1967 F-100 project

[67nukeford]

After looking things over, I'm going to go ahead and make new pieces where I cut them off. I can make them fit much better than I could have adapting the ones I cut off. I'll be cutting off the tops of the mounts that are still bolted up, and welded in steel. I made up some rough cardboard templates of what I will need. Should do the trick.

[67nukeford]

Obtained the steel I needed, and dug out the plasma cutter. cut out all the pieces, then, ground them smooth, and began tacking them together.

[67nukeford]

Checked everything for measurements, and seemed all was well (or so I thought. What I wouldn't do for one of those plastic mockup motors!). Went ahead and burned in all the welds, and cleaned them up. All seemed to be fine with the high-dollar, super whammy dyne jig I made.....

[67nukeford]

Measured and cut out the holes for the mount studs, using a drill and the die grinder.

[67nukeford]

Time to see if it all worked. Bolted the engine up to the tranny, and lowered them in. With everything set, the engine has about a 4.5 degree angle (should get another degree or so when the cab and front clip are on. Tranny will sit right where I'll want it!

[67nukeford]

Now, for the bad news. Must have been off on one of the measurements, the Pass. side sits just off canter on the perch. So, that's next to be addressed, I'll have to do some cutting and re-welding to get it to sit right.

[67nukeford]

Did a lot of small cuts, and set the engine. Pull it, cut some more, set it again. After 3 tries, fits perfect. Burned it in, cleaned it up, and set the engine again. Fits like a glove! Now, on to that trans mount.....

[67nukeford]

For the trans mount, I'm using a 1/4 inch thick plate. I had to cut off the front section of the frame mount, the trans case was hitting it. I am going to bolt this plate to the cross member, but, I think I will probably also weld it, since, I don't plan on it being moved after this, and that will strengthen it.

[67nukeford]

Time to install the transfer case. Here is a lesson for anyone thinking of using the ZF-5 and it's transfer case. The Transfer case is HUGE! To be able to mount it, I had to actually notch out a section on the frame. I'm going to install gussets on each side of the notch to strengthen that area up.

[67nukeford]

With the transfer case now in, you can see that I won't be using a two piece driveshaft. I will also have to have a shaft made for the front, too.

[67nukeford]

Got the new hinge springs put on the doors last night. Man, that was not fun. Also, since I'm hoping to mount the cab this weekend, I'm going to have to cut down the rear 2wd mount pads. For whatever stupid reason, Dennis Carpenter won't make the 4x4 rear cab mount pads. All they would have to do is cut down the 2wd ones, they are the same thickness as the front pads. So, I get to do that myself. The front mounts are the same for both 2wd and 4x4.

[67nukeford]

So, time to see how this thing fits. Decided to rig up a lift with the engine hoist. It worked, but, it was really, really unstable! I'll come up with a better plan next time. Anyway, set the cab on, and, found a few areas of conflict.

[67nukeford]

Had to cut a hole for the transfer case shifter. This thing stick way out, so, I'm going to have to come up with a plan. May just have to heat the shifter, and bend it so it's out of the way. I may also see if the machinists here at work can cut, and then duplicate the holes, and grooves for the shifter.

[67nukeford]

Surprisingly, there were no problems with the transmission hitting anywhere. The transfer case is another story. This thing is doing it's damn best to be a pain in my butt! Of course, its hitting on the cab. And in the worst spot, right on the floor support. So, I had to notch it out, and weld back in pieces to retain its strength. But, now the cab sits down where it's supposed to. Nice to finally have this done!

[67nukeford]

Just a quick update, back welded the modified engine perches for strength, then coated them in POR-15 and top coated with Eastwood's Chassis Black, and bolted back in.