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After running all the wires through the passenger side fender well, we decided to protect them with a custom inner fender splash shield. The original Ford design did not have a protective panel in this area, but they also did not have Electronics installed inside the fender.
https://lh3.googleusercontent.com/-t....10.15_001.JPG https://lh3.googleusercontent.com/-O....10.15_003.JPG https://lh3.googleusercontent.com/-p....11.15_002.JPG We mounted a series of reservoirs next to the radiator including coolant overflow and supercharger coolant. https://lh3.googleusercontent.com/-I....17.15_003.JPG The customer wanted a new steering wheel, but we all liked the look of the original style wood wheel. One trick we've learned is to clear coat the original style wheel with automotive clear. This provides a very comfortable wheel with long-lasting polyurethane clear protection. https://lh3.googleusercontent.com/-T....22.15_003.JPG |
At this point, we installed an Odyssey Battery, added fluids and fuel, and started the truck. It had an issue because the original Ford ECM was looking for the factory dashboard assembly as part of the security system and would not activate the fuel pump. However, our friends at GRC Performance reflashed the ECM and removed the security function. After that, the truck fired right up! We actually took it for a few test drives and it drove like a 2002 lightning. It was a success!
Next, the tasks turned to the aesthetics. The goal was to restore the 2002 chassis, engine, and suspension to a new appearance, tidy up the underhood and floors on the cab, but not do any paint work to the outside of the cab or bed. We also wanted to paint all of our new bracket tree that we had made for the conversion. Apart it comes! https://lh3.googleusercontent.com/-Z....22.15_004.JPG https://lh3.googleusercontent.com/-R....22.15_005.JPG https://lh3.googleusercontent.com/-X....22.15_006.JPG https://lh3.googleusercontent.com/-y....23.15_001.JPG https://lh3.googleusercontent.com/-y....23.15_003.JPG |
We had sent many of the parts of up to the media blaster, which revealed some areas that required repair.
https://lh3.googleusercontent.com/-4....30.15_001.JPG https://lh3.googleusercontent.com/-8....30.15_002.JPG https://lh3.googleusercontent.com/-e....30.15_005.JPG We did not want to disassemble every single piece, so the supercharger and engine would be cleaned and detailed as assemblies. https://lh3.googleusercontent.com/-w....01.15_001.JPG https://lh3.googleusercontent.com/-0....01.15_008.JPG https://lh3.googleusercontent.com/-_....01.15_009.JPG https://lh3.googleusercontent.com/-J....01.15_014.JPG |
Next, many paint booth loads of parts would be cleaned, hung on racks, masked, and painted with the appropriate coatings. Most parts received black epoxy and then a black Imron industrial coating.
https://lh3.googleusercontent.com/-Y....01.15_017.JPG https://lh3.googleusercontent.com/-u....01.15_018.JPG https://lh3.googleusercontent.com/-M....03.15_005.JPG https://lh3.googleusercontent.com/-A....06.15_025.JPG https://lh3.googleusercontent.com/-R....06.15_029.JPG |
The chassis was also media blasted and coated with Axalta epoxy and Imron satin black paint.
https://lh3.googleusercontent.com/-3....10.15_006.JPG |
With the cab off the frame, it was easier to access some of the areas that required metal finishing. These included filling unused holes on the firewall and finishing off the rear cut-out over the frame rails.
https://lh3.googleusercontent.com/-E....06.15_037.JPG https://lh3.googleusercontent.com/-8....23.15_030.JPG https://lh3.googleusercontent.com/-S....24.15_038.JPG The finished firewall was primed and painted with Imron satin black. https://lh3.googleusercontent.com/-w....27.15_041.JPG |
Once the chassis parts were cured, the crew then began the reassembly of all the chassis and suspension components. We installed a new set of Bilstein shock absorbers, new brake rotors and pads, new suspension bushings where they were needed, and made the chassis a roller once again.
https://lh3.googleusercontent.com/-e....16.15_002.JPG https://lh3.googleusercontent.com/-2....17.15_001.JPG The chassis almost looks square with the wheels and tires bolted on! https://lh3.googleusercontent.com/-2....20.15_001.JPG https://lh3.googleusercontent.com/-e....22.15_006.JPG https://lh3.googleusercontent.com/-r....23.15_006.JPG https://lh3.googleusercontent.com/-x....23.15_007.JPG The bottom of the cab was stripped clean, and treated to our epoxy and Imron coating process. Then, it was coated with 3M Body Protection coating to reduce noise and prevent stone chips. |
Inside the cab, the crew scuffed the old paint and repaired metal were necessary. After seam sealing, the interior black surfaces were all restored with new satin black paint.
https://lh3.googleusercontent.com/-Q....28.15_046.JPG The gray is a high-solids primer sprayed on the areas to be block-sanded smooth. https://lh3.googleusercontent.com/-X....28.15_047.JPG https://lh3.googleusercontent.com/-h....28.15_049.JPG https://lh3.googleusercontent.com/-O....28.15_051.JPG https://lh3.googleusercontent.com/-n....28.15_052.JPG https://lh3.googleusercontent.com/-U....28.15_050.JPG https://lh3.googleusercontent.com/-e....28.15_053.JPG |
After the inside was sanded and painted black, the cab went back on the frame for the last time.
https://lh3.googleusercontent.com/-R....30.15_003.JPG https://lh3.googleusercontent.com/-X....30.15_004.JPG https://lh3.googleusercontent.com/-V....31.15_003.JPG The engine was in excellent condition, so the crew merely degreased it and did some minor disassembly for better paint application. https://lh3.googleusercontent.com/-k...06-15_0006.JPG https://lh3.googleusercontent.com/-t...06-15_0004.JPG |
Aluminum parts like the supercharger and transmission were cleaned and masked, then they were sprayed with Eastwood nano ceramic high temperature engine paint. They were sprayed in satin silver to keep an aluminum look, but now they will stay this way without corroding the way cast aluminum does.
https://lh3.googleusercontent.com/-T...06-15_0008.JPG https://lh3.googleusercontent.com/-m...06-15_0002.JPG https://lh3.googleusercontent.com/-c...06-15_0020.JPG https://lh3.googleusercontent.com/-C...06-15_0021.JPG https://lh3.googleusercontent.com/-w...06-15_0024.JPG https://lh3.googleusercontent.com/-F...06-15_0027.JPG https://lh3.googleusercontent.com/-K...06-15_0028.JPG https://lh3.googleusercontent.com/-p...06-15_0033.JPG |
With most of the pieces painted, it was time to start putting the truck back together. The crew began by reinstalling the wiring harnesses, ECMs, relay centers, Vintage Air equipment and ductwork in the dash.
https://lh3.googleusercontent.com/-_...07-15_0043.JPG https://lh3.googleusercontent.com/-I...07-15_0047.JPG https://lh3.googleusercontent.com/-x...07-15_0048.JPG Next, the inner fenders were reinstalled and the crew installed as much wiring as they could before the engine and transmission were dropped in place. https://lh3.googleusercontent.com/-P...07-15_0050.JPG https://lh3.googleusercontent.com/-K...07-15_0051.JPG https://lh3.googleusercontent.com/-p...07-15_0052.JPG https://lh3.googleusercontent.com/--...07-15_0053.JPG |
The supercharged 5.4 liter V8 was reassembled with it's freshly detailed parts, including new gaskets and wrinkle coated valve covers, new gaskets for the supercharger assembly, and other detailed pieces. The supercharger has been upgraded with a higher RPM pulley for increased compression. The goal was to install as many connectors, harnesses, hoses and hard lines as possible while the engine was on the stand to make installation go quicker.
https://lh3.googleusercontent.com/-u...09-15_0058.JPG https://lh3.googleusercontent.com/-p...09-15_0066.JPG https://lh3.googleusercontent.com/-4...09-15_0068.JPG The radiator core support was built on a stand before it was installed in the truck as an assembly. The core support assembly consists of the support, radiator, electric cooling fans, fan controller, steering reservoir, AC condenser core, oil cooler, and coolant reservoirs. The supercharger heat exchanger would be attached after the core support was installed. https://lh3.googleusercontent.com/-0...09-15_0059.JPG https://lh3.googleusercontent.com/-O...09-15_0069.JPG https://lh3.googleusercontent.com/--...12-15_0083.JPG https://lh3.googleusercontent.com/-x...12-15_0084.JPG |
The transmission was bolted to the engine and the whole assembly was lowered into the truck including all the wiring and the headers.
https://lh3.googleusercontent.com/-q...09-15_0073.JPG https://lh3.googleusercontent.com/-S...09-15_0075.JPG https://lh3.googleusercontent.com/-H...09-15_0080.JPG https://lh3.googleusercontent.com/-p...09-15_0081.JPG The core support assembly was installed, and then the heat exchanger was added. The new brake lines were put back in place, as well as the master cylinder and Hydratech hydraulic brake booster unit. The factory 2002 Lightning anti-lock brake module and hardware was installed, which remained functional in the 1969 truck. https://lh3.googleusercontent.com/-X...12-15_0086.JPG https://lh3.googleusercontent.com/-L...12-15_0089.JPG https://lh3.googleusercontent.com/-g...12-15_0091.JPG https://lh3.googleusercontent.com/-b...12-15_0094.JPG https://lh3.googleusercontent.com/-G...12-15_0096.JPG |
Nice update, the truck is looking great!
Is it bad that each time I read one of your posts I hear you narrating it like on your You Tube channel? :lol: |
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GREAT JOB!!! |
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Underneath the truck cab, the 4R100 electronic overdrive sits comfortably on it’s new mount.
https://lh3.googleusercontent.com/-V...13-15_0098.JPG https://lh3.googleusercontent.com/-t...13-15_0099.JPG Topside, the pieces are coming back together, like the power steering and hydroboost lines and the fabricated cover for the radiator and coolers. https://lh3.googleusercontent.com/-u...13-15_0100.JPG Wiring is hidden below the inner fender, which will all be tidied up and protected with a the new splash shields. AC and heater lines route through as well. https://lh3.googleusercontent.com/-S...13-15_0101.JPG The driver side hides the forward harness lines in a similar fashion. https://lh3.googleusercontent.com/-4...14-15_0111.JPG Here, the painted air intake is reinstalled, along with the throttle and cruise control cables. https://lh3.googleusercontent.com/-0...19-15_0115.JPG Hoses are kept tight with Gates heat shrink clamps. https://lh3.googleusercontent.com/-J...19-15_0119.JPG |
The inner fenders and grille assembly are reinstalled.
https://lh3.googleusercontent.com/-Q...19-15_0120.JPG https://lh3.googleusercontent.com/-Z...19-15_0121.JPG https://lh3.googleusercontent.com/-2...11-15_0001.JPG Inside, the Dakota Digital VHX gauge system is reinstalled in a restored dash bezel. Heat and sound deadener is installed. https://lh3.googleusercontent.com/-Z...20-15_0123.JPG https://lh3.googleusercontent.com/-c...20-15_0126.JPG https://lh3.googleusercontent.com/-T...20-15_0129.JPG https://lh3.googleusercontent.com/-G...20-15_0132.JPG https://lh3.googleusercontent.com/-v...22-15_0150.JPG |
The stock hood hinges were rebuilt for more precise operation and painted with Axalta Imron.
https://lh3.googleusercontent.com/-l...20-15_0131.JPG The hood is reinstalled, and LED headlights will light the way with many more lumens than the original bulbs! https://lh3.googleusercontent.com/-f...21-15_0139.JPG The vintage air runs off a stock controller with a new lens. https://lh3.googleusercontent.com/-B...22-15_0148.JPG The new red interior is installed, including carpet, dash pad, and a recovered original seat. The new wood rimmed steering wheel has been sanded and sprayed with automotive clear coat for a long-lasting lusture. New door weatherstrip helps block wind noise and leaks. https://lh3.googleusercontent.com/-M...21-15_0095.JPG https://lh3.googleusercontent.com/-M...21-15_0100.JPG https://lh3.googleusercontent.com/-q...21-15_0103.JPG |
Lightning bolts are stitched in the seats for a little hint of the fury under the skin!
https://lh3.googleusercontent.com/-A...21-15_0098.JPG “Thunder’s Truck” is polished up and a new set of 18x10” Billet Specialties SCL85 wheels and Nitto 295-45/18 tires are mounted up, and it’s ready for the road! https://lh3.googleusercontent.com/-X...16-15_0022.JPG https://lh3.googleusercontent.com/-2...16-15_0028.JPG https://lh3.googleusercontent.com/-Q...16-15_0039.JPG https://lh3.googleusercontent.com/-t...16-15_0055.JPG https://lh3.googleusercontent.com/-0...16-15_0061.JPG https://lh3.googleusercontent.com/-i...16-15_0124.JPG https://lh3.googleusercontent.com/--...16-15_0131.JPG https://lh3.googleusercontent.com/-P...16-15_0149.JPG https://lh3.googleusercontent.com/-w...21-15_0069.JPG https://lh3.googleusercontent.com/-I...21-15_0078.JPG |
The build series was featured on the V8TV television show airing on Tuff TV, the Rev’n Network, and The Action Channel as well as online.
V8TV Build Videos: The truck performs fantastically, and met all of its goals. The V8 Speed & Resto Shop crew really enjoyed working on this one, with the extremely stock and slightly weathered exterior and modern tech and power under the skin. What ideas do you have for your next ride? |
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