1999 f250 super duty build thread.

[broncomitch]

Small update, I got the front axle out and cleaned up my springs and parts of the frame so I can get the rear back on the ground ASAP.


I decided I'm going to do the 08+ rear spring swap but will most likely buy the kit and just be done with it???but I'm going to wait till the rest of the truck is done before I do that tho..

For paint I'm using rust-oleum and a lacquer sealer..I'm told that combo is the **** and should last a long time.
I also used that lacquer sealer on the bolts and then used a heavy coating of anti seise.

 

[broncomitch]

Well I down the hole weekend and Sunday I got food positioning so I didn't get anything done...
Got my latest parts from sunrise ford!

I also spent almost $100 just on bolts and hardware that's upsetting. Lol


Starting to Feeling better now so hope to hit the truck hard this week.

My goal is to have the frame cleaned up and the rear axle in and start on the front by sat.

 

[broncomitch]

Small update,


I was hoping to just bang out the dust shield's but there to badly smashed...so had to take the hubs off to cut em out and I'm swapping out the parking brake lever so I can re use my old parking brake cables.


Got the axle in and just waiting on parts again.


Good news is I'm going to do the Saginaw pump conversion wile I have everything out.


So should get parts in 2 weeks and be able to slap this baby together.


This week I'll be starting of the front sense I can't do anything on the rear till those seals show up and the missing brake parts.

Old "left" new "right"

And steering box

 

[broncomitch]

Ran into a problem, the track bar bracket I got was off a 09 SD and it's a little different then the 05-07 so got one at the junk yard.

I thought I needed to drill one hole for it but it turns out I need to drill 3..


First, mount the coil buckets, the track bar bracket uses one of the holes on the bottom of it.
So mount the bucket, dill out that hole then you can drill out the other 3 holes for the track bar bracket.


spent a lot of money on parts yesterday...
Got a case of royal purple powersteering fluid,
New rear rotors and pads,
New lug nuts,
Hub socket and hub seals,
Saginaw pump and remote can,
Remote reservoir,(OEM)
351 Sag pump bracket and hose kit.

shooting to have the rear end done and on the ground Saturday.

 

[broncomitch]

Got the rear end finished up tonight..


Going to start on the front now..


I love the bigger brakes,the rear's are as big as the old front rotors!

Was getting cluttered in the shop so had to get some shelving lol

 

[Bart]

Wow, what a transformation. Nice job.

 

[broncomitch]

Thanks, but now the real transformation begins

Got the coil buckets and radius arm mounts installed.
Just need to drill a 1/2" hole on each side for the arm mounts and everything else bolted right up.


Also got my crap for my sag pump conversion!

 

[rockdog]

Mitch, where did you learn about the Saginaw steering conversion? I hate the fact I can't turn the tires on my sd when it isn't moving. It makes it a bitch to back trailers up in tight spaces!

 

[broncomitch]

Powerstroke.org grate info there on anything SD.

I am in the same boat with steering..that's why I'm going to give this a shot.

you can call PSC and order a kit...but it's spendy..

 

[broncomitch]

Made some awaome progress this weekend.

got all the holes drilled and all brackets installed and torqued the grade 8 hardware to 76flb with lock washers.

Got the axle cleaned up and went through and all is good apart from a smashed steering stabalizer

but the axle is under the truck and hope to get it sitting on suspension again in a few days.

 

[LT.]

Pictures, Bro, PICTURES!!!

LT.

 

[broncomitch]

Okay...

so in the process of getting the truck back on its suspension I go to change a song and my LCD on my phone is shattered so had to take the pics with the iPad and it has no flash...
My first problem is that I was pretty sure something was going on with the axle cus my caster/pinyon angle was crazy bad...I was told to just keep jacking up the axle and the coils will pop in....so I did and they did also...


I didn't think the stock coils compressed so much...but the caster angle is a lot better and I about had a hart attack when the coils settled in the seats lol
But after taking my sweet time it's off the big jack stands and on the little ones now lol

I'm not happy how the coils are sitting and might take out the leveling kit for now and save up some $$$ for a nice leveling kit with radius arm dorm brackets and do the adjustable trackbar...but we will see...it's a 2.5" puck but with the duel shock setup I'm pushing almost 3" so I'm going to hack off a 1/2" on the puck..

 

[broncomitch]

I also got the wrong the adapter for the sag pump...PSC both the 5.8 or the 5.0 will work...I went with the 5.8 cus it was cheaper but the hole locations clock the pump far into the bracket and the feed tube is pointing under the alternator and not straight up..

so not sure how that will work out just yet...

 

[bryson]

Just a thought on the caster/spring bow issue - could the control arms be on upside down? I don't even know if that makes a difference, but if the arms aren't symmetrical along their long axis it could affect caster.

 

[broncomitch]

I thought the same thing but they seem to be the same from eye to eye (from the bracket to the top & bottom mounts on the axle.)

 

[broncomitch]

That night, before I went to bed I was bouncing the front end and last night I was looking at the coils and they where sitting Normal...?


But I can't decide what to do about this front end...I'm going to trim down the pucks a 1/2" so the axle is more centered cus the passenger side is kicked over so far the bump stop and coil are almost touching and when the axle drops they do...so not sure if I want to even bother with it right now or make a adjustable track bar..


And here is some bad news... I can't use the duel shock setup.
The shock mounts will work but the swaybar won't...this setup moves the swaybar behind the motor and it's ment for a 4"-8" lift...so there is no room for it at stock height..


My only chance is to mount it in the front and ether make a mount off the shock bracket and make custom links but then I would only be able to run 1 shock on each side so I only got the bling factor going for me(witch I do love the white hoops)


So I can't decide what to do...do I sell the setup and finish my truck or keep it and try and hope I can make it work and post pone the build till I can buy the few things to finish it?

And it turns out that PSC sells both sag pump brackets for the 5.0 or 5.8 and they say they both will work on the superduty...so I found this... And he used the 5.8 and didn't need to notch the bracket for the fill hose and figured it would work better then the 5.0...well it makes it worse and the fill hose is pointing right under the alternator...


So I gotta call them up and see if they will send me the 5.0...


And I knew the pulley shaft sizes where different but only by .60 thousands...
So Dave over at apex machine chucked the pulley on the lathe and bored out the hole to .748.5 and it's a perfect press fit on the sag pump shaft can't wait to get that finished up.

 

[broncomitch]

Well, it's going together for the final time.
I ran the brake and vacuum lines a little different...for what ever reason the brake lines just didn't have the length to go into the normal spot and the 99 brake line location is on the other side of the coil bucket...so I wound up flipping the brake line bracket and re bending it to clear the coils, modified the brake line mounting tabs and mounting them on the coil bucket and used some brake line I had made for a different project that I couldn't use to connect to the factory hard line with the help of a brake line connector.


It worked out really slick how the brake line is ran it runs around where the shock goes and won't have a problem with it hitting anything..

I also trimmed down the pucks to 2" and ditched the duel shock setup but also saved me 3/8" and the axle and coils sit a lot better now..

Put a tire on and man these turn ALOT better then my old axles....I think I'm in love...lol


So far left on the list is...


Sway bar links,
The 0.5 bracket for the PS pump (the 5.8 won't work)
Front shocks,
Alignment,
X1 steering stabilizer shock on the duel stabilizer setup.
Mount the 6.0 PS cooler,
Do my tank mods,
Need a nut for the draglink..
Shorten front driveshaft or get a 05+ driveshaft.
Mount the goose neck hitch,
Go on a trip.

 

[broncomitch]

Got the hitch cleaned up and in..

 

[broncomitch]

I'm going to hold off on doing the tank mods cus one, I'm pretty broke right now...and two cus I'll need to drop the tank anyway when I do the 08+ spring swap.


But figured I would check the filters and was very surprised they where pretty clean..
I figured they would be 30% more dirty then that. Lol

 

[broncomitch]

okay, axle swap is done!
all that is left is bleed the brakes,front shocks,alignment and the powersteering stuff witch i should get tomorrow...

the junkyard that i go too got rid of the truck that had the swaybar links and shocks on it...so i just used the ones with the duel shock kit and used the hoops sense i couldnt sell it as a kit now..witch im fine with cus i like seeing em in the wheel opening. hehe

hope by sat ill have it running and driving around.