89 F150 Crawler Build - Foolsize on Wontons

['84 Bronco II]

Hahaha 🤣 the best was missing a couple of bolts I didn’t realize until we noticed the corner of it 5-6” off the frame 😳 but just putting those back in will help with some. But I’ve still got a couple cross members to build when the transfer cases go in.

Sounds good, I figured I'd give you a heads up. It looks like a decent bed, so it would be worth the effort to try and make it survive in my opinion. My cousin's bed has literally ripped itself apart trying to fight the flexiness of the frame.

 

[I Bleed Blue]

Sounds good, I figured I'd give you a heads up. It looks like a decent bed, so it would be worth the effort to try and make it survive in my opinion. My cousins bed has literally ripped itself apart trying to fight the flexiness of the frame.

Yeah I appreciate that. the truck overall is quite clean, so it’s almost a shame that it’s going to be put through all of this... but I don’t plan on purposefully beating the crap out of the body!

MotoFreak405 already flexed his truck into it 😭😂 but only left a small dent

 

[I Bleed Blue]

8/24/2020 - Got the rear brake lines finished up (hopefully the one from the frame to the axle is going to be long enough!!) It came off the bronco and seems like it should do the trick, we'll find out soon enough I guess! Need to contact my local shop to build some custom length ones for the front so I can get fluid in the system and plumb my hydraulic hand/parking brake.

To get ready for my shock towers to go in and my shocks just ordered I removed the rest of the passenger inner fender (since by the time I was done cutting it to clear there was basically nothing left of it anyhow). Cut down the drivers one as much as possible while leaving the parts that held the wiring harnesses and covers the computer and intake for a little water protection. The truck will not be seeing mud aside from what is on trails, and even that I'll cringe. I do have to notch some of the frame on each side to clear the steering at full compression, so that is on the to-do list. Sent the misalignment spacers for the heim joint back for some smaller ones since I can honestly say I didn't know what I was ordering and got 3/4 spacers which would leave none of my pitman arm left! So some 5/8 ones are on their way then I can finally complete the steering.

The biggest limiting factor on the rear suspension travel was the rear tires would hit the inside of the wheel well and stop up travel rather quickly. Since I got some KR2's (39x13.50) and am keeping the lesser offset wheels to keep the tires inside of the bed and not have to radius the outsides, I went ahead and started to "tub" the bed. Coming from my hotrod and streetrod background I had always wanted to tub something I just never imagined it would be a 5.0 f150 for the sake of running 39" tall tires! 😂 I basically came straight up from the edge of the frame bringing the inner fenders in roughly 5-6' (I didn't measure because who actually does that?). Used the ribbed parts of the bed floor to fill the top of the "tubbed" portion that I will eventually toss bed liner on and make for a nice grippy spot to stand when in the bed. Just need to get a little sheet metal to finish filling the rest of the fender in.

Here's some shots off all of that! My ORD Triple Stick shifters apparently arrived today so I will be drooling over those tonight when I get home from work!

Yes I still need to cut all of the u bolts down!

 

[bobbywalter]

Good work.

Might want to wait on cutting ubolts untill you know how those springs will hold up....may have to play around to dial them in or replace them.

Floating bed lives longer.


Bulging bedsides and fenders helps fitment and some more track width. Wheel offset options..

A couple key cross member additions for traction bars and under bed battery relocation can help put the springs to full use before cage tie ins.

Pull out bed drawer/under bed stowage for spare shit is nice.

 

[Snowracer]

really like this build, keep it up

 

[I Bleed Blue]

Thanks guys! It's come a long way but still plenty to go!

It's been a couple days worth of waiting for UPS and addressing some clearance issues and mach up on others. On the rear, the tire stuffing into the inner fender and stopping up travel was the issue... up front I wasn't reaching full compression because the drag link would hit the frame and tie rod was close on the passenger side. I did not take note of exactly where it was contacting to just clear that area, so I went ahead and shotgunned it. Essential C notched the frame to clear both drag link and tie rod at full compression and both turned as well as straight. I needed to finish boxing that part of the frame anyhow so figured I should get that out of the way. It's not beautiful (goes back to my limited fab experience and years away from the game) but it should do what is intended of it and keep the steering from binding when the passenger side is stuffed.

Next I went ahead and bolted the ORD Triple stick shifters in to see how they would clear in the trans tunnel with the hole I had cut for the factory inspection cover. To my pleasant surprise I did not need to trim anything (yet) and they bolted right in. I am still waiting for my dual case adapters to send out that way I can build the NP203/205 and get rolling on the crossmember but this gives me a feel of how the interior will come together. Been holding off on mounting my hydraulic handbrake (for front digs, and trail parking) until I knew where the shifters would end up. Played with a couple of different locations, I dont love the way this brake is setup so that made it difficult but but finally landed on one that kept it out of the way for normal driving but convenient enough that it wont be inconvenient to use. The brake come out of the bronco that I had used for parts and since I am still kind of trying to stay "budget friendly" I didn't see it necessary to spring for a different one that would've tucked in the way I originally wanted.

Started by cutting out part of the factory provision for the stock Tcase shifter on 4x4 trucks and pushed it into the tunnel some to keep the brake tighter to the tunnel and not in my foot space. After that I built a standoff using my poor mans break (vise and hammer) to have a sturdy and flat spot to mount the hydro bracket. I have yet to decide where I will plumb the brakelines in for it... the OCD part of me just wants to make a couple clean bends on drop them through the floor right below me... but since the truck will eventually probably get bucket seats I may plumb it near the back of the cab for if I build a console and move the handle up higher and back. So that is TBD!

Will end up having to heat and bend the tcase shifters a little bit most likely for the 4 speed to clear them, but will wait until the cases are in and linkages on before doing so.

 

[rattle_snake]

Needs more levers and controls.

 

[I Bleed Blue]

Needs more levers and controls.

Anti-Theft devices? I got 'em! 😎🤣

 

[6gun]

Anti-Theft devices? I got 'em! 😎🤣

I'm seriously looking into making a plate to lock all three shifters in low. Won't stop a thief but it would slow them down tremendously!

 

[I Bleed Blue]

I'm seriously looking into making a plate to lock all three shifters in low. Won't stop a thief but it would slow them down tremendously!

That would be cool! I'm hoping that it's a manual with 5 handles to chose from, a push button starter separate from the ignition, and the fact that I live in the Bay Area it will scare most people off who look inside 😅

 

[rattle_snake]

Today's thieves can't drive a stick/clutch anyhow. 5 levers on the floor will confuse and won't be quick or easy for them to look up on google.

 

[I Bleed Blue]

Today's thieves can't drive a stick/clutch anyhow. 5 levers on the floor will confuse and won't be quick or easy for them to look up on google.

🤣🤣 all so true! I should put the automatic steering column back in it also to add to the confusion lol

 

[Sterlingfire]

Nice progress!
I like the stand you built for your cutting brake. I might steal that idea for mine.

 

[I Bleed Blue]

Nice progress!
I like the stand you built for your cutting brake. I might steal that idea for mine.

Thanks bud! Don't worry I stole the idea from someone else so have at it! 😎

 

[I Bleed Blue]

Had a couple days of not touching the F150, between a truck meet after work and then picking up this badass camper shell!!! If you follow on IG you would've seen my nerding out over it already 😅😅 I've always been a sucker for the aluminum camper shells and I've lowkey looked off and on for one for my last OBS, this one, and the F150 for camping/wheeling trips. I almost bought a whole truck on saturday just for the shell... then my buddy let me know his grandpa had this one since new on his 85 C20! and it was FREE! Long story short it ended up being nicer than I anticipated (needs a little work but not much) so it will be staying on my 7.3 and I'll try to find another one for the wheeler. This one is too clean as a whole to possibly destroy on a trail... plus it looks better on the 7.3 than we had speculated 😎

Okay, now back to our regularly scheduled programming!

 

[I Bleed Blue]

Part of Sunday and most of monday I got back on the F150... The to-do list keeps getting shorter but I'm getting a little impatient waiting for ORD to send off my dual case adapters since they were ordered in the beginning of August and that is holding up half of my to-do list at this point. Anyways, I got my shocks all on the truck. They may be a little long on the rear thanks to me not accounting for the lower mount changing the measurement😣 The fronts SHOULD be okay, but i have a feeling I am going to need to raise the upper mount 2 inches or so... but I'm going to wait and get the truck running/driving and cycle the suspension before just shotgunning the changes since the shock uptravel that is left is about right at what the truck flexed to... It's going to be close and I may have screwed the pooch a bit but we will see.

These ruffstuff shock towers fit great and are another quality piece from them. Took some of the guess work out of the install even if i put the mount to low lol

Not pictured, I did make a sheet metal mount for the couple of smog items that runs from the passenger inner fender to the top of the shock tower. Dang california and their smog!

Got the remainder of the steering on, just waiting for the misalignment spacers to show up for the heim joint but got the pitman arm drilled out and everything painted. I'm enjoying the outcome for sure with the color combo!

Also got the KR2's mounted up on the wheels and tossed them on the truck because it was killing me to not see it on the ground. I had fully drooped the suspension during my shock install out back and the brake line still had plenty of room to droop out as well so that should be good to go. Picked up my rear axle breather insert today so I can get some hose to run those lines front and rear now.

Love the way the rear of the truck looks with the art work on the rear diff! Found an old Silver State 4 Wheelers decal from my Uncle who was big into the Reno/Sparks and Sierra Nevada regions wheeling back in the late 80's and 90's with his scrambler. Since the Lizzerd Offroad decals I made as a faux thing to memorialize him and a flashback to his Lizzerd's Offroad Products back in the day, I figured I'd toss a couple of his other decals on as well... oh and the other one on the tailgate I found online and thought it was funny so don't @ me lol

So here she sits! This week I should finish up tubbing the bed, get my front brake lines made up, and work on plumbing in that parking brake so I can get the braking system bled and working. I am kinda bummed that I was not able to drive the truck on my birthday last week or this weekend for labor day, but as a whole I am quite content with my progress so far. I was in far over my head to build this truck alone with no real fab experience and on a crazy timeline that I set for myself. Hopefully the tcase parts will show soon then I can finally build that crossmember, drivelines, finish the shifters and get the interior back together. Even if the truck wheels horribly (fingers crossed it shouldn't! 😧😬) I will be ecstatic just to drive the truck around!

 

[rattle_snake]

Had a couple days of not touching the F150, between a truck meet after work and then picking up this badass camper shell!!! If you follow on IG you would've seen my nerding out over it already 😅😅 I've always been a sucker for the aluminum camper shells and I've lowkey looked off and on for one for my last OBS, this one, and the F150 for camping/wheeling trips. I almost bought a whole truck on saturday just for the shell... then my buddy let me know his grandpa had this one since new on his 85 C20! and it was FREE! Long story short it ended up being nicer than I anticipated (needs a little work but not much) so it will be staying on my 7.3 and I'll try to find another one for the wheeler. This one is too clean as a whole to possibly destroy on a trail... plus it looks better on the 7.3 than we had speculated 😎


Okay, now back to our regularly scheduled programming!

I agree that camper shell looks good on your 7.3, but it would look much better on my 72. Looking for an old-school shell for it.

 

[I Bleed Blue]

I agree that camper shell looks good on your 7.3, but it would look much better on my 72. Looking for an old-school shell for it.

I can't argue that! They pop up from time to time and can get some good deals

 

[rockota]

Had a couple days of not touching the F150, between a truck meet after work and then picking up this badass camper shell!!! If you follow on IG you would've seen my nerding out over it already 😅😅 I've always been a sucker for the aluminum camper shells and I've lowkey looked off and on for one for my last OBS, this one, and the F150 for camping/wheeling trips. I almost bought a whole truck on saturday just for the shell... then my buddy let me know his grandpa had this one since new on his 85 C20! and it was FREE! Long story short it ended up being nicer than I anticipated (needs a little work but not much) so it will be staying on my 7.3 and I'll try to find another one for the wheeler. This one is too clean as a whole to possibly destroy on a trail... plus it looks better on the 7.3 than we had speculated 😎




Okay, now back to our regularly scheduled programming!

That's badass...

 

[I Bleed Blue]

That's badass...

Thanks! I love it haha, it's gotten a lot more attention and positive feedback than expected driving it around and such lol

 

[I Bleed Blue]

One side of the bed is done! Man that's time consuming lol. My friends who are painters and body guys won't be too impressed but there's so much room for the tire to tuck into now! I now know how to cut the other side to hopefully make the rebuilding part a little quicker and more straight forward.

After finishing the one side of the bed last night I bit the bullet and put the lund visor I had sitting around on the truck. It will hurt when it eventually gets damaged but in the meantime it looks cool and I was tired of moving it around my garage.

Dropped front brake lines off this morning to get lengthened so I should get those back before the end of the week and can get a couple more items checked off my to-do list!

Look at all of that room for activities now!

 

[rattle_snake]

So, did you leave room in the wider rear wheel well for an outboard shock mount?

 

[I Bleed Blue]

So, did you leave room in the wider rear wheel well for an outboard shock mount?

There is room that I could outboard them but I am keeping them in the stock location for now. The inside of the wheel well is now flush with the outside of the frame.

 

[I Bleed Blue]

Bed is done! That's one more off the to-do list. This side came out a lot better IMHO since I was able to reuse the ribbed pieces I cut out from the center, giving it the look I wanted for the other side. With 40" left between the wheel wells my spare will fit nicely in between there until I build a carrier.

Misalignment spacers will be here tonight so I can be done with the steering and my tcase adapters finally shipped and should be here this weekend! Then I can get those built and start on my crossmember as well as finish up the interior to get that back together!

 

[rattle_snake]

Dope

I'll bring some white spray paint in trade for that old camper shell. Address?

Most hacks would just cut tubs out and leave a half-assed hole. Good job on finishing and keeping the bed more functional. Don't want your stuff (beers) falling out.

 

[I Bleed Blue]

Dope

I'll bring some white spray paint in trade for that old camper shell. Address?

Most hacks would just cut tubs out and leave a half-assed hole. Good job on finishing and keeping the bed more functional. Don't want your stuff (beers) falling out.

🤣🤣🤣 hahaha It's going to take a lot more than white spray paint to take that camper off my hands! '

Thanks bud, even if its not a total beautiful I've seen enough of those half-assed builds to know I not to replicate them.

Agreed, can't be losing any of that precious cargo 🍻

 

[I Bleed Blue]

Trying to continue making some progress even while I'm waiting for parts. Doubler kit should be here today along with shorter rear shocks... Last night went ahead and ran my axle breather lines and started running rocks lights. theyre just cheap amazon pods that were 10 for $35 😅 so if they last one trip or the life of the truck they're cheap and easy enough to replace lol. Since sloppy/not thought out wiring is one of my pet peeves I ran the wires as hidden and clean as I could for this. I will get some pics in the daylight on my day off but 4 of the 10 are in and wired up to a harness for the front, then I'll wire the remaining 6 into their own harness and tie them both into the relay under the hood. Also need to wire the visor lights into the parking light circuit!

These pics reminded me to also do something with that power steering line that is just pushed up onto the crossmember since its original mounting location "fell off" in a fight with the plasma cutter

 

[I Bleed Blue]

My Labor Day Weekend is normally spent on a lake or bbqing having some fun... instead this year we tweaked on my transfercases and sweated our A**es off in the 110+ degree weather for two days straight 😨🔥

Got my NP203/205 doubler all built. The 203 did not want to come apart and thankfully we only needed the reduction part of the box because there was some definite carnage taking it apart. We had never experienced such a stubborn transfer case to get apart! I guess that was a little bit of payback for how cheap I got all of the drivetrain and other components from that bronco... But with a little liquid, fire, and 10 lb sledge motivation it came apart (not salvaging a lot of parts to sell afterwards, but oh well. You win some and lose some).

My only complaint with the ORD Kit is they include instructions for the triple stick but not for the case build itself, you have to pull it up online. Not the worst thing but when you're greasy and oily I'd rather flip through paper instructions than use my phone. Otherwise it wasn't too hard of a build once we got the 203 apart. Just be sure and use plenty of patience and grease to hold the needle bearings in when you're mating the 203 reduction case to the billet adapter. I didn't realize my 205 already had the twin stick shift rails in it so I did not need to order those so if anyone needs those hit me up otherwise I'll return them to ORD.

Got the cases installed that night and pushed up to check out clearances and with the clocked adapter plate that kept everything tucked up nicely inside of the frame rails. I am currently at 24.5" to the frame rail and 135" wheel base so whatever clearances I can get I'll take!!

Sunday I got my crossmember built. Utilized the stock mount location on the transmission along with a transfer case support from TMR customs on the back of the 205. I used 1.5 x 3 tubing for the bulk of the crossmember with a couple pieces of the left over DOM tubing from my steering in the places where clearances were minimal. It's not quite as clean and pretty as planned but It should do the trick and I'm sure I will add skid plates across it and tweak some stuff over time. It was 105 degrees out and I was crawling in and out from under the truck all day welding, cutting, and grinding so I'm not too upset with the result lol, I won't be putting those into production any time soon but for my application it should be just fine.

 

[I Bleed Blue]

Cases tucked up quite nicely in the frame rails, not handing down too low being that there's roughly 3/4" to the bottom of the cab floor, so they're about as high as they'll get.

It was looking like the 205 was going to not clear the gas tank at first but there ended up being plenty of room once actually installed. All the cases, trans, and axles are also all now full of oil so it's almost looking like it'll be driving very soon!

don't , mind a couple of the "on my back booger welds". I notched the ends of all of the square tubing to keep it from hanging that much lower from the bottom of the frame. Once I pulled it all out for final welding I cut pieces of DOM to go around the holes and act as a sleeve between the frame and tubing so tightening the bolts wouldn't crush the tubing in the middle.

The DOM may not flow with the rest of the square tubing design but it's what I had on hand and it fits in between the tighter spots how I wanted it to

Pulled out to finish weld it. There's a better look at that TMR transfer case support and you can see one of the DOM sleeves on the front left mounting location.

All welded up with a Fresh coat of 99 cent gloss black and it's ready to go back under the truck!

 

[frickn yahoo]

whats left to do before the maiden voyage?