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all 4 leaf springs are done being rebuilt again. This time fully coated in graphite paint, and the steel shims from the excursion leafs are in the rear pack now instead of the plastic ones i made  Brought the truck around, and snapped the very last pic before i rip the suspension apart again  It already has a PMF 2.25" Superduty Shackle Reversal kit on it. This time around im replacing the original spring hangar on the frame rail with Sky's low clearance one:  Yesterday i got the driver side bracket on the frame:  Today its raining, so maybe tomorrow i can get the passenger side bracket swapped. I thought this was interesting- shows the difference between the X code leafs im removing, and the V codes im installing   The X code has almost a full inch more arch to it, and both leafs are 1/8" thicker in the middle & 1/16" thicker at the ends. So this pretty much confirms what everyone on the internet says, that the front end should go down ~1" and the ride should be nice & soft. We'll find out soon enough. One of my front shocks is shot, so i ordered a pair of Bilsteins which should get here tomorrow. Hopefully the weatherman is wrong, and i get some dry days here so i can get the front-end done and get it turned around so i can tear into the rear. Just a couple weeks to go before the East Coast Bronco Roundup, so i gotta get this thing done! Oh yeah, this is cool too. I tossed the X codes into the rear of the DD bronco and brought em to work, because a coworker bought em off me. I had some issues closing the tailgate though. Check this out:  Gotta hurry up and get the red one done, because it looks like the green one needs some sheet metal repaired asap!
Any job worth doing, is worth doing twice! Or something like that. I bought a couple cans of Slip Plate (which is graphite paint), so i disassembled the springs and repainted them. Ive also decided to use the steel shims from the Excursion packs, so they got painted too:
If i have time this weekend im going to start assembling them. I also have to get the 4th pack apart & painted. Going to try to get that done so i can hopefully start the front spring swap monday. Theres been lots of rain in the forecast, and theres more coming so we'll see how this all goes. So im starting the suspension upgrade. From top to bottom: rear Excursion (G code) rear Superduty (B code) front Superduty (V code)  ...and a set of the correct helper springs  I also bought a set of Sky's low clearance shackle hangars & their adjustable tracbar.  Springs coming apart:  ...and after some wire wheeling and paint
i bought a whole bunch of new anti-friction pads from Dorman, because most all of them were shot Amazon.com  Ford used these plastic shims between the leafs, but all of mine were broken except for one  Fortunately Speedway sells it in a roll, which i already had from rebuilding the leafs in the '90, so i made some new ones  ...and now ive got the rear springs all back together!  I added the 2 lower leafs from the Excursion pack to the B codes, hopefully itll work out well  I goofed on the front leafs, the new center pins i ordered have a shoulder thats too long for a 2-leaf pack. Also apparently the local spring shop closed their doors so i had to order another set online, which i wont get until probably Friday. So i guess its going to be another week until i can swap the front springs. Been working on a few projects around the house/garage. First up, we actually used the AL bed to haul a yard of mulch for the garden beds
With how much bigger this bed is, 2 yards should fit in there just fine. Next up was to fix the remote mounted Warn x8000i. After 20 years the cable was sprung, and one of the solenoids was only intermittently working, so i opened it up and swapped them out. 
 ...and finally i also got 2 small projects done in the garage. #1 was adding a light to the drill press  ...and the other was replacing the old bottle jack on the press, with this new pneumatic one  ...and with all that done, its time to start building some new leaf springs for the F250  The tires on the diesel are beat:  Looks like we're staying with the 16.5s for another round, which means theyre overdue for a cleaning & polish. Lets gooo!  cleaning...  ...polishing...  ...and clean!  ...and looking good!
Thats all fine and dandy, but the tires are beat. So its time for new rubber!
 ...and installed!
Predictably, the one vehicle youre not working on gets jealous and decides to break. In this case it was the turn signal switch in the column of the '90 Bronco. The book says the column has to come and be disassembled to do this job, but i had another idea. First up, lower it to make some room  Turns out if you de-pin the connector on the end and remove it, you can pull the switch right out of the column
After de-pinning & removing the connector on the new switch, i was able to fish the new one down thru the column, and get it installed  ...putting the connector back together...  ...and done! Column repaired.  Used the new aluminum bed a few times now to haul stuff, and im already tired of the spare tire being loose back there. Not that it moves around, just that its big and always in the way. So i took the time to remount the original tire carrier that was in the bed  Simple and effective.
So i studied my wiring diagrams for a bit  ...and then came up with a plan to improve my old wiring, while also simplifying it. Step one involved moving the wiring for the pump away from the water tank since the pump is now on the frame rail  From there i was able to break down my old sloppy wiring harness, and make a nice clean one to take its place. My old wiring harness:  ...and the new one:  So with that done i replaced the float in the tank since one of the wires was frayed  put the nozzle back in the intake...  ...and powered the system back up!  water-methanol injection V.20 is now complete! Now to just drive the truck and get it tuned! Working on getting the tank mounted:  I started making a bunch of straps to suspend the tank in the frame:  ...and then:
So with 7 brackets all bent up, i grabbed a piece of scrap steel sheet, and made side shields, and a lower panel, to keep road debris from hitting the tank
...with that done, it was time to reinstall the tank and hangar!
This shows the feed line from the sump in the tank, to the failsafe solenoid:  Ultimately, i decided to mount the pump in the underside of this xmember:  ..and with the pump mounted and plumbed, its time to start on the wiring. This is the original harness i ran down the frame years ago, with a wedgelock connector on the end so i could plug in the extension harness:  ...and this is th eenxtension harness. Originally the harness ran up the bulkhead of the bed, but with the dump bed conversion done years later i had to make and extension harness to run down to the end of the frame rail and then double back along the underside of the bed. Well, with the new tank location we wont be needing this anymore:  ...and this is the wiring harness that was inside the toolbox under the water tank. With the new pump & tank locations, now is the perfect time to take this apart, clean it up, and lay it out a bit nicer  So now its time to dig into my 10-15 year old wiring diagrams, reverse engineer this system, and clean up the wiring!  Its time to reinstall the water/methanol injection in the F250!  Originally the system was installed in the tool box where it was safe and out of harms way:  But this time, with the aluminum dump bed i dont want the tank in the bed anymore, so i need to come up with a new place for it. So since we swapped the 38 gallon tank in place of the rear tank, that means that technically i dont need the front tank anymore. So, out it came!  This frees up a ton of space to install my 12 gallon tank:  I took the original fuel lines and made a stubby line to connect the two ports on the diverter valve, so i cant accidentally dump fuel under the truck. This will suffice for now, until i do the e-fuel conversion  Mocking things up, this is the plan for the water tank location:
It looks like its sticking way up but its not too bad. In its current temporary place its flush with the bottom of the frame rail and clears the bottom of the bed, so this will work, altho i think im going to lower it an inch or two, just for some extra clearance. Now to get a hangar designed and built.... |
