78 Ford CCSB Fummins swap

fummins97 said:
how is the fitment between the oil filter and where the ac lines will hook? I made a bracket to put the ford ac about where the dodge ac was and I only have about 1 1/2-2".
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The one we are going to use will have the fittings come out the side instead of the end. So there will be a little bit more room just not sure of exact amount yet. That was just a test fit to make sure it all fell on place.
 
Hydro boost we are using instead of the vacuum booster.[IMG]http://i337.photobucket.com/albums/n373/Chevycummins/IMG_20130913_095729.jpg[/IMG]

Was hoping that it would be a direct replacement. Yeah right, with my luck anyways.

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Two holes were close and it needed two drilled, plus some excess meat cut off.

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Drilled them out and trimmed it up.

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Next the clutch/ brake tree. Since this truck was auto and is now getting a manual.

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They appeared almost identical but the clutch pedal took place of the brake and the brake had a new location closer to the fire wall. The pedals were also different.

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Ended up using the tree from three manual setup and brake pedal from the auto because the brake pedal from the manual had interference issues.

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Bolted up quite well after that. Just needed a 1/2 in bolt and brass bushing.

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Set the whole thing up on the fire wall and realized it was going to be quite hard to put the Booster in and get bolts in. So I hung it with a strap.

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Put the nut on inside.

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Bolt bushing and arm.

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And its done except for the lines.

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Got the location for the clutch set. Did a ton of research trying to find the stroke of the master cylinder only to get mad and disassemble it to find out myself. 1-3/8 to 1-1/2 in of travel. Ground down the old spring perch and drilled a 1/4 in hole for the bolt that goes to the arm. Also relocated the perch down 1-1/4 in to give necessary travel.



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Matched the mount to some 1/4 in plate and made a brace.

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Forgot I used brake clean to take oil off the plate to trace my pattern. Got warm quick.



Got it cut and cleaned up nice though.
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Fairly satisfied with the end result.
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Looking good, this is the stuff that takes up all the time, but makes it right in the end!
 
Stabbed the engine. It needed the frame cross member trimmed.
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Trimmed some of as close to the original lines as possible. Goal is to make it look like it was factory and hasn't been modified.

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With some clamps and heat we got it where we liked it.

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With the engine back out we beveled the parts to ensure good penetration. Starting in the middle setting my gap between 1/16 and 3/16 I worked each side down to tolerance.

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One tack at a time until it was in place. Had to clamp from multiple angles to get it right.



Then welded it all up.

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Then time to polish it all up!

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Going to hand work the end pieces the set them in place soon.
 
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Cut some pieces to fill the gaps. Hand worked them with a vice and hammer. Once they were in place I welded them up to look like the original piece. After welding and polishing I used a cut off wheel to match the factory weld on the seam.

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It's hard to see with all the shine but it turned out quite well.

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Now on to the transmission support and engine mounts. Once they are ready the engine will go back in to finish the engine mounts. They are only blanks bolted to the frame until the engine is in final location.
 
Chevycummins said:
Cut some pieces to fill the gaps. Hand worked them with a vice and hammer. Once they were in place I welded them up to look like the original piece. After welding and polishing I used a cut off wheel to match the factory weld on the seam.

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It's hard to see with all the shine but it turned out quite well.

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Now on to the transmission support and engine mounts. Once they are ready the engine will go back in to finish the engine mounts. They are only blanks bolted to the frame until the engine is in final location.
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DAMN, That Turned out perfect, don't think Any of us ever even would have known if you didn't show us the pictures
 
TRUBBS said:
DAMN, That Turned out perfect, don't think Any of us ever even would have known if you didn't show us the pictures
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Thanks that is what we were shooting for. It took a little time but we are very satisfied with how it turned out.
 
Started the front clip and it turned out to be a royal pain in the ass. Using the existing condenser and dryer was the plan. However, the dryer would not fit between the intercooler and radiator. Cut the brackets off it and made a piece to fill the gap.

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The intercooler was quite easy. The first holes drilled at top of the core support made it stick to far out. So I took some washers and tubing to recess them 1/4 in.

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That solved my clearance issues with the front clip. Then I made some support feet for the lower intercooler mounts. Just cut some 3/16 sheet how I wanted them and bent them over a vice with 2 lbs of persuasion.

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The plastic grill was very time consuming. I trimmed off what I thought was needed.... then repeated.... again and again. Finally got it though after 10 or so trim and fit runs.





Also mounted another battery box but forgot to take pics. Well have more on the front end later.
 
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Engine is blasted. Have not had any word if it is painted yet. It is getting charcoal metallic KBS extreme coating. Only takes 96 hrs too cure.....



In other news the turbo is in. BW S362 turbo. 62/68/.80 are the numbers if anyone is curios.

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Got the engine mounts mocked up and trans cross member done. Forgot to get pics of the cross member will post them later.

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Passenger side



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Driver side.



Both sides are tacked into place and ready to gusset and weld when we get the engine back from paint. Don't want to weld it all out only to have clearance issues with the new a/c stuff. I hate rework.
 
Your moving along really quickly everything is looking great.

Dale
 
Been busy...
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Ended up using the engines original passenger mount. And using the 24 valve passenger mount for the drivers side. We had a storm block for test fit that had extra mount holes that our engine didn't have. Good thing it was only tacked in place.

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Bolted all hardware on to do a test fit with the original engine since it's back from paint. Once again we have a problem with the a/c compressor. That will be solved soon.

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The turbo seems to have good location for inter cooler plumbing.

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Still have a few issues to work out with engine alignment but all appears to be going well.
 
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