Cummins 4BT '68 F-250 4x4 swap

[eggman918]

Well I have finely started on the Beast again.The trans is rebuilt and the motor and trans are in the truck!
The shifter/T-case shifters are in.now comes all the "little" things,and for me that is the hard part too easy to get sidetracked.
http://s1042.photobucket.com/albums/b429/eggman918/
here is the link to new pics.

[eggman918]

Tomorrow I pick up "new" HX35 and inter cooler and the associated plumbing
So the project is back on the front burner,I brought home a stray boat I found and allowed it to distract me ..two projects at one time.
Should have pics of progress in the next week or so.
Steve.

[eggman918]

Got the turbo,soaked the exhaust housing/body joint with the 50/50 acetone/ATF mix from the shop section worked like a dream.
Cleaned turbo then plugged the wastegate and pivot shaft hole,test fit turbo to motor it will fit.Now I must gather funds for the EGT sensor to drill and tap manifold.
I have the inter cooler that came with the turbo so now I will start on inter cooler/radiator set up as well as many of the small things that seem to take so long.
New pics
http://s1042.photobucket.com/albums/b429/eggman918/
Steve.

[eggman918]

Lot's of little things accomplished turbo is mounted and oil drain modified,engine compartment exhaust is done,tack drive is done,intake manifold has been enlarged to 3".steering is finished.
Now I need the drive line quoted at aprox. $200.00 , a EGT gauge ,master cylinder and a fan. It is getting close now!
Found a radiator in my store/junk room that will work fan shroud and radiator/intercooler mounting is next.
New pics at same link
Steve.

[Ranchero50]

Steve, this thread would rock if you went back or started over with the pics and some text about them. I just had a 6BT given to me, needs a few things since it was out of a truck that rear ended a semi but I digress.

You can click the img code on your pic and just paste it into your thread.

Jamie

[eggman918]

My typing skills suck but you are right,I have tried to get a pic of each step in the not so orderly order that they happened.
The next time that I am too sore to work I will start adding info. to the pics.
Thanks for the input if it will help others it will be worth the time
Steve.

[eggman918]

More progress new pics and titles to pics.
Steve.

[68SPECIAL]

Im doing a hydroboost conversion now. How did you lengthen the rod from the booster to the brake pedal. I noticed you used the existing power booster brackets and mounted the hydro to that. That looks a lot easier than making a new mounting plate for the hydro to mount directly to the firewall. Only thing is that i have a hydro from a 77 lincoln and the pedal rod will need to be lengthend. Any thoughts would be very helpful.

[eggman918]

I made a piece that slipped over the existing rod,I think the rod was .375" .I made the new piece so that it accepted the old rod 1.5"
deep with a tight slip fit then I used red locktite on the joint.the new piece was 1" dia. turned down to .625" on the end that mates to the existing shaft.
on the other end I milled a flat and bored a hole to fit the bolt on the pedal. If you need pics let me know and I will pull the part and get some good pics.
Steve.

[68SPECIAL]

pictures or a even a drawing would be very helpful. My shaft on my hydro is one piece and i will have to cut off the flat end with the hole before i will slip anything over it. I am guessing yours was the same way?

[eggman918]

Yes it had the flat with a hole for the bolt. if you tell me the size of your shaft,the length from the end of shaft to center of bolt on pedal
and size of bolt I can make you one easier than making a drawing.You will also need a spacer/rod extension to mate master cyl. to hydreboost,I have not yet made that part on my project.
PM me if you want to do that, otherwise those dimensions are what you need to make the part. When I made mine I started with a piece of 1" dia. bar stock and did one operation at a time.
Test fit after each opp. as it was a prototype,the part would fit in a small flat rate box so it would be a $10 part with shipping .
Steve.

[68SPECIAL]

I will PM you with measurements when i get home tonight. I appreciate your help.

[averagef250]

You can also just run a 3/8" die over the old shaft after cutting the end off and use a female threaded heim joint/w locknut to the pedal. If you like threading using a lathe or threading machine you can pull the rod right out of the back, it is only held into the hydroboost with a small rubber donut (the donut will need replaced, which comes in the hydroboost rebuild kit or not much money). The hydroboost rods are case hardened alloy, but cut fine with quality high speed dies. The case depth can't be more than a few thou.

I like the ability to fine tune the final pedal height easily.

[eggman918]

Today I started the 4 BT for tyhe first time After MANY set backs, delays and budget issues.It fired right up and idles smoothly still cant drive it non oped and still needs front shocks and hoses for the power steering,but hearing it run was great I cant stop smiling
Steve.

[Ranchero50]

That's great, I'm trying hard to remember when I stashed all my parts. Cleaned the garage the other day looking for my new spring nuts and fender bolts.

it's all in the details.

Jamie