Gary Lewis

I don't think so. But it sure is a nice truck!

Today I trial-fitted the frame boxes. They fit perfectly and the bolts go right through the holes in the boxes. So I marked where they fit and I'll have to media-blast them and then paint them with weld-through primer. And, I'll clean and paint the inside of the frame with weld-through as well so I can then weld the boxes in place. Next I figured out some things about the frame sleeves. The issues have been the way the sleeves fit and whether they need to be tacked into the frame to ensure they don't rattle. The quick answer to the latter question is NO. They are held in very tightly by the outside flange of the cross member so there's no chance of them rattling. Given that, there's no need to tack them in, and I can powder coat them. But, that didn't answer the question of fit. Heretofore I've had to torque the left frame over to get the bolt in through the spacer. However, I finally realized that the spacer is sitting at a bit of an angle because of where the inside hole is in the frame. But, the spacer is only there to ensure that the distance between the inside and outside flanges is maintained. So there's no reason not to open up the inside hole in the frame. Here's what that looks like - and the passenger's side spacer is shown sitting on top of the frame just so you know what I'm talking about. That change made all the difference as I was able to put the bolts in by hand w/o torquing the frame over on the next installation of the cross member. Here's a shot of everything put together and the bolt torqued down. You can see the large head of the spacer is captured by the outer flange on the left, and the inside end of the spacer is in the hole on the inside of the frame. So now I'm ready to start painting and powder coating.

I know the feeling. I have two Bullnose trucks and both are down. But, I guess I should be happy as it doesn't ask WHYDTYBTT? So I can report on my 2015.

That sends chills up my spine every time you say that! Yipes! That's not something I'd want to do, but I do agree that eyeS are a very good thing, so like you I'd do it if I had to.

Beautiful!! Have you started a thread so we can follow your progress? I sure want to follow along.

Cool! What color are you going to paint it? On the plugs, which ignition system will you run? If that will be the '86 ignition system then you use the recommended gap for it.

Oh, ok. I see what you are saying.

Don't worry about being tech savvy. We don't mind.

It took a long time to sell at $15K. Dunno why they think it'll go for lots more now.

I'm thinking that the upper flange bent down when I pulled that corner of the frame in 3" and then let it go back to 1" from where it was. That flange was probably stretched when the frame went out, and it had to go somewhere when the frame was bent back so it went down. And you could easily see the difference of the upper flanges between the left and right sides. So since the right side was where it should be when I measured down the center, I'm thinking the truck was hit in the left front corner. But since the frame was bent out, not in, I'm a bit confused as to how that happened.

Shaun - An "itch" caused you to pull the whole front clip? Hope you don't get poison ivy! Bill - Glad the new location for the shot is helping. As for the guy that was lost in life, he's even lost in death. Two places claim to have his bones.

Ok, is it working?

Today I got back to work on the RSK install. The first step was to mark the spots for the holes to be drilled in the frame. But, I soon discovered that there was a minor problem on the driver's side - the top flange of the frame was bent down a bit. Apparently when I bent the frame back into alignment the top flange bent down. That caused the "box bracket" to be positioned too low, and the holes in it wouldn't line up with those of the cross member. In the pic below I've put a red arrow where the box bracket is hitting the top flange of the frame, and yellow arrows where the interference is. So off came the cross member and I put a big Crescent wrench with a cheater on the top flange. It was all I could do, but little by little I got the top flange up where it isn't pushing the box bracket down. Then I drilled the holes and put the cross member back in place w/o the box brackets just to check. Yep, it fits! So now I have to figure out how I want to "finish" the various parts. I'll paint the frame with gray POR15. And I'll powder coat the cross member, the rear shackes, and the brackets. But that leaves the box brackets and the frame sleeves to finish. Sky recommends welding the box bracket in to ensure it doesn't rattle, and I'm thinking of at least tacking the frame sleeve in. So the question is what to finish them with. Perhaps weld-through primer? Is that stuff durable enough?

Scheduled injections????? As for the gauge, I like your plan. Always nice to have a real gauge. When's the new engine going in? Who's going to win this race?

I'm sure he'd be happy with any fender, but since Ford moved the placement of the upper trim, if he has it, in '85 IIRC, he might as well have the right one. Plus, some fenders had wheelwell trim 2" above the wheelwell, and if he doesn't have that he won't want the holes/studs there.

Bill - That makes sense. I know the E4OD is loooooong, so I understand the issue with the driveshafts. And placing the t-case where the carrier bearing is a good idea. As for Matt's Excursion, it might be sporting U-code springs, which is what I have. But some of them have the stiffer V-codes. I'm hoping the U's work as that will give better articulation. Speaking of that, I'd not thought about the front driveshaft and how placement of the t-case figures into the angle thereof. Good thinking!

Rooster - If you've posted on a thread, and especially if you started the thread, then you should automatically be signed up for email notifications of posts on the thread. Is that what you are trying to do?

Jan - There were minor differences over the years in where the trim attached as well as due to the level of trim. Your signature doesn't say what year, so maybe you could tell us the year? And, how 'bout a pic of where the trim goes? If there are multiple fenders available you ought to have the right one.

I don't know Bill's specific reason, but generally the "benefit" to divorced transfer cases is that they use a 2WD transmission. I put "benefit" in quotes because it really isn't a benefit if you are sourcing a new trans anyway (just get a 4WD trans to start with). But it is a plus if you have a lot into your current 2WD trans and want to keep it. As to the coil spring TTB Dana 50 being worth 3 grand, it sure isn't to me. But for people who want a prerunner-style suspension that can go fast in the desert, coil spring TTB is about the best you can do in a 4WD. And for that type of use compliant bushings are undesirable. People who are pushing those boundaries are very willing to give up some vibration and harshness for the precision and ruggedness of heim joints. So a number of the Jeeps seen in those videos are probably running Heim joints? Many of them look to have pretty serious suspension systems.

I have several of David Vizard's books, and find them to be some of the best-written and informative ones I've found. I think you are on the right track.

It looks like the Hell's Revenge video "rolls over" (groan) to a NotaRubicon video of a trail called " " in the Johnson Valley OHV area in California. I haven't watched that video recently, but I took a quick look now and it does have the orange Jeep, highlighted, rolling in the background.I've never been to Johnson Valley, but I've read about it in magazines pretty frequently, and have watched videos (but not recently). My impression is that most, if not all of the trails there are well above my pay grade! So no, I'm not recommending that for you!And as I noted, 'most everything after about 5:30 in the Hell's Revenge video shows optional harder lines, or even side trails. I didn't do any of them, and I'm not recommending them to you either! But the first 5 minutes shows mostly what it's really like, and like you, I think you could do it. But right away in the video is the fin that's right at the start of the trail. That's the one that, from my trail report, you thought Janey might veto. I think the video shows that pretty well. It's not difficult, but there's definitely some "pucker factor" to it!Yes, that's the one! (And for anyone else looking, I'm embedding it below and starting it at the point we are talking about.) That stuff is WELL above my or Big Blue's pay grade. As for Hell's Revenge, the fin isn't quite so bad when you see it in the larger context. At least, it doesn't look so bad on a computer screen. But through the windshield.... Perhaps on Day 3 or so of a trip.

Did I miss something? I don't recall a rollover in the video I linked. And I just scanned through it again and didn't see a rollover. At what point in the video did you see it? Or are you thinking back to the " " video I linked earlier? Apparently I let it roll over, pun intended, to Heart Attack Hill as I just watched Hell's Revenge again and it isn't there. What I saw was an orange jeep with a good-sized guy go over in the background of a video. They'd put a bright spot on him in the background so your attention was taken there. And then they used one Jeep below to pull him back over and three above to stead him. So, Hell's Revenge isn't too bad. I think I could do that.

I had to use all the harnesses from the style side parts truck because of duel tanks and I did not have a flare side tail light harness. Someone cut off the frame rail harness plug and use other wire to wire in them cheap boat trailer lights that were not wired & broken. Like Cory did I have to splice on the flare side light plugs to both the new lights and the style side harness so it should all look factory when done like the other things I have added. Dave ---- It will look great! I'd say "professionally done", but we all know that is lurking, and he's apparently paid, which makes him "professional".

You are on the map. That's a pretty area. Used to live in Katy and have been to the Schlitterbahn many times.

Welcome! Nice truck, and a good project. Boy do I understand the need to get your hands dirty. Spent my career in IT, inc networking for Conoco and DuPont, so I can commiserate. Where in The Hill Country is home? We have a member's map (Bullnose Forum/Member's Map in the menu) and I'd be happy to add you if I had a town.