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Discussion Starter #1 (Edited)
Hey guys! Just thought I'd introduce myself! Kind of a long read here but bare with me! I'm Josh, a 24 year old Diesel tech at Penske. Mostly new to Fords, been a GM guy for the most part my whole life. After doing a few small block and LS swaps I've just gotten bored of them. I bought my first Ford last year, a 2014 Mustang GT track pack last year, 20k miles, premium, 6 speed manual. Fell in love. Fast forward to about 2 months ago (this is where you guys will start to realize how crazy I am ??...) Decided to buy an 88 Bricknose, super cab long bed 4x4, 7.3 zf5 truck. This truck was originally intended to be a WINTER BEATER but after realizing how shot the cab was, I found a whole southern rust free body for $600. Loaded up the truck and went down to Tennessee 2 weeks ago to grab it. That Monday I ripped the body off and decided what a perfect time this would be to update the drivetrain a little. Fast forward to last weekend. Picked up a wrecked 03 6.0 F250. Kid slid off the road and whacked a pole. Drove the truck home 60 miles, didnt skip a beat (it sure was cold though!) So yeah. That's where I'm at now. Just wanted to give a shout out to Cummins Junkie, I've been following your 6.0 OBS build and it has really given me the inspiration to do mine. Some bad ass work you have going on there. Anyways, I look forward to getting to know some of you guys, and sharing my new found interest in Ford Diesels!!

PICTURE TIME!!!

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Project Shamu
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Very nice! Cant wait to see the build.

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Haha I was just going to say, if you have any questions I might be able to help a bit! Ill follow this one for sure. Shoot now I really gotta get mine done...

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Discussion Starter #4
Sweet lol I appreciate that! Not gonna lie when I read your post about how the front cab mounts fit right on the SD frame I got a little excited. I was originally gonna keep the brick frame until I saw that. Luckily for me the CCSB SD wheelbase is only 1 inch longer than the ECLB OBS, so I shouldn't have to do any frame shortening. Not ready for all of that firewall work though lol. I think I'm just gonna see if I can either notch mine or make some sort of doghouse like a van
 

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Yea you could totally do that, I thought it would be more convenient to have the whole firewall so all the holes for wiring and steering linkage, etc would already be there. It's mainly from where the throttle is over to where the HVAC box is that's the part that needs to be cut up. You may even have to modify that HVAC box a good deal to get it to clear as well. Also, the wiper channel needs to be cut into extensively. Still dealing with that crap show right now actually... I can tell you what not to do at least in that respect.

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Discussion Starter #6
Are you using the Super Duty HVAC and dash or no? Ideally I'd like to keep the bricknose dash with the super duty cluster stuffed in it, but we'll see how it pans out.

On another note, going to pick up another truck this weekend! 2004 F250, another 6.0 truck, supposedly studded and deleted. 206k on it, needs a trans. Guy is asking 1500. Cant pass it up! Planning on taking the good 5R110 out of my donor truck and throwing it in this one, since I'm going ZF6 anyways. Hoping for a quick flip but we'll see!
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Yea I am using the super duty HVAC stuff, or trying to at least. Im gonna have to customize a lot of the air ducts I know it because of the firewall. I will use the cluster from the 6.0 too; it won't start without it. Im keeping the obs dash, it's gonna have all super duty wiring under it though.

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Discussion Starter #8
Yeah that's what I was planning on doing too. I think the 03-04 cluster will fit in the bricknose dash mighty fine! Atleast I can hope lol

Anyway BIG SCORE TODAY!!!

Snatched me up a complete 6.0 ZF6 today! 1500 bucks, came with everything I need (I think) even managed to snag a clutch pedal and a FICM for the white 04 I just bought. We are getting there! Almost got the cab ready to come off the donor super duty, so I can do some test fitting soon!
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Discussion Starter #9
Quick update. Got some work knocked out over my unanticipated 3 day weekend. Had to go to the ER today after I got some metal embedded in my eye when I was cutting the SD cab up to scrap. Ended up calling off work, which meant more time to work on the truck!!

Super duty cab is finally off! Found some awesome things out about my 302k "mystery" 6.0. The kid told me it was completely stock and that it was his uncle's truck. Apparently he was wrong. It's a studded and deleted 2004 motor. Cool! I'm going to do the oil cooler as preventative maintenance while everything is out in the open, then I'll probably call it good.

As soon as I find my tape measure I'm going to measure the firewall out, and see where I have to start cutting. Anyways heres some pictures

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Yea and I told myself I was just going to do a stock rebuild... Careful, it'll get ya.
 

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Discussion Starter #11
Yea and I told myself I was just going to do a stock rebuild... Careful, it'll get ya.
Lol I think we all know how that goes ??. I cant go too wild, I'm trying to redo my Cummins truck as well, got a southern cab and bed at the body shop for paint and I know that isnt gonna be cheap. Too many projects eating a hole in my pocket lol
 

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Discussion Starter #12
Welp, sorry I havent posted in a few days but I managed to get a **** ton done on the truck. Cab is mounted, rear mounts are built, ZF6 is installed. Even managed to get the bed on today! Everything is looking sweet. Ended up going with 1 inch body lift blocks in the front to help clear the ZF6, then built the rear mounts so that I didn't have to use blocks in the rear. Ended up with about half an inch in between the floor and tcase.

The more I put this truck together the more I think this frame is made for this OBS body. The rear 4 bed mount bolts line up PERFECT! Dropped right in. Obviously have to build a crossmember for the front bed mounts, but that wont take long

PICTURE TIME
*I am not a pro welder so spare me lol
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Shoot, you'll get yours done before I get mine done at this rate! Wow you did in a few weeks what I haven't been able to fully do in 2 years lol.
 

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Discussion Starter #14
Shoot, you'll get yours done before I get mine done at this rate! Wow you did in a few weeks what I haven't been able to fully do in 2 years lol.
Lol I almost feel like I'm cheating though. You're doing everything right, going through the motor, rebuilding everything else as you go along. I'm almost just trying to bring this thing back to running and driving status as quick as possible. I should be painting the frame and such, but that'll happen later down the road when I have more time and space. Planning on buying a house within the next year, and it'd be wayyyy easier to drive this thing than move it in pieces lol
 

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Discussion Starter #15
Quick update. Managed to get the firewall cut out and notched for the downpipe. Idk what happened along the way, my welds turned out like hot wet buttery garbage (throwback to one of the greatest driver writeups I've ever read). Starting to wonder if my welder was overheating as I went along but who knows, I wont make a bunch of excuses. Guess I'm a grinder now lol. Whatever. All done up with 16 gauge steel so its nice and sturdy. The HVAC box even clears! Now that this hurdle is out of the way, we are getting closer and closer!

Some pics for your time. Roast my welds I guess lmao

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Discussion Starter #16
Update time

Got a ton of work done over the weekend. Unfortunately didnt grab very many pictures. Brake and clutch masters are installed, clutch is bled, everything is going sweet. Also got the steering column mocked up, I've decided to stay with the bricknose column for simplicity. The super duty column would never look right. The clockspring may get interesting for cruise control but we will cross that bridge when we come to it.

Firewall is finished, applied seam sealer and painted, and the downpipe is in its permanent home fitting nicely.

Started cleaning up the HVAC box up and yanked both evaporators. Turns out the super duty evap will fit in the OBS box with slight modification, which means I can use the super duty AC lines and not have to worry about modifying anything. I have the box wrapped up, it'll be going back in tonight, then I can put the passenger side fender on.

Also managed to get the automatic harness gutted. Next is the dash harness which should be a neat project. Yay spaghetti

New wheels and tires are here as well!!

Overall I'm super satisfied with the progress. I have a front end rebuild in order before this truck goes on the road, but I'm projecting it to be done by May.

Picture time!! (Yes my garage is destroyed)
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Nice dude! The a/c evap thing is cool, never tried that on mine so I never knew. Oh well, even with the obs box, I would still have the same clearance issues lol... Those wheels look pretty killer too.
 
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Discussion Starter #18
Nice dude! The a/c evap thing is cool, never tried that on mine so I never knew. Oh well, even with the obs box, I would still have the same clearance issues lol... Those wheels look pretty killer too.
Lol yeah I kinda got crafty with that one. I don't have the tools to make AC lines anymore so I have to work with what I have. Did manage to get the hvac box in and the passenger fender bolted up so I was able to snap this awesome picture. Cant wait to see this thing in one piece

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Nice work. Following along.
 

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Discussion Starter #20
Nice work. Following along.
Thank you, I appreciate it! I will post updates as much as I can. Did manage to get the truck cranked over yesterday, but still not a runner as of yet. If I jump the starter it'll fire for half a second then die, and I have no gauge cluster. Feel like I'm missing a ground somewhere. I'm gonna keep at it though. My plan is to have it running this weekend, then I can finish putting the frontclip on and start working on the cooling system
 
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