'86 Extended cab project thread

BlindAmbition

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Another long gap in this project, almost done with school which has taken precedence.

Rebuilt my injectors correctly, working on getting several sets together as I will be running WMO and need to keep plenty of spares around. Got the engine timed to 9.5*, ready for turbo reinstallation. Ordered viton seals (212, 215, 329, all 75 durometer) for the turbo, waiting on those. No longer smokes like crazy, it was the injectors sticking. Timed it at 2000 psi with open headers until the turbo goes back on. Smokes a bit, guessing the pump has the fuel turned up a bit, it is essentially N/A right now until I put turbo back on.

Made a pop tester from a hydraulic ram pump, a digital gauge, and some adapters with an extra injection line

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Rebuild "station" with shims from all of the injectors I've pulled from the junkyards. I pull them apart, ultrasonically clean everything, then lay out a new layer of shop towels for that injector. I reassemble with the old nozzle, if it pops good, I use it, otherwise I put a new Chinese nozzle on it courtesy of AliExpress as I could not find any other source. It's a tedious process, adding shims and measuring, I see why the rebuilders charge what they do. I'd like to get 4-5 full working sets so I invested in this setup, plus I like working on my own stuff. Currently I have a working set in the truck with Chinese nozzles, they have a better spray pattern than the set I rebuilt with used nozzles. All pop +/- 50 psi of 1850.

I'll eventually get a flat glass or granite for lapping the sealing surfaces, I think I'll have more success with reusing nozzles that way.

If I wasn't planning on running WMO I'd likely just get a rebuilt set from a one of the folks here.

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Worked on the wiring some, still learning how to do vehicle wiring cleanly. It's a work in progress. Somewhat complicated because the supercapacitor hooked up to the starter requires that my second battery be separate for the glow plugs. System works really well, fires up immediately, faster than many of the videos I've seen on Youtube.

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hacked89

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Injectors, agree, that’s one of those things that you realize is reasonably priced to pay someone else to do.

The wiring, I would think of some way to make a plastic cover for your under the hood panels. There’s alot of opportunities there that you can easily have a wrench or object touch between chassis ground and hot and turn into a glow stick
 

BlindAmbition

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Injectors, agree, that’s one of those things that you realize is reasonably priced to pay someone else to do.

The wiring, I would think of some way to make a plastic cover for your under the hood panels. There’s alot of opportunities there that you can easily have a wrench or object touch between chassis ground and hot and turn into a glow stick

I agree on covering wiring, I had to be aware of where I left my wrenches when timing it. I'm looking at redoing it a third time so that I am satisfied while also enclosing it all in some sort of waterproof box. It's been a learning experience for sure!
 

1mouse3

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Worked on the wiring some, still learning how to do vehicle wiring cleanly. It's a work in progress. Somewhat complicated because the supercapacitor hooked up to the starter requires that my second battery be separate for the glow plugs. System works really well, fires up immediately, faster than many of the videos I've seen on Youtube.

That a is a interesting lab rat you have there.
 

Jesus Freak

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That a is a interesting lab rat you have there.
I'm with you. Just read over the thread, way beyond me as far as the wiring stuff but hey, I totally dig the DIY dedication. I cut the windshield out of my parts bronco today and will be putting it into my dually in a couple weeks, because I just can't imagine paying someone to work on my stuff. @BlindAmbition , hats off to you man! I got a bunch of injectors myself that I'd like to mess with sometimes, you sir have inspired me.
 

BlindAmbition

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Finished my Masters degree, am able to actually work on this truck now.

Scope keeps changing, my plan is to now...

Convert it to 4x4
Swap 2005+ SD axles
Add a gear vendor unit
Swap side tank with a 38 gallon SD unit
Redo the wiring (again, I hate it)
Add air horns I found from an International big rig
Add air bags on rear

Here are some pics of progress

Removing Starling 10.25
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New Sterling 10.5 partially in, doing hub seals, checking bearings, changing gear oil, adding aluminum diff cover before putting weight on it.
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Frame I am stripping stuff from. 2005 2wd F-250 long bed crew cab I got with wheels, driveshaft, exhaust, steering gear, fuel pump, and rear axle for $700. The brackets for the radius arms and coil buckets are the same for 2wd and 4wd according to part numbers, swapping them to my truck in due time. Swapping steering gear as well to accommodate new pitman arm on SD front axle

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$350 score (plus 3.5 hour each way, worth it)
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Going to mount it to this, or considering finding a 460 gasser 4x4 ZF5 for the different ratios.

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BlindAmbition

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That RV in the background is based on a 1981 F150 with a 3.08 9" rear end. Going to take all my old 8 lug stuff from my truck and stick it on that RV. Should ride better with 3.55 rear end. Has a 300 inline six, I have an Offenhauser 4 barrel inake, though I'm planning on selling the RV so I'll keep that and do a 2 barrel carb swap instead on the existing 1 barrel intake, saving the offy for a 300 turbo build later down the road.

Then debating turning the SD frame and 9" axle (or I found a 10.25 for $125 locally) into a trailer using my long bed as I plan to find a flatbed or utility bed for my blue truck. I would have a matching truck and trailer combo then.

The only leftover parts from all this swapping would be the haggard 81 front suspension bits and the black wheels.
 
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Austin86250

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Love it man, I’m slowly building my 86 extended too. Got the block and heads to the machine shop today cant what to do the Saginaw swap
 

BlindAmbition

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Mostly finished the rear Sterling 10.5 axle swap. Need to figure out parking brake cables. Got rid of the frame, sold the catalytic converter from it, basically got my rear axle and a full set of wheels for $300 at the end of the day. Also was able to cut off all the brackets I needed for a front axle swap to boot.

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Bilstein 5100 shocks installed ($56/ea from Amazon Warehouse) Working how to install my existing rear sway bar, I think I need to move the shock brackets towards the wheels a bit for it to clear. Then decide if I can utilize the existing end link mount or if I have to go to a 4x4 style. I pulled two front shock mount brackets from a junkyard truck to use as end link brackets in case I need to use those. Or maybe go through catalogs and find some that are a couple inches longer to use existing mounts. Or make my own.

Front shock brackets work as end link brackets for 2WD trucks with a washer.

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Shock is too close to sway bar

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2005 rear axle shock brackets bolt on, should be able to move closer to wheel to get clearance.
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Got a 1350 flange ujoint mount/adapter/yoke whatever it is. Also got a 1330/1350 ujoint so I didn't need to change the flange yoke to a ujoint style. Just sitting there, not bolted up yet, though bolt holes are correct. Will need to drop driveshaft a couple inches to account for 2" lift

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BlindAmbition

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I had an old chaise lounge that I was getting rid of. Took a bunch of the foam out of it and stuffed my doors after applying a ton of sound deadening material. Will take pictures when I pull the doors apart again. Also installed 6.5" GTO609 component speakers that will run from a 4x400 Taramps amp and a Dayton DSP-408. Installed new window track felt, took the window out and greased everything with white lithium, put in new lock motors. Basically freshened everything up as well as I could. Can close the truck door with 1 finger now and it makes hardly any noise. Also put in the bottom pocket from a newer truck instead of keeping the old clapped out pockets that came with the truck. May end up dying them or just finding some blue ones down the line.

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BlindAmbition

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I ordered a torque cam from Russ. Was originally going to build an engine on a stand and put it in then, but decided to just go ahead and stick it in. I needed to remove the pump again anyways as I'd ordered an RnD 80cc pump. To go along with the cam are some Comp Cams 910-16 springs, as well as the .030 shims needed. Also ordered a valve spring height micrometer to make sure I get the 1.80 installed height correct. This engine had a Dealer's Diesel tag on the valve cover when I got it, so I'm not sure exactly what the history is, but it has definitely been rebuilt. Fought my driver side block drain that was red loctited in, going to replace it with a hex plug and then fight the other side to get all this rusty bs out of my engine.

Cam installed, minus front bolt and washer.
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Found the Comp springs on eBay, offered $72.50 and the seller accepted, nice little score.

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BlindAmbition

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RnD pump arrived. Will be a bit before install can happen, but excited about it. Also found that it can be turned into a 90cc pump without much hassle. Will be nice if I ever stud the engine. Inlet test pressure was 6 PSI, that is what I'll be setting my fuel regulator to when I redo the fuel system.

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