'68 Highboy.... rebounding from neglect (LS Swap and Mechanical Restoration)

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biggurn
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'68 Highboy.... rebounding from neglect (LS Swap and Mechanical Restoration)

Post by biggurn »

Meet Ilene.

We've had this truck sitting on the back burner for a few years, just waiting for an opportunity to live again!

A little history: this truck is an amalgamation of trucks. The frame appears to be from a later model highboy ('76ish with an open knuckle front axle). It has a 390 with an AC compressor, but no sign of AC ever having been installed in the F250 cab (note its a 2x4 not an F26).
There's not a panel on the truck that doesn't have significant amounts of rust/holes/missing chunks/Flintstone floors and a seat that tries to molest anyone that sits on it . The truck was "undriveable" when we bought it (clutch just needed adjusted). So with all that in mind, Ilene was not nor will ever be a "show stopper" or "correct numbers matching" vehicle. Our goal with Ilene is to get her on the road, reliable and ready to do pickup stuff!

The day we hauled it home:
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Along the way, I picked up a '67 F250 (which has a running 352/360/390) for parts (grill & badges). I had planned to use its body, until last week when I found a much cleaner (i.e. two quarter size rust spots) '70 F100. The '67:
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Since I'm a big fan of modern power plants, and unfortunately Ford is not well supported in the aftermarket or where it is (Coyote, Voodoo, Godzilla) extremely expensive, Ilene is getting a 5.3L and 4L80E for power. I have the same set up in my '70 F100 CrownVic swap and it's been a phenomenal combo (16mpg town/21mpg interstate) .

You're not an LS fan or fan of anything but a Ford in a Ford? Give me a Godzilla and I'll happily install it! But for fuel economy and the current budget, LS it is! Once a Godzilla and 10R140 are "LS cheap" we'll repower again. I eagerly look forward to that day.

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While gathering parts, stumbled across a set of 17s with 35s on them... everyone claims 35s fit and clear on highboys, these rub the fenders when turning... a lot... hopefully new springs resolve that, if not, it'll be getting smaller tires.
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The body donor F100 was previously converted into a trailer, so this week I played bed swap, putting the rusted out '68 bed on the trailer frame to be sold
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I also managed to pull the keeper parts off the '67 this week and swap the front clip off the body donor '70 back on to it, giving me a 1967-ty that will need to soon find elsewhere to reside.
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The donor body now sits and waits until I can get the mechanical part of this project done...
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Next up will be finishing the disassembly of the '68 body, pulling the 390 and starting on mounting the LS. From there it'll be a Saginaw powersteering mod, rebuilding the axles (while adding limited slip front and rear) and new springs... I just need some more days off! Hopefully, that'll happen next week!
The Fords:
2016 SuperDuty F350 LWB Crew 6.2L
2019 Ford Expedition Max 3.5L
1993 F350 LWB Crew 460
1988 Ford Bronco II 2.9L
1970 F100 (full frame swap Crown Vic Underpinning, LS Powered, 4L80E)
1968 F250 Highboy (LS Powered, 4L80E)
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biggurn
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Re: '68 Highboy.... rebounding from neglect (LS Swap and Mechanical Restoration)

Post by biggurn »

Pulled the front clip off the truck today so that I could pull the 390. With all the rust, made it quick and easy 😁

The 390 is actually a pretty good running engine, but nothing like a modern engine.

Next up will be making new engine stands for the frame and motor mounts. Hopefully, I'll be able to swing the engine into place on Saturday.
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The Fords:
2016 SuperDuty F350 LWB Crew 6.2L
2019 Ford Expedition Max 3.5L
1993 F350 LWB Crew 460
1988 Ford Bronco II 2.9L
1970 F100 (full frame swap Crown Vic Underpinning, LS Powered, 4L80E)
1968 F250 Highboy (LS Powered, 4L80E)
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biggurn
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Re: '68 Highboy.... rebounding from neglect (LS Swap and Mechanical Restoration)

Post by biggurn »

Today I had planned to work on powertrain, but unfortunately the motor mounts did not arrive. So, it was power steering day. I decided to go with a Saginaw box from a GM, rather than the more common later Ford box that everyone uses. I like the mounting better and it was a pretty quick process. I machined the spacers on the lathe (most time consuming part) then just welded it all together. I'm be making a new drag link and tie rod that will have heim joints.

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The Fords:
2016 SuperDuty F350 LWB Crew 6.2L
2019 Ford Expedition Max 3.5L
1993 F350 LWB Crew 460
1988 Ford Bronco II 2.9L
1970 F100 (full frame swap Crown Vic Underpinning, LS Powered, 4L80E)
1968 F250 Highboy (LS Powered, 4L80E)
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biggurn
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Re: '68 Highboy.... rebounding from neglect (LS Swap and Mechanical Restoration)

Post by biggurn »

Ilene update:

Today I was able to get the engine and Transmission mounted. I have a foam block mockup engine with a bellhousing off a 4L60E. This combo makes fitting up and adjusting things much simpler than in and out with the whole engine/transmission assembly.
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I was able to reuse the transmission cross member, I just had to move it back and make new mounts for it.
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With everything in place, I measured for the new drive line (a total length of 15") and then pulled it all out. I had to notch the front cross member, so I bent up a new piece of 1/4x4 plate and burned it in to securely put it all back together.
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Finished up the day pulling the junk cab so that tomorrow I can get the frame cleaned and finish up the fab work on it.
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The Fords:
2016 SuperDuty F350 LWB Crew 6.2L
2019 Ford Expedition Max 3.5L
1993 F350 LWB Crew 460
1988 Ford Bronco II 2.9L
1970 F100 (full frame swap Crown Vic Underpinning, LS Powered, 4L80E)
1968 F250 Highboy (LS Powered, 4L80E)
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biggurn
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Re: '68 Highboy.... rebounding from neglect (LS Swap and Mechanical Restoration)

Post by biggurn »

Ilene update ('68 F250 4x4): Today was frame day! The frame was degreased, sandblasted, rust sealed and painted. The wet sandblaster makes quick work of rust... it just flash rust really quickly, so the metal needs coated and painted as soon as its dry. There's still some welding that needs done on the frame to fix a few things, but that can be easily touched up after it's been repaired.

Next up will be pulling the axles one by one and rebuilding/adding TracLok to them. Hopefully, by the time I'm done with that, new springs will be here!
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The Fords:
2016 SuperDuty F350 LWB Crew 6.2L
2019 Ford Expedition Max 3.5L
1993 F350 LWB Crew 460
1988 Ford Bronco II 2.9L
1970 F100 (full frame swap Crown Vic Underpinning, LS Powered, 4L80E)
1968 F250 Highboy (LS Powered, 4L80E)
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biggurn
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Re: '68 Highboy.... rebounding from neglect (LS Swap and Mechanical Restoration)

Post by biggurn »

Didn't get as much done on Ilene today as there was a Scout II in the shop. I did manage to hang the muffler and tail pipe and Integrate a receiver hitch into the bumper. I started out planning to build a separate set of mounts for the reciever, but since the bumper is made of 1/2" plate, there really wasn't a reason not to Integrate the two together. I'm very pleased with how it turned out, and now I have a place to store my Idaho Spud.

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The Fords:
2016 SuperDuty F350 LWB Crew 6.2L
2019 Ford Expedition Max 3.5L
1993 F350 LWB Crew 460
1988 Ford Bronco II 2.9L
1970 F100 (full frame swap Crown Vic Underpinning, LS Powered, 4L80E)
1968 F250 Highboy (LS Powered, 4L80E)
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biggurn
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Re: '68 Highboy.... rebounding from neglect (LS Swap and Mechanical Restoration)

Post by biggurn »

Ilene update (1968 F250 4x4): The front axle is all done (all new bearings, seals, added a TracLok limited slip), Warn Locking Hubs, brake calipers and I fabricated up a new tie rod. Used my TMI alignment plates to set it square, then built the tie rod.
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Finished up running all new brake lines on the frame.
Hopefully, I'll have U bolts in the morning so that I can hang the new springs and the rebuilt axle... then hopefully I can pull the rear axle and start on it before going back to work.

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Once the rear axle is done, I can put the new powertrain back in and start on the body work, which fortunately is too expensive.
The Fords:
2016 SuperDuty F350 LWB Crew 6.2L
2019 Ford Expedition Max 3.5L
1993 F350 LWB Crew 460
1988 Ford Bronco II 2.9L
1970 F100 (full frame swap Crown Vic Underpinning, LS Powered, 4L80E)
1968 F250 Highboy (LS Powered, 4L80E)
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biggurn
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Re: '68 Highboy.... rebounding from neglect (LS Swap and Mechanical Restoration)

Post by biggurn »

Ilene Update: The front axle and new springs all installed.
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The rear axle is all disassembled and on the bench waiting for parts and me to have another day off to work on it.

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The Fords:
2016 SuperDuty F350 LWB Crew 6.2L
2019 Ford Expedition Max 3.5L
1993 F350 LWB Crew 460
1988 Ford Bronco II 2.9L
1970 F100 (full frame swap Crown Vic Underpinning, LS Powered, 4L80E)
1968 F250 Highboy (LS Powered, 4L80E)
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jzjames
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Re: '68 Highboy.... rebounding from neglect (LS Swap and Mechanical Restoration)

Post by jzjames »

New parts! :thup:
69Highboy
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Re: '68 Highboy.... rebounding from neglect (LS Swap and Mechanical Restoration)

Post by 69Highboy »

I'm eagerly watching this since I'm (hopefully) going to be installing that same steering box and front axle on my 71 in the next week or two, would you mind posting up the approximate drag link length you wound up with?
1968 F250: Old Whitey. Almost replaced Old Red. Sold.
1968 F250: The Blur. Replaced by New Red. Sold.
1969 F250 4x4: Old Red. 3rd gen family truck. Retired in favor of New Red.
1970 F250: Big Red. One of my brother's many (sold) trucks.
1971 F250 4x4: Yella or "Big Mustard". My truck.
1992 F250 4x4: New Whitey. Sold in favor of Old Red.
2000 F250 4x4 Diesel: New Red. Project hauler extraordinaire.
2015 F350 4x4 Diesel: The White Truck. Wrecked and rebuilt.
2019 F350 4x4: Diesel: White Lightnin'. Workhorse and luxury combined.
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biggurn
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Re: '68 Highboy.... rebounding from neglect (LS Swap and Mechanical Restoration)

Post by biggurn »

I cut down and modified the original pitman arm so that I didn't have to worry about interference with the tires when turning full right. I made a couple pieces that are angled to allow the drag link to sit level. Welded them to the pitman, then used the lower one a a drill guide to drill through. It all works beautifully. I'll be running a 33"ish tire, so I'll have lots of clearance (I'm mocking up with 35" tires, that don't clear the fenders).

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Wrapped up my day today by painting the rear axle (waiting on parts still) and installing the new wheel cylinders and hard lines.
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The Fords:
2016 SuperDuty F350 LWB Crew 6.2L
2019 Ford Expedition Max 3.5L
1993 F350 LWB Crew 460
1988 Ford Bronco II 2.9L
1970 F100 (full frame swap Crown Vic Underpinning, LS Powered, 4L80E)
1968 F250 Highboy (LS Powered, 4L80E)
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biggurn
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Re: '68 Highboy.... rebounding from neglect (LS Swap and Mechanical Restoration)

Post by biggurn »

Ilene Update (1968 F250 4x4): it only took three weeks to rebuild the rear axle (waiting and waiting on parts) but the truck is back on all fours with a new set of shoes (Cooper Discoverer S/T in a 255/80R17 which is a 33x10). Monday we'll get the cab in the shop and maybe even put the powertrain back in the frame!

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The Fords:
2016 SuperDuty F350 LWB Crew 6.2L
2019 Ford Expedition Max 3.5L
1993 F350 LWB Crew 460
1988 Ford Bronco II 2.9L
1970 F100 (full frame swap Crown Vic Underpinning, LS Powered, 4L80E)
1968 F250 Highboy (LS Powered, 4L80E)
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biggurn
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Re: '68 Highboy.... rebounding from neglect (LS Swap and Mechanical Restoration)

Post by biggurn »

This week I was able to get the rusted spots cut out of the floor and patches welded in. While welding on the cab, I also repaired the passenger side cab mount. Applied POR15 to all the surfaces, then installed Kilmat. Painted up and rebuilt the steering column and the interior door panels. Today, I pulled the cracked up dash pad and the faux wood trim. Next up, we'll start on installing the new wiring harness and rebuilding the doors.
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The Fords:
2016 SuperDuty F350 LWB Crew 6.2L
2019 Ford Expedition Max 3.5L
1993 F350 LWB Crew 460
1988 Ford Bronco II 2.9L
1970 F100 (full frame swap Crown Vic Underpinning, LS Powered, 4L80E)
1968 F250 Highboy (LS Powered, 4L80E)
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biggurn
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Posts: 148
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Re: '68 Highboy.... rebounding from neglect (LS Swap and Mechanical Restoration)

Post by biggurn »

Ilene (1968 F250 4x4) Update: The last couple days I've been working on installing the new wiring harness. This is a full cab/chassis harness. Started out by splitting all the wires into separate groups (front, rear chassis, engine, instruments, accessories, cruise control etc). Then mounted the fuse panel and started running the various wiring groups out and towards their final destinations. Since I thought I had the overhead wiring done, I installed the new head liner... I was wrong, it needs to come back out 🤣.

Today, I wired all the lights, gauge cluster, wipers and the rest of the interior. The cluster recieved a new lens and LED bulbs. Other than having a faulty light switch (verified by pulling a known good switch from my '70 F100), all the wiring seems to be functional. Finished up the day by installing the transmission shifter (to wire in neutral safety).

Tomorrow I'll start on rebuilding the doors, and wrapping up more of the cab work.
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The Fords:
2016 SuperDuty F350 LWB Crew 6.2L
2019 Ford Expedition Max 3.5L
1993 F350 LWB Crew 460
1988 Ford Bronco II 2.9L
1970 F100 (full frame swap Crown Vic Underpinning, LS Powered, 4L80E)
1968 F250 Highboy (LS Powered, 4L80E)
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biggurn
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Re: '68 Highboy.... rebounding from neglect (LS Swap and Mechanical Restoration)

Post by biggurn »

Ilene update (1968 F250 4x4): Doors and wing windows rebuilt. Speakers installed and wired. Had this Sony out of a past LS donor. The trim piece was broken, so figured I could modify it and not feel bad about it. Trimmed it up to fit in the stock radio bezel. It'll work, for now... if your curious, Ford door locks use Schlage pins in the cylinder. Keyed the doors to match the ignition with pins from my Schlage set. Made my day 🤣
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The Fords:
2016 SuperDuty F350 LWB Crew 6.2L
2019 Ford Expedition Max 3.5L
1993 F350 LWB Crew 460
1988 Ford Bronco II 2.9L
1970 F100 (full frame swap Crown Vic Underpinning, LS Powered, 4L80E)
1968 F250 Highboy (LS Powered, 4L80E)
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