My 83 4x4 build

[ThatOneGuy]

Here is the pic of the rear bumper, and how I delt with the license plate.

 

[ThatOneGuy]

I'm hoping to start getting the harness into the cab this weekend, ive gotta install the fire wall section from the expo. For the B.W.P. to pass through I figured it would be easier to cut a square hole and either weld or rivet the section in than cut a notched circle out. Than I'll get the dash side of the harness installed, trying to decide if I should run the wires for the 4x4 controler, incase I ever want to run an e-shift t-case. Probably also gonna hit the parts yard, find me a fule tank,

 

[ThatOneGuy]

I had been going back and forth with myself on what to do about the fule tank. I finally decided to use the 83 tank and modify it to install a fule pump and sending unit for a 4.0. The sender assembly was 1.25 inches longer than the 83 sender, so I based my design on some 1.25/.25 flat stock. I bend the first one into a circle the same outer diameter, as the new sender, than bent another smaller that was just big enough for the little locating tabs on the underside of the sender, about 3/4 of an inch between the two rings. Than I welded them to a piece of 1/8 inch sheet, I cut out the center, than welded some half inch square stock in 4 locations around the perimeter, these will house the mounting bolts. I then cut out a badly rusted section of the tank and welded in a patch panel, than I welded my custom adaptor flange to the tank about where the stock sender sat. My welds wernt perfect and I had a few leaky pin holes so I then went over the patch panel, and all the way around the flange sealing it with jb weld. I then cleaned up a few inches around rust converted, primed, and under coated the tank and new flange, at this point I still need to refinish the rest of the tank, flat sand the seal seat of the flange and install the bolts. First pic shower the 83 sending unit next to the 4.0 sender

 

[ThatOneGuy]

Today I started installing the cab side wiring harness for the 4.0. The BWP, and fuse panel still need to be worked over, and I still need to finnish making all the connections from the 83 harness to the 91 harness for indicator lights. I've got the transfer case control module installed and, the wires run through the firewall, I plan on manual shift tcase but wanted it set up for eshift just incase. Not sure if im gonna do anything to mount the buttons anytime soon but its there. I've also got the aftermarket keyless system mounted, and the wiring started for those conections. Once done, the fob will be needed to power the 4.0 systems, but the key will still crank the starter over using the 83 wiring. I'm still not sure if running the engine management wiring from the 91, with all the body wiring from the 83 was the easiest option, but I didn't want to rewire everything, but I wanted the 91 cluster. And I wanted to be able to leave the truck drivable with the stock drive train, while I worked on it. As far as the cluster goes i set it in place just to check fitment, it's going to work out. Up until now I've just been hoping lol will definitely require fabing some mounts and a bezel, but zip ties will definitely work in the short term. Another thing I realized is the 83 cluster, and 91 cluster need the speedo cable in different places, so ill either need to get a longer cable, or maybe an extension, started to research that a bit but idk.

 

[Angie]

nice project!!

 

[ThatOneGuy]

nice project!!

Thank you its been fun. I actually like the wiring work, even if it is tedious lol.

 

[BlackBII]

Some really nice work here! Glad to see it getting done the right way. The worst part about restoring vehicles is having to fix all the previous owners garbage. Looking good man. I like wiring work too. It's so satisfying to make it nice and clean with heat shrink and such. The 4.0 will be nice. They get some hate but I love mine

 

[BlackBII]

Your weld doesn't look bad, just need to work on getting a consistent travel speed to get a more even bead

 

[ThatOneGuy]

The last few days I've been rounding up some of the last parts I'll need for the 4.0 rebuild, unfortunately my budget is running a little lean, gonna need to scrounge up some overtime to keep the wife off my back lol. Picked up new rocker arms, push rods, and head bolts. I have a full set of melling lifters on the way, still thinking about the oil pump I would love to get the melling high volume pump, but idk, if I keep buying like this I can say goodbye to getting the bottom end rebuilt, this year.

 

[ThatOneGuy]

Installed new rocker arms today, kinda in a slow part of the build its started raining again wich is nice there was no rain for 4 months but it slows progress. Still trying to figure out how to fund the rebuild, I really want a 410 cam, which means I need to return the push rods because I bought stock replacement, due to trying g to save cash, but why rebuild it and not be happy? Also I want to get the melling high volume oil pump, I have new lifters on the way should be in tomorrow. I need to talk to the machine shop about making payments lol. But come tax returns ill have enough for it all.

 

[ThatOneGuy]

Well I droped the block off at the machine shop today. He told me it would be 8-12 weeks, wow that's a wait time. This weekend I finnished the mounting flange for the gas tank, and today I started cleaning some parts. Even got paint on the oil pan. I've got 10 out of 12 new melling lifters sitting in oil, hopefully I'll get the other 2 this week. The national

shortage of engine parts is making it hard to get them, on top of that oreilys keeps partial filling my orders with sealed power brand, that are used returns, or have seized internals, so I refuse them, and get them to order more. So far I've got all the lifters from Washington, Denver, and Sacramento, slim pickings out there. Thanks covid.

 

[BlackBII]

Looks good!

I've been having a hard time finding parts as well, it's obnoxious!

 

[ThatOneGuy]

Cleaned some more parts and painted them, my plan is for the block, oil pan and heads to be red then the intake, valve covers and accessorie Mounts to be ford blue honestly we all know with a 4.0 we will never see the block from above anyway. I also started running all the bolts through the wire wheel, than coating them in oil and wrapping in plastic till needed. I've got all the intake bolts, oil pan bolts done so far need to replace a few missing water pump bolts as well such a tedious job, but there is no way I'm putting nasty old crusty hardware on my rebuilt freshly painted engine lol.

 

[ThatOneGuy]

Well I've gotten the trans and transfercase cleaned and painted. During the process I started trying to find a transfercase shifter. Turns out the early transfercases, like mine from 83 have a diferent shift arm than all the others, and no stock shifter will mount and work with an m50d. Si I ended up fabricating my own. Still needs some work to get the shifter just right, however that will be easier once in the truck can only guess so much while on the ground.

 

[Angry Possum]

Great job so far. I commend you for taking on such a project as such...