For the 6.9 rebuild for the crew cab............ it's listed below. Not all of this is for power, but for reliable hauling of that heavy fifth wheel anywhere I want.
As far as a swap......... honestly, if I wanted another engine (Dmax, PSD, or cummins.....) I'd buy a truck with those engine in it. I like and want the IDI in the 'ol girl. Is it the "best" for all out power.........?????? No. It is reliable, cheap to maintain, and simple to repair/diagnose/work on.
Plus, that '86 crew cab is too nice of an old truck to stuff some other company's engine in.
Just as a final tally of parts and their cost, here's the list (it's a little scarey):
Machine work and installation of new cam bearings $1100 ($220 of that was balancing work)
Gasket set and valley pan (Victor Rienz) $250
Clevite 77 rod and main bearings $314.25
Mahle reduced compression pistons with rings, pins, clips $550
"typ4" cam $200
New Ford lifters $90 (eBay find)
Intake vavles (Perfect Circle) $75
Exhaust valves (EngineTech Stelitte face) $105
Comp cam 910 springs $81
Rear main seal with repair sleeve $42
Head work (had to be redone, 1st shop didn't do what they said they did) $410.26
ARP head studs $215
7.3 PSD intercooler $200
Intake hat $66
Intercooler piping/boots $194
Moose pump $689
Moose injectors $1085
Water pump (new Ford) $95
Head dowels $12.50
New 7.3 rockers (Melling) $95.92
Rodney Red Radiator $750
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Total = $6619.67
Heath