1987 Crew Cab 2WD Build

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ok so after further review the intake manifold that came off the truck doesn't want to go back on the truck? Has anyone else experienced this? I am going to have to clean up my old intake manifold and use it instead. I still have the dilemma of the Valley pan gasket bolt holes not aligning.

On a positive note I think i found a truck as a donor for any parts i have been needing and it's only about an hour away. i figure i go get it and use what i can. Unless it's in way better shape than i expect then i may feel to bad lol just another boat in the driveway im sure the neighbors wont mind lol it's no mystery i'm seriously anti HOA.
 

IDIBRONCO

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Between the valley pan and the intake both not matching up any more, I'm going to guess that this is from the amount of materials that was removed from the heads. It's not that the intake and/or the valley pan don't fit, it's that the bolt holes are no longer where they were from the factory. You can remedy this by enlarging the holes in both of them slightly. I can only remember one time that I had to do this on a 6.9/7.3, but it wasn't all that uncommon with a 6.2/6.5.
 

Big Bart

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For the future, it could help to put on the intake and put in the intake manifold bolts (Leave them loose but say half way in, then torque the heads down. It can help insure the heads are better lined up with intake. But if you see it is binding (Keeping the head from sealing.) you would not want to continue. Sometimes the head can be slightly right, slightly left, slightly down, slightly up, canted, and now the intake manifold will not allign. I do not recall if the IDI's have centering pins, if so then maybe it would not do much.

However if too much was taken off, then you may have to have the machine shop machine down the intake to fit. This was a very common problem on the ford FE series gassers. The intake was integrated into the head. Once you machine down the head, the intake would hit the block or not fit down in the V before and seat properly on the head. So Ford had directions on how to machine the intake to allow it to work with the newly machined heads.
 

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So I called and double checked. The machine shop did not resurface the heads. Meaning the original manufacturer of the reman engine most likely used a head that had been ground down previously. That still doesn't explain how the intake manifold was bolted down and sturdy on reman engine when i received it, but wont rebolt now. I am going to enlarge the gasket bolt holes being as careful as possible not to damage the gasket seal and then also enlarge the bolts holes on the manifold. Ill keep you posted.

On other good news my turbo should be complete by end of next week and I can continue assembling everything. Anyone have a referral for an exhaust shop in Oregon (close to portland)? I want to run 4" to the tail. Thoughts?
 

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Ok... so i got the intake on. Wow. that was a reeeaaal harlot. Primarily because I had to

.Enlarge the intake bolt holes to 27/64"
.Shorten roughly 8 Bolts.
.Sanded the intake head surface

Its fairly soft material which makes this a lot easier than something more dense. Even still it was twist by twist bit by bit. Here is the progress currently.
 
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To my post above... the truck fell through.He cancelled the meet up several times and ultimately I cant have that beast on the street. Not enough room. I need to live on a farm or acreage!!

Here she is. All of what looks to be bare metal is actually coated 2-3 times in https://www.amazon.com/dp/B006ZLQ0J...l_k1_1_9&crid=3UYBAJTC6GXFO&sprefix=rustoleum . At first start up i plan on running the engine per the directions for heat up and cool downs to fully cure. There will be more blue to help tie everything together. Not looking for a show queen just something impressive if the hood gets popped. lol.

I currently need the following if anyone has any leads. radiator core support with AC. washer fluid reservoir. Coolant overflow tank. Tranny cooler lines.

As i write this i am lounged in a hospital recliner waiting on my wife's contractions to get rolling. We are having a boy. His name will be Ford. Happy Tuesday.
 

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Ok some progress.

-Exhaust fully removed.
-Front tank out. Was rusted on the interior.
-Rear tank out also rusted. Both have a decent amount of fuel. Any issue with running the fuel through a filter and using it?
Turbo is here and installed. Pondering options on the exhaust downpipe. While I'm pondering any weight ins? I have the flat (dumb)beat stock one that sneaks by the fire wall. However I'm thinking something 3" from the usual suspects. The waste gate delete is of interest. Any experience benefits/ negatives?

-38 gal tank arrived
‐Windshield gets replaced next week

Next up is diff seal and fluid change plus a knock down of surface rust on the tail. Ideally I have 3 months to finish this. That beats most the rain and get us a second car sooner than later. Thanks all for riding along. Have a great evening.
 

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IDIBRONCO

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I don't think that I would try to reuse the fuel. I would be afraid that there would still be contamination in it and would damage your pump and injectors.
 

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Update.
-Fuel tank received spectra 26d.
-Ordered a new rear tank sender because mine was in terrible shape. I am going to use the ccd sump kit therefore deleting the pick ups. I still have not figured out how to wire it.
- Banks turbo down pipe received. I wrapped it with exhaust wrap. Great build quality. Really happy I made the investment
- Diff fluid changed and painted the cover primer gray with high temp clear.
- Changed the front pinion seal, washer, yoke, and nut. Not cheap, but when in Rome? Wait... no wrong saying..
-Windshield replaced. NO RUST. CRAZY
-i dropped off my headliner to a local shop. Not an easy job. They bid it at 300$ and that's with me supplying fabric. The damn foam core makes for a bear getting the old foam off without damaging the cardboard layer. It also needs repair at the corners. I got it out if the truck completely gutted and realized I will have to put it back without obstruction. Hmm
- I picked up another full truck wiring harness to correct/ have a back up as I finish items. $250 and in great shape
- FINALLY PUT THE HVAC BACK TOGETHER. I was nervous about this because of the inherent temp Flux. I used a plastic welder and welded the pieces back together with right stuff as the channel.
- I got the exhaust in. Diamond back 4". Should sound gnarly.
- I have 64 sf of dynamat going in next week. Doors and firewall. Encouragement for remainder?
- This week is organization week. Have to get this clutter sorted so I can continue progress.
 

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IDIBRONCO

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The damn foam core makes for a bear getting the old foam off without damaging the cardboard layer. It also needs repair at the corners. I got it out if the truck completely gutted and realized I will have to put it back without obstruction. Hmm
Yes it is difficult to get off. I'm using a scraper and trying to be careful enough to not damage the cardboard. My corners next to the sun visors need to be repaired as well. A friend in the auto body field who has some interior experience as well told me that Gorilla tape is what he uses to hold the cardboard together. He told me that if you put it on the bottom side (the side that the material will be on), you can see the tape even with the material with the foam backing. He said that the only place that he will use it on the bottom side is at the front corners where the sun visors will be anyway. It sounds a little bit far fetched to me, but I'm going to trust him and follow his advice since I have no prior experience here.

- I have 64 sf of dynamat going in next week. Doors and firewall. Encouragement for remainder?
What I'm going to eventually do is put Dynamat in the doors, on the firewall, on the back of the cab under the rear window, in between the roof braces above the headliner, and underneath the carpet on the floor. Between this and the headliner, it's all that's keeping me from reassembling my interior. That and I'm getting ready for a possible ATV riding/camping trip this weekend.
 

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Shipping times, shipping damages, and order of process delays are for the most part why I am only this far. I hear you there! That's sounds like a blast. I want to get this truck done so that I can use it to do the fun stuff!
 
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IDIBRONCO

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Mine will be my nice truck as well as my tow rig. This one will eventually be painted. I can't say that for my other two. This one will get to do some fun stuff after it's driving too.
 
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