Awesome job!
 

Making it look easy indeed!

The bed needed to be re-worked to sit on the new frame and match the body lines of the cab. Adam carefully cut the cross-braces from the bottom of the bed, then welded in new steel to reinforce the supports.

http://v8tvshow.com/1969_Ford_Lightn....12.14_001.JPG

This channel allowed for the bed to sit lower on the frame.

http://v8tvshow.com/1969_Ford_Lightn....12.14_004.JPG

New bed supports were attached to the Lightning frame to match the ‘69 bed mounts.

http://v8tvshow.com/1969_Ford_Lightn....12.14_011.JPG

http://v8tvshow.com/1969_Ford_Lightn....12.14_005.JPG

LOVE it!

The guys are doing Nice job Kevin!

So cool.

Thanks, they sure are.

You know how these things go, you solve one challenge and another pops up. This time, the fuel tank needed to be shortened to fit the shorter wheelbase.

We ordered a new tank so that we were not cutting and welding on a tank that once held fuel. That’s just something we don’t do in our shop, especially when a new replacement is around $200.00.

http://v8tvshow.com/1969_Ford_Lightn....19.14_002.JPG

http://v8tvshow.com/1969_Ford_Lightn....19.14_003.JPG

The tank would have to be about this long to clear the axle.

http://v8tvshow.com/1969_Ford_Lightn....19.14_017.JPG

We cut the tank, and Adam TIG welded in a new side. We estimate we only lost a couple gallons of total capacity, and all the original fuel pump, sender, and line fittings connect right up.

http://v8tvshow.com/1969_Ford_Lightn....19.14_019.JPG

http://v8tvshow.com/1969_Ford_Lightn....19.14_020.JPG

http://v8tvshow.com/1969_Ford_Lightn....19.14_026.JPG

Neat idea, bet the truck will be fun.....mine is.

How are you planning on getting fuel into the tank?

Just curious what you guys come up with.

Keep up the good work.

Sean

We have a plan to use the stock filler neck on the '69 and pipe it to the 2002 tank. It will look cool, the only drawback is that it will probably be a slower fill process, but we'll see.

Thanks for the encouragement!

We've followed your truck build, that is very cool, great work!

Beautiful job on that tank man. That's not easy. Cool ass build.

Thank you!

The Lightning chassis has a longer nose than the ‘69 F100 Ranger, so the next task was to shorten the front frame horns and create mounts for the 1969 bumper. The Lightning frame can be seen sticking out in this initial test-fitting photo from the beginning of the project.

http://v8tvshow.com/1969_Ford_Lightn....14.14_071.JPG

After measuring, Adam removed the front of the frame horns and created a stepped mount that would attach to the bumper brackets.

http://v8tvshow.com/1969_Ford_Lightn....22.14_001.JPG

http://v8tvshow.com/1969_Ford_Lightn....22.14_004.JPG

http://v8tvshow.com/1969_Ford_Lightn....22.14_010.JPG

http://v8tvshow.com/1969_Ford_Lightn....22.14_006.JPG

http://v8tvshow.com/1969_Ford_Lightn....23.14_009.JPG

The lightning frame was also slightly lower than the Ranger, so the brackets were adapted to bring the bumper height to its proper position on the Ranger.

http://v8tvshow.com/1969_Ford_Lightn....22.14_012.JPG

http://v8tvshow.com/1969_Ford_Lightn....22.14_013.JPG

http://v8tvshow.com/1969_Ford_Lightn....22.14_015.JPG

http://v8tvshow.com/1969_Ford_Lightn....23.14_011.JPG

Once mounted and aligned, everything looks factory original and correct for 1969.

http://v8tvshow.com/1969_Ford_Lightn....23.14_014.JPG

Such a rad build, I'm used to seeing the swap go the other way due to smog laws so this is a nice change

What's the plans for the mufflers, reason I ask is I just put a http://www.blackwidowexhaust.com on my 6.2lt and it sounds amazing

We're building a MagnaFlow system for this truck. They will exit in a similar position to the original side outlet, but with duals all the way back.

very nice work.

Thank you!

Looking good Kevin.

Thanks Wayne!

Good job guys!
Looks awesome.

The Ford Lightning required several coolers, including the radiator, steering cooler, transmission cooler, and a supercharger heat exchanger. Adam fabricated a series of mounts and close out panels to stack all the coolers in the nose of the ‘69. He used a Mittler Brothers bead roller, box pan brake, and punch and flare set to add contours to the panels as well flared holes for strength.

http://v8tvshow.com/1969_Ford_Lightn....29.14_001.JPG

http://v8tvshow.com/1969_Ford_Lightn....29.14_002.JPG

http://v8tvshow.com/1969_Ford_Lightn....29.14_003.JPG

http://v8tvshow.com/1969_Ford_Lightn....29.14_005.JPG

Here, he uses an HTP Versa Spot welder to weld the pieces together.

http://v8tvshow.com/1969_Ford_Lightn....29.14_008.JPG

The panels form a housing and are designed to duct cool air through the cores.

http://v8tvshow.com/1969_Ford_Lightn....30.14_005.JPG

http://v8tvshow.com/1969_Ford_Lightn....30.14_006.JPG

http://v8tvshow.com/1969_Ford_Lightn....30.14_007.JPG

We used a larger aftermarket aluminum radiator (designed for the Lightning) as well as an upsized heat exchanger. Also required is the Vintage Air A/C condenser coil.

http://v8tvshow.com/1969_Ford_Lightn....30.14_010.JPG

http://v8tvshow.com/1969_Ford_Lightn....31.14_001.JPG

http://v8tvshow.com/1969_Ford_Lightn....31.14_003.JPG

The next task was to build the exhaust system. The crew started by removing the factory exhaust manifolds and replacing them with a set of BBK Shorty headers designed for the Lightning.

http://v8tvshow.com/1969_Ford_Lightn....31.14_007.JPG

The BBKs fit tight to the block, and the driver side was a challenge to install.

http://v8tvshow.com/1969_Ford_Lightn....31.14_009.JPG

http://v8tvshow.com/1969_Ford_Lightn....31.14_011.JPG

It took a set of hands topside and below the truck to snake the driver side header into position. Kelle, Adam, and Trevor traded inappropriate words throughout the process.

http://v8tvshow.com/1969_Ford_Lightn....31.14_012.JPG

The customer wanted a stainless steel mandrel bent exhaust system with a set of electric cutouts. Straight pipes were run from the headers to the middle of the truck to the cutout location.

http://v8tvshow.com/1969_Ford_Lightn....08.15_001.JPG

http://v8tvshow.com/1969_Ford_Lightn....08.15_002.JPG

http://v8tvshow.com/1969_Ford_Lightn....08.15_003.JPG

The cut outs were placed in an area where they could cleanly dump the hot exhaust.

http://v8tvshow.com/1969_Ford_Lightn....08.15_004.JPG

http://v8tvshow.com/1969_Ford_Lightn....08.15_007.JPG

Magnaflow 2 1/2 inch mandrel bent stainless tubing was used with the stock muffler and the exhaust was extended to the rear of the truck. It is TIG welded for a clean look.

http://v8tvshow.com/1969_Ford_Lightn....09.15_002.JPG

http://v8tvshow.com/1969_Ford_Lightn....09.15_004.JPG


The system exits behind the rear wheels, and a pair of slash cut stainless tips provide a finishing touch.

http://v8tvshow.com/1969_Ford_Lightn....12.15_002.JPG

http://v8tvshow.com/1969_Ford_Lightn....12.15_001.JPG

http://v8tvshow.com/1969_Ford_Lightn....12.15_005.JPG

Nice update Kevin. :thumbsup:

That thing should make some inappropriate noises.

:D

Nice progress exhaust looks great

wow....this is really impressive!

You guys are doing a great job with this. Keep it up. Should be a really nice truck when it's done.

Love the work on the radiator mount. You have some talented guys.

Next up was the air intake tubing and filter. We wanted to isolate the filter and opening to breathe cool air, and reduce the underhood noise. A tubular intake was built.

http://v8tvshow.com/1969_Ford_Lightn....05.15_001.JPG

A baseplate / filter mount was made. This also holds the Mass Airflow sensor.

http://v8tvshow.com/1969_Ford_Lightn....05.15_005.JPG

The filter would point downward and breathe air from the inner fender area.

http://v8tvshow.com/1969_Ford_Lightn....05.15_007.JPG

http://v8tvshow.com/1969_Ford_Lightn....05.15_012.JPG

Great work, coming out really nice!

Will you be finishing the back of the cab cuts where they were opened up for the added frame width? No one will see them, but with your attention to detail, I was wondering how you would finish that body work. Nice project. I vote for stock wheels with dog dish caps and sticky tires. IMO.

Yes, these will be metal finshed closed to appear like O.E.

Wheels are still up in the air... not much fits the Lightning that doesn't look like it was made before 2000...

Love this build!

Somehow I forgot about this thread - Love the frame work/moving and detailed pics!

Then you go and fab up your own intake and exhaust - badass work everyone!

Great work guys!
Keep the updates coming.

Thanks guys, we're fortunate to have a crew that knows their stuff and really enjoys the work!

Using the Lightning fuel tank was easier for the fuel system, pump, and fitment, but we needed to make the connection between the new tank and the ‘69 fuel filler location. The ‘69 had the tank in the cab, and the ‘02 uses a fuel filler in the bedside. This connection allows us to run a filler hose from the stock location down to the Lightning tank under the bed.

http://v8tvshow.com/1969_Ford_Lightn....26.15_001.JPG

http://v8tvshow.com/1969_Ford_Lightn....26.15_002.JPG

http://v8tvshow.com/1969_Ford_Lightn....26.15_002.JPG

This truck will be a driver, so the owner wanted a tilt steering column and air conditioning, along with a good audio system. Here, you can see the Vintage Air A/C system coming together.

Stock “gutted” interior:

http://v8tvshow.com/1969_Ford_Lightn....13.15_002.JPG

Original heater box opening closed off:

http://v8tvshow.com/1969_Ford_Lightn....14.15_001.JPG

Vintage Air Gen IV unit installed under dash:

http://v8tvshow.com/1969_Ford_Lightn....14.15_015.JPG

The hoses were run through the passenger side fender well for a clean underhood appearance.

http://v8tvshow.com/1969_Ford_Lightn....15.15_006.JPG

Receiver unit mounted out-of-the-way…

http://v8tvshow.com/1969_Ford_Lightn....15.15_008.JPG

Condenser mounted in nose.

http://v8tvshow.com/1969_Ford_Lightn....15.15_012.JPG

Hose connection to condenser core through the inner fender, protected with grommets.

http://v8tvshow.com/1969_Ford_Lightn....15.15_010.JPG

The unit will be controlled with the stock heater controller:

http://v8tvshow.com/1969_Ford_Lightn....15.15_015.JPG

The Gen IV system uses electronic sliders to convert the cable controls to electronic signals to operate the servo motors in the evaporator unit.

http://v8tvshow.com/1969_Ford_Lightn....15.15_017.JPG

http://v8tvshow.com/1969_Ford_Lightn....15.15_018.JPG

A/C vents installed in the dash:

http://v8tvshow.com/1969_Ford_Lightn....28.15_003.JPG

Here, Adam fabricates a vent that surrounds the steering column to provide a cool breeze to the driver.

http://v8tvshow.com/1969_Ford_Lightn....18.15_007.JPG

http://v8tvshow.com/1969_Ford_Lightn....19.15_002.JPG

http://v8tvshow.com/1969_Ford_Lightn....19.15_001.JPG

We think it turned out pretty slick.

http://v8tvshow.com/1969_Ford_Lightn....24.15_006.JPG

As you can imagine, there is a lot of wiring to do on a project like this.

One challenge was to figure out gauges for this truck. However, we got lucky with this one. Dakota Digital makes a VHX series dash for the 1969 Ford F100, and with their CAN bus and OBDII Interface module, it actually plugs into the OBDII port from the Lightning to receive engine data from the ford EEC-V ECM.

Here you can see the Dakota Digital VHX controller and the OBD-II interface and the custom harness we made that uses weatherpak connectors. The VHX system is very flexible in that it allows you to use various engine sensors and connect them to the controller, which then drives the gauges.

https://lh3.googleusercontent.com/-T....12.15_002.JPG

https://lh3.googleusercontent.com/-A....12.15_005.JPG

The dash cluster:

http://www.dakotadigital.com/img/vhx-67F-PU-k-r_lg.jpg

And at night…

http://www.dakotadigital.com/img/vhx...r-night_lg.jpg

Of course, you can install this unit in a stock truck, but we were happy to have a way to read what the 2002 ECM was saying.

We mounted the controllers in the glove box.

https://lh3.googleusercontent.com/-y....13.15_002.JPG

The real estate was running thin in the dash, so we created a relay and power center that will live under the seat.

https://lh3.googleusercontent.com/-B....25.15_002.JPG

This bank of relays handle the electric fuel pump, the A/C power, the ECM power, and others.

https://lh3.googleusercontent.com/-V....25.15_003.JPG

We added an OBDII connector to the harness, and used a Diablosport InTune hand-held device to communicate with the ECM. This will allow us to scan and clear codes, and perform minor tuning and calibration changes. It will also allow us to upload a complete performance tune later.

https://lh3.googleusercontent.com/-A....01.15_011.JPG