It's Done! The Final 6.9 Project Report! (I hope)

[hesutton]

Finally.................... I think it's finally finished! I certainly hope so anyway. If you missed the previous updates, they are linked below:
Start Here
Second Update
Third Update
Fourth Update
Fifth Update
Sixth Update
Seventh Update
Eighth Update
Ninth Update
Tenth Update


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
-------------------------------------------------------------
Total = $6619.67


Here is the finished radiator support. It's now widend 1.5 inches, painted, and ready to go back on the truck with the rest of the front clip. Again, this was done to make room for the '99-'03 PSD intercooler without having to ditch/cut the stock trim/valance.

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Front clip back on the truck (yet again).

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Rodney Red installed and a clearence check with radiator in it's new location.

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Spacers (1.5 inch) for upper radiator mounts.

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More to follow:

Heath

 

[6.9poweredscout]

Seesh...i have about the same amount in mine in the scout. I just didn't know where the deals were when I built it!

 

[hesutton]

After test fitting the IC, some mods were needed to the radiator shroud mount and shroud itself to clear the IC inlet/outlet. The mods are documented below.

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Final mods to radiator support to mount intercooler.

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Radiator and shroud mounted and ready for the intercooler.

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Mods to A/C condensor to move it closer to the radiator. Had to cut notches in the tube brackets and move the mounts to the back of the condensor.

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A/C condensor mounted in new location.

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Clearence between rad and condensor.

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More to follow:

Heath

 

[IH POWER]

Tight fit with the radiator there Heath! But nice job! I'd love to take the time and do a complete overhaul to mine someday.

 

[hesutton]

The intercooler was mounted up next. I've got some shots of the upper and lower supports for the IC below.

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Bumper installed and new trim/valvance support in place.

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Plate to block off CDR mount on Banks intake, before and after installation. I'm running a RDT this time around. I don't want all that oil vapor collecting and fouling up my IC and it's plumbing.

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More to follow:

Heath

 

[92F350CC]

Power wise, how does it compare with your other truck?

 

[hesutton]

I moved the dipstick back on the head to make room for the IC pipe.

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ATS intake hat was modified for the IC installation. Again, the details are documented below:

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3 inch pipe test fit on ATS intake hat. This short piece of 3 inch aluminum was welded to the hat to make connecting the IC pipe more secure and with a smoother transition.

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This step in the hat needs to go. Too much turbulance for my taste.

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ATS intake hat, modified. With a die grinder, I turned the stepped surface into a smooth cone.

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More to follow:

Heath

 

[hesutton]

My buddy Reid TIG welding my IC piping. I've know this guy for most of my life. We went to school together from kindergarden through college. A great friend and an excellent welder. He was kind enough to weld the aluminum pipe for free. Thanks Reid!

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Front of truck with IC, trim, and valance installed. She looks completely stock and that's exactly what I wanted.

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Under the hood......... it's a different story. It doesn't look stock at all anymore. Here are some shots of the IC piping installed and this is how she sits right now.

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I'm so glad to have it back on the road. I need to test it's metal now with a good pull with the 5'er hooked up and see what I've created.

Heath

 

[hesutton]

Seesh...i have about the same amount in mine in the scout. I just didn't know where the deals were when I built it!

I didn't really know how much I had spent on this project until I added it all up today. Holy Crap! It can get expensive in a hurry. Especially when you consider I found some good deals along the way.

Tight fit with the radiator there Heath! But nice job! I'd love to take the time and do a complete overhaul to mine someday.

It's not as close as it looks in the photo. There is an 1.5 inch gap between the radiator and the fan/fan clutch. However, once the radiator shroud is on, you don't have room to move the radiator any closer to the engine, as the shroud will hit the A/C compressor and other things.

Power wise, how does it compare with your other truck?

They feel different behind the wheel as the F250 is running on 37's and has a T19. The F350 has 32's and a typ4 mod'ed 460 ZF5. I can tell you the crew cab feels more powerful than the F250. And, compaired to the power output before I did this rebuild.......... it is night and day.

Heath

 

[subway]

that is some real clean nice work you have done there that should last a long time! cudos to you Heath!

 

[junk]

Wow that turned out really nice. Should pull that 5ver just fine.

 

[towcat]

hey Heath-
how about adding the pics and install notes on the IC in Rob/F350camper's "let's talk intercoolers" thread?
congrats. this is a seriously noteworthy update on IC install milestones on our IDI's .

 

[The Warden]

Agreed with Calvin there. I honestly didn't think it was possible to mount a full-size intercooler on an '80-'86 front end without removing the grille. Very ingenious solution to that issue!!

Of course, THANK YOU for the updates Hopefully everything goes smoothly from here...shame I can't get out to the rally to see/hear the truck for myself!! Maybe in a couple of years...

 

[Darrin Tosh]

Looks Professional there Heath, Real nice Job! That truck deserved it. Now get some miles on the thing so you can get the bugs worked out before the Rally. Are you planning a test tow with the camper?

 

[trackspeeder]

Very nice.