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  1. G. Mann

    Positive Battery Cable

    Here is what I've done on 3 of my trucks. Currently running this setup on all three with NO issues. In each case I used the existing cables, just hacksawed the lead lugs off and swagged on solid copper welding cable lugs with 3/8 diameter hole and used the Marine style battery lugs with wing...
  2. G. Mann

    PU box weight

    3 guys can easily lift a bed and walk it to position, without breaking a sweat. 4 guys and it's a piece of cake.. I'm guessing, with the tail gate off, 300# . Build one of these and do it yourself, one man show. Or, just put a nylon strap on each corner pocket and hook it to your engine...
  3. G. Mann

    Slow Cranking IDi

    Sorry, my post wasn't clear... Check your NEW batteries with a load tester.. It is possible one of the new batteries has a bad cell and isn't making full power.. I've this happen to me recently.. brand new battery, meter says it has a 12.67 Volt charge.. but when I load test it.. it dropped...
  4. G. Mann

    Slow Cranking IDi

    In your original post, you say you replaced ONE battery.... because it was ??? doing what? On a two battery system... if one goes bad.. it will take down the other battery... I strongly suggest you load test BOTH batteries you currently have.. I'll make a bet you have at least one that is...
  5. G. Mann

    Fuel tank replacement

    Pull the bed. If you have a cherry picker [engine lift] you can do it by yourself, just use nylon straps to the corner pockets, and tie them all off to the lift, jack the bed up just enough to clear the tires [after you disconnect the fuel fill tubes, don't forget, and the tail light plug...
  6. G. Mann

    Off Brand Turbos?

    May be made in China, assembled in USA, or not.. Worth a call to the seller, who looks to be in CA..... It is likely that most turbos on the road today are made in China, with all the outsourcing of parts for the "world market" that's being done. Child slave labor can make good parts now...
  7. G. Mann

    86 f250 6.9 rebuild/refresh advice and questions

    You will be back... once you own a Ford IDI you're infected, you'll have to get another one to be able to feed your addiction.. ;)) As for myself.. I determined that I have both OCD [Obsessive Compulsive Disorder] and ADD [Attention Deficit Disorder] .... Everything has to be exactly f-kin'...
  8. G. Mann

    A charging question

    You need the ground wire on the alternator. Without the alternator being properly grounded it doesn't complete the charging circuit, I believe. One of the wires on the two wire plug that goes to the Alternator should have 12 volts when you turn on the key.. I believe that 12 volts then...
  9. G. Mann

    Need ideas on oil cooler

    I'm late in this, but thought I would pass along my "tech tip" for making sure I had flat mating surfaces. Sheet of glass, like a glass coffee table top [send SHMBO out shopping, or something] Clean it really good so there is no bumps .. spray it with a spray bottle of plain water, and lay...
  10. G. Mann

    Super cab owners...

    Take a hard look at the rails that run across the bed on the bottom side, the ones the bed bolts run through, to bolt the bed to the frame. If the bed has been over loaded, or loaded heavy and taken of rough ground, those rails will bend where they bolt to the frame.. I'm betting that's what...
  11. G. Mann

    HydroBoost Brake System?

    I've driven vacuum boost Ford diesels now for over 20 years.. I still cringe at ever stop, knowing I don't have enough brake. Took the automatic adjusters out, threw them away.. I keep the rear brakes adjusted and still braking sucks.. Now.. fast forward a bit.. I bought a 92 F 450.. It has...
  12. G. Mann

    No Charge!

    As it happens, I'm having the exact same issues with my 92 F450, 7.3, external regulated alternator. Problem: Not charging. Done so far: New alternator. Still not charging. Tested the one taken off, it was working fine on test bench. Replaced voltage regulator. TWICE.. still no charge...
  13. G. Mann

    AC service possibile conversion

    If you run the old style York compressor, the compressor has a sump that holds the oil, just like your engine, which lubricates the pistons and rods for the compressor. If you have any of the later style rotary compressors the oil is dispersed into the coolant and travels with it as it cycles...
  14. G. Mann

    picked up an awesome new IDI, might have f-ed up using starting fluid

    Try warming the engine up, using some good engine flush, and fresh oil and filter to quiet down the valve noise. Oil may be at the end of it's change time, it's been setting, and lifters are likely full of junk also, like the fuel filter was. Worth a try.
  15. G. Mann

    Wet Passenger floor

    Since the firewall took a big hammer pounding in that area I would suspect the heater core felt the hammer and developed a leak. You can easily lose enough coolant to make the carpet wet and put steam on inside of the windshield and not show up at the radiator tank. 8 gallon system.. if you lose...
  16. G. Mann

    AC service possibile conversion

    Dye check and black light works for me.. for hard to find leaks especially.. A can of dye check into the system and enough refrigerant to get it to work for a while to push some dye out the leak. The pull a vacuum on a newly assembled system procedure is one I've used for 30 years... If it...
  17. G. Mann

    AC service possibile conversion

    First put a set of gages on your system and check if you have any charge remaining.. BEFORE you pull a vacuum on the system.. Pulling a vacuum on the system will evacuate all coolant you have in the system.. so IF you have R12 remaining.. you likely still have a sealed system.. just lost...
  18. G. Mann

    FSS Wiring Refresher

    Have a good look at the hard line that runs from driver side under the engine across to the passenger side.. to the fuel pump... you could have a crack or a rust hole in that line.. Where is your electric pump mounted? Is it mounted on the frame before that line? Or , is it mounted in the...
  19. G. Mann

    FSS Wiring Refresher

    Check the olive at the back of the engine on the return fuel line.. check for any dampness at any of the return caps or return fuel lines. Check for and dampness at the injector line connections.. either end.. If you have a stream of fuel when driving, you should get a stream of fuel when...
  20. G. Mann

    the newest piece of fecies.

    On the subject of engine bay harness... Anybody know what difference there is between gas and diesel harness? Is it more than fuel solenoid to the IP and some other small differences.. or is the gas harness way different? I need an engine bay harness for the 92 CC Diesel "new truck" and I'm...
  21. G. Mann

    header flanges are in!

    Engineering: That field of work where you can go from saving face to trying to save your ass in increments of time so small they defy measurement. In my other life, before IDI trucks, I worked in the jet engine engineering field fighting the same issues we are discussing here in the design of...
  22. G. Mann

    header flanges are in!

    THere you go.. some of the Bernoulli principle of fluid dynamics in action.. you can bet the boys with the big paychecks and big degrees pencil all of it out before hand.. V-10 gas engine is likely more sensitive than diesel IDI.. however.. every detail overlooked means less available energy...
  23. G. Mann

    header flanges are in!

    I also have spent a bunch of time looking at the intake.. and came to the conclusion it was useless for a turbo engine. If you do plates and short straight tubes, with a roll nub at the end to keep silicone hose clamps in place.. the intake ports would easily clear STOCK injector lines, and...
  24. G. Mann

    header flanges are in!

    I'm thinking that a set of flanges for the intake and then well short tubes that have a rib rolled in the open end to hold silicone hose/clamps followed by more tubes with bends to make up the manifold, which would be fed by the intercooler. Then tube/hose/clamps from the turbo to intercooler...
  25. G. Mann

    header flanges are in!

    :popcorn:popcorn:popcorn:popcorn Settled in to watch the build... ;Really Don't forget to take pictures... Need a build truck? I have one I would "let you" work on.. :rotflmao :rotflmao

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