Thoughts on a heavy hauler...

I have not actually seen gas vs diesel Aeronose supports removed from the truck, but the picture in the link sure looks like the IDI support with the big drop down between the frame rails:



Compare with the 1986 IDI core support I just pulled:



Technically I ~could weld the top of the Aeronose support back together. Then I could chop the drop down off of the bricknose support and graft it on to the Aeronose core support, but that’s a lot of hacking and chopping and I would be a little concerned about the integrity, especially since the top has already been chopped and welded (badly) once already...

I wouldn't be too afraid to graft it, if need be.

Would the Bricknose dash and harness fit in an Aeronose?

It's got to be easier than finding all the butchery in that harness, and a good cluster.

The back end lights are coming off with the box.
I believe Cory and Dave have some good discussion about using the Grote trailer lights on their Flaresides.

I was looking at some big poly drums in the barn and thinking that might make good fenders for something like you are doing.
Real sturdy and can't ever rust or get crushed.

Jim, the Bricknose dash and wiring could potentially be swapped, but it would be just as much work as a Bullnose dash swap. Only advantage to using the brick stuff is that I would have the HVAC box and vent ducts to use out of the red donor. For a Bullnose swap I’d have to buy that, but I believe I have everything else.

You'd have to swap firewalls as well to use the Bullnose a/c plenum, no?

ArdWrknTrk wrote

You'd have to swap firewalls as well to use the Bullnose a/c plenum, no?

I am unclear on this. Shaun tells me that the HVAC box from a Bullnose bolted directly to a Bricknose cab. So those two firewalls should be the same.

Chris McGaugh has been researching the potential of running the improved 134a evaporator core system in his Bronco, and he thought the outer box stayed the same from 87-96. This conflicts slightly with a dash swap thread I read on FTE that said the Bullnose HVAC box didn’t completely align with the Aeronose firewall opening. That thread suggested some small block-off plates would be needed. So my hypothesis is that there may have been a change in 94-96 when the improved evap core for 134a was introduced. It seems odd that Ford would have changed the firewall opening then, but it is possible. Granted, this is all internet anecdotal info and guessing... but it sounds like a brick or bull swap would work equally well or equally poorly. If I keep the Aero interior, I will need to be careful when finding a replacement box as I may need a late 94-96 one.

Bill Vose has done this.
In fact he got the entire gray dash and A/C system from the '95 450.

But it was my understanding that it wasn't a direct fit into Darth.

Dave's swapped firewalls, why not you?   🤣

Outer (underhood) box became larger in 1994 with the introduction of R134a, inside had detail changes (side demister grilles) Firewall openings remained the same from 1980-1996/7.

Well then, I'm mistaken, and stand corrected.

You guys are such a wealth of information. 😎
It's an honor to be in the presence of greatness!

ArdWrknTrk wrote

The back end lights are coming off with the box.
I believe Cory and Dave have some good discussion about using the Grote trailer lights on their Flaresides.

Yes sir, the Grote lights are easy to install, and only about $25 bucks each...maybe less.

I think those and a couple of LED floods cut into a length of C channel would make a great bumper on a flatbed.