off a '94 F450 onto a '86 F350 4x4. Overall the general idea is a drop-in or a bolt-on but it is not completely foolproof. The general alignment of the body lines makes the job much easier and most of the bolt holes do line up. I will use the pics to detail the issues I came across when doing this graft.
 

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towcat

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now the explanation. I will address the items from the top left and work my way down to the bottom.
1) cowl- the cowl in the pic is the 80-86 with a 92-97 hood installed. the bodylines are completely different and it must be changed out. also, the hood contour is completely different.
2) right and left fender tops to windshield pillar. note the cuts and gap between the two. this is an item you will have to learn to live with unless you want to weld on some metal to close up the gap.
3)cowl end mounting tab- the pictures speak for themselves. no way in hades will it bolt up. you will need to fab and bolt in two small angle pieces to tie down the ends.
4)lower inner fender-you have to open the doors to access the bolts. this is one area you do not have to mod.
5)bottom fender mount. the 80-86 is a flat mount whereas the 92-97 hangs down at a 90*. fab bracket to work.
6)in general, all bumps, creases and critical items do line up and make the job pretty straightforward.
any questions? post here!
 

david85

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Good write up there. Pretty much eliminates any temptation I may have ever had to do this (even then it was probably only about 5% tempted LOL).

I knew the lower rear fender mounts were different (not positive but I think the 87-91 is similar to the 92-up), but did not know about the A pillar gap. That would scratch my eye every time I got in the truckLOL
 

Diesel_brad

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Nice writeup Calvin.

For the little tab that the New(92-97) cowl bolts to. I just lengthened the tab by cutting it out of the fender bracket more(if that makes any sense).

I will assume you used the 92-97 rad support?
 
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Diesel_brad

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I knew the lower rear fender mounts were different (not positive but I think the 87-91 is similar to the 92-up), but did not know about the A pillar gap. That would scratch my eye every time I got in the truckLOL

Once everything is painted the same color, you never even notice
 

icanfixall

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It will buff out...:D Thats a lot of body work you did. Why did you make the swap from late to early body. Just wondering. Almost seems like you could add some spacers and move up the clip so the lines you pointed out will match closer....:dunno Great pics too. Nothing worse than blurry pics attempting to show something interesting... Bulrry pics are worse than a last call turnoff....:eek::angel:
 

towcat

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It will buff out...:D Thats a lot of body work you did. Why did you make the swap from late to early body. Just wondering. Almost seems like you could add some spacers and move up the clip so the lines you pointed out will match closer....:dunno Great pics too. Nothing worse than blurry pics attempting to show something interesting... Bulrry pics are worse than a last call turnoff....:eek::angel:
gary-
the windshield pillar base and the fender top cut is completely off. if I tried to move it any more, all the other lines would be off. I'll take the lesser of two evils.;Sweet
 

towcat

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Nice writeup Calvin.

For the little tab that the New(92-97) cowl bolts to. I just lengthened the tab by cutting it out of the fender bracket more(if that makes any sense).

I will assume you used the 92-97 rad support?
i'm just going to weld an angle tab to it and be done. that's a good idea though for those who don't have a spotweld machine.
yes, the radiator support is 92-97.
 
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