Fullsize Overland Project - 1997 F250 Crewcab Shortbed 7.3L Powerstroke Diesel

[Crutledge]

It seems like most overland builds are jeeps or tacomas but I'm kind of a different soul so I decided to go with a fullsize rig! Sure it's probably not near as capable as the smaller rigs but it should do the trick for what I'm going to do with it.
I'm going to build a 1997 Ford F-250 crewcab shortbed 7.3L Powerstroke
I will be posting progression pictures as I go along.
Here is where it sat when I started on it about 2 weeks ago.

At this point the truck is still a running and mobile truck.

I am going to completely repaint the truck to help get rid of the 321k miles of abuse. I figure if I'm going to build it I want it to be done right and I want it nice.

Loaded on the trailer headed to my shop for all the mechanical and suspension work. I am converting it over to 4wd using 2015 F250 superduty axles. It will also be getting a little pep in its step via a few engine and trans mods.



We pulled the factory 12 gallon rear tank to replace it with a 38 gallon one for added fuel capacity. I mean you can't ever carry enough fuel for those long trips right!



We got the tank primed and cleared with automotive grade primer and clear coat to help protect it from the elements.

I scored me a sweet deal in a transfer case! Didn't need the ZF5 speed but I couldn't pass up the deal on the packages soooo I got them both! Haha

I decided that after 21 years of use and abuse that I didn't want to take the chance of her not starting in the cold so I'm putting all new OEM battery cables on it along with all new hoses, degas bottle, radiator and belt just for added precautions.

I'll have much more to come shortly as I'm adding to the list and doing more everyday.



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[Crutledge]

Got a little more done on the truck. We pulled the seats and carpet to clean the floor and sound deaden it. To my surprise it was actually pretty dang clean under there.


I was also able to score myself a sweet Leer Topper for it for $75! Dang I love Facebook Marketplace sometimes. Haha



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[Crutledge]

It has been some kind of busy around my shop the past couple of weeks and I just have had time to do much to my truck. So I decided yesterday to just make time.

I got the sending unit modified and the tank mocked up on the truck.





Now time to get the new Irate Diesel E-fuel setup plumbed! I decided to run this system for several reasons. First being that the factory mechanical pump is probably the original one and with 321k miles it's time to do something with it. Haha Second they are a nightmare to change in a nice well equipped shop much less on the side of a mountain somewhere.
Being that I was going to run e-fuel I decided to start looking into kits. I knew there were several on the market for these trucks but dang I didn't realize there where like 40!! Most of which are the same just made by different companies. I ultimately made my decision based on the regulated return. Irates setup used pre-bend hard Stainless tubing instead of braided Stainless lines. I felt that was a much better design on top of a much cleaner look!




This is not my engine for my build but it does give a good illustration of what they regulated return lines look like installed.




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[akmedic77]

This will be a build to keep an eye on! Are you keeping the same color scheme or going with something different? I hope to be able to find a rig like this some day!

 

[Crutledge]

This will be a build to keep an eye on! Are you keeping the same color scheme or going with something different? I hope to be able to find a rig like this some day!

Im going to keep the same color scheme. You dont see many this color and IMO these trucks look good two tone.

 

[Crutledge]

Today I was finally able to steal a couple hours on one of the vehicle lifts in the shop. Hard to find time this part of the year.

No how we are pulling the factory 2wd suspension in preparation for the 4wd conversion to start! This I feel will be the one thing that will change the look of this truck the most.




I spent a little time figuring on what would be the best way to convert this truck. I had originally planned on building with a period correct Dana 60 axle from a mid 90s Ford, however I decided against that when I got to thinking about how rough it would be with a full leaf spring suspension not to mention the lack of travel.
That led me to my second option which is what I ultimately decided to go with 2015 Superduty axles and suspension. I am using everything from the 15 chassis all the way to the steering box. This will allow for a much smoother ride along with greater suspension flex for the trails. There are also many more suspension options for newer trucks i.e. shocks, coils, coilovers, etc.
You would be amazed at all the parts made to do this swap on 92-97 Ford trucks nowadays.
Parts list thus far
RYD Motorsports Track Bar Bracket
RYD Motorsports Sway Bar Brackets
RYD Motorsports axle conversion brake lines
PMF Suspension fabricated blocks with built in airbag tangs
PMF Suspension 5/8s Ubolts
PMF Suspension dual steering stabilizer





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