Original truck is a 1986 F350 (6.9 non-turbo) 4x4 with 4sp manual trans. I asked earlier about project scope and schedule in this thread: "Time and budget estimate for project" It's pretty clear I"m running behind schedule, but based on your feedback, it seems like my goals are doable. I wanted to start a thread to document my progress, and get input from you guys that have been here before. This is my first "project" truck. I've done a lot of targeted repairs, but never a large scale project like this. Here are the project goals: Reliable and mechanically sound enough to be daily driver. MPG target of 17MPG. Rust abatement throughout the truck so it lasts another 30 years. Able to pull 10K trailer up hill at 50MPH. Able to accelerate to highway speeds on the on ramp. Solid and last for years. Drive well, and interior clean and comfortable. Here's some of the things that I know (or I think I know) I want to do. ZF5 Swap. BW4407 T-Case swap Get drive line to work with new T-case/trans. Fix grill and bumper damage - go with original grill. rebuild injection pump. Super duty power brake booster upgrade Headlight upgrade upgrade glow plug controller paint frame? Add turbo. 1" body lift. New tires (maybe rims) New shocks. Get working tailgate Clean up interior. Get good temp and pyro gauges. Check axles. Progress. When I started, the truck was very hard to start. There was a knock when in 4wd that was not present in 2wd. I pulled the engine to check the broken off glow plugs before root causing the noise in 4wd (bad-I know). I'm not sure if it's the T-case,or the front axle. Hind sight is 20/20, and I wish I would have figured out where the noise was coming from before starting. I was just going to pull the engine and put it back in, but once it was out, it seemed like doing trany swap while engin was out would be easier, and I could clean/paint the frame, and ... - so it begins. At this point, I've pulled the front clip and the engine. The heads were sent to machine shop and got valve job with the turbo valves. Clearances were OK. I added the ARP head studs. I've replaced the old glow plugs and injectors with new ones. I also resealed oil pan, and front and rear seals. I replaced the injection timing gear cover, as the ond one was cracked and leaking. I just removed the bed and the cab to gain access to the drive train and frame. My plan is to remove trans and T-case. Then maybe clean/fix/prep the frame and any suspension parts. From there, install the engine and then get the frame in the shop so I can work inside to add new trans and T-case. I want to get the frame stuff done and inside before it starts raining. I'm a little fuzzy on what I need to do to get a clean solid build, and what is a rathole waste of time that I should avoid. The thought crossed my mind as I looked at the state of my truck that it may never run again. Hopefully this is just fear creeping in, but it does seem a little daunting. I'm hoping you guys can help keep me on track and help me when I get stuck. Some questions. What you advise is "must do" vs. "nice to do" or "don't even bother"? How important is paining the frame? Do I need to remove axles, suspension, brake/fuel lines, gas tanks, etc? Any input would be appreciated. As I stated above, this is my first large scale project so I'm not really sure what I'm doing.