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Old August 1st, 2009, 09:18 PM   #41
camccardell
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I ask that you forgive the blurry-ness of the photos, but the first fender is spot on. The 2nd will need some shimming.
Speaking of shims, anyone know where to get some cheap, because mine are rusted as all getout. Had to use the energy suspension bushings and spend an hour or so on the wire wheel.

Anyway, enjoy!







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Old August 15th, 2009, 09:25 PM   #42
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Got the rear discs on finally!

Had one hell of a time getting the brackets right. Apparently the ruffstuff brackets don't work too well on a 95 sterling, but Dan was cool and had some custom made, and here they are!



I also got the engine running, as well as installed a lot more accesories.

Need to tue up a lot of odds and ends, but so far everything is great except I cannot get the alternator to charge the battery.

more pics soon!
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Old August 15th, 2009, 09:28 PM   #43
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Looks Good! Keep up the Good work.
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Old August 15th, 2009, 10:37 PM   #44
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Originally Posted by camccardell View Post
Need to tue up a lot of odds and ends, but so far everything is great except I cannot get the alternator to charge the battery.
Take it up to an auto parts and have them test it. Sounds like the regulator may have went bad. That or check all your plugs for corrosion.

Nice looking truck so far. Definitely looks more complete than when I seen it last.
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Old August 16th, 2009, 06:40 PM   #45
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here are some pics I took today.
Still a long way to go, but it is definetly on its way.



hood is just coverin everything up for now, still needs to be fixed before I bolt it on


nothing hanging down anymore!


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Old November 15th, 2009, 05:39 PM   #46
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so here we are today, exactly 2 months since the last post, and the thing seems to be going backwards.

I had to pull the tranny back off to fix a huge oil leak. Got that back on and put on the rebuilt t case too (lots of fun putting a e4od back on by yourself, lemme tell you!)

The bigger booster from ebay ended up being a p.o.s. and had an internal leak. Took me awhile to figure out while the engine was idling so friggin high, bit I found it. I installed the new booster today.



I also replaced the rear diff cover with the one that I got from great lakes offroad today.
I posted a picture, you guys tell me what you think. I personally think that the lip is too damn narrow, and am worried about seepage, but we will see I guess.

The bolt holes are huge, like bigger than 3/8 maybe even 7/16 yet the bolts are wayy smaller than that so they float around in the cover. I also had to grind off al the slag inside the cover, and dicided not to on the outside. The inside of the cover was not welded at all. I threw some paint on it after cleanin it up.

I have never ordered anything from gl offroad before, but I am kinda concerned with this diff cover. Hell it will probably sit on the rear axle for another year before it ever sees any abuse anyway though.


Anyway, the Y pipe is damm near touching the oil pan. I don't remember it being that close before I installed the headers. Anyone out there have a 5.8 f series or bronco with a digital camera? I could use a stock pic for reference.

I ordered all new lights and they should be here later this week.

I also transferred all the accessories, and she is just about road legal, so I am kinda ancy!

I broke the hood release cable, so i gotta fab up something to be able to pop the hood.

Still needs a front bumper, Hoping to make one out of plate steel, just not sure how I'm gonna mock it up. carboard?


later for now

Last edited by camccardell; November 15th, 2009 at 05:44 PM.
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Old November 15th, 2009, 06:31 PM   #47
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So you get what you needed for the oil cooler?
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Old November 15th, 2009, 08:14 PM   #48
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That cover would concern me, too. Glad to see the t-case is going to be used instead of just sitting here forever.

You've done way more than I've been able to.
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Old November 25th, 2009, 09:37 PM   #49
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This project is sweet. Its kinda like mine!
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Old February 22nd, 2010, 07:58 PM   #50
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1st test drive happened yesterday.
I know, I know... You want pics.
I was going to take some today, but the truck is buried in snow.

I still need a front bumper and I need to fix some exhaust issues, but I am really motivated to get it finished now.

Sad thing is, I will probably be tearing it apart again to do a SAS soon now that I have my custom sterling front axle built.

Pics commin soon!!!
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Old March 17th, 2010, 10:59 AM   #51
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Took it out to "break it in yesterday"
Got it a little muddy, and broke the rear driveshaft. Totally awsome.
New shaft has been ordered and a new exhaust as well.
Damn header leak. I will be making my own y pipe as well with 2.5" tubing and 3" exhaust after the collector.

Anyway, here are some after pics.



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Old March 17th, 2010, 07:51 PM   #52
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The driveshaft must have been compromised already or something. I've beat the crap out of several of them in my trucks and never broke one. Still don't have a bumper?
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Old March 17th, 2010, 07:56 PM   #53
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yeah, no bumper yet. Still thinkin about making one.
The shaft was from a ranger and had an awsome 1310 to 1350 adapter joint on it. Shoulda saw that one comming!
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Old March 17th, 2010, 10:37 PM   #54
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So does this mean your putting in a full 1350 shaft in now? Find one reasonable?
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Old March 18th, 2010, 02:35 PM   #55
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Well my Uncle Sam christmas happened today!

Got my new driveshaft and my parts for my new exhaust.





Check out that yoke! I went 1350 all the way.




I'll be putting the headers on today, and hopefully making the y pipe tommorrow.
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Old March 18th, 2010, 08:39 PM   #56
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well if it wasn't for bad luck....

The driveshaft is at least an inch too short. I have 2 1/2" of slip yoke hanging out past the seal.

I bought a new USA 3/8 tap to clean up the holes for the header bolts and went on cleaning them out. I was using a wratchet and just swinging it easy as pie and the damm tap broke off inside the head.
I can't get a pair of needle nose pliers on it, so I'm gonna try welding a rod to it and see if I can't just twist er out.

I'm done for the day.... Blaugh
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Old March 18th, 2010, 11:03 PM   #57
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How much is sticking out(if any)? If theres a bit sticking out, you might be better off trying to weld a nut to it. Just get it really, really hot so it burns in good.

For future reference, I've never heard good things about using taps in heads. Thread chasers are the only way to go.

What was wrong with the current headers you have? And that Flowmaster scavenger Y is gonna make a big difference. I've made a few like that myself and its a very noticeable gain.

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Old March 18th, 2010, 11:43 PM   #58
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Quote:
Originally Posted by camccardell View Post
well if it wasn't for bad luck....

The driveshaft is at least an inch too short. I have 2 1/2" of slip yoke hanging out past the seal.

I bought a new USA 3/8 tap to clean up the holes for the header bolts and went on cleaning them out. I was using a wratchet and just swinging it easy as pie and the damm tap broke off inside the head.
I can't get a pair of needle nose pliers on it, so I'm gonna try welding a rod to it and see if I can't just twist er out.

I'm done for the day.... Blaugh
suck, gotta hate days like that. the truck is looking good though!
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Old March 19th, 2010, 09:19 PM   #59
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thanks guys.

Well I got the busted tap out today. I also double checked the driveshaft and the yoke was throwing me off. It still sticks out 1/2" from the seal even when it is bottomed out. So I still have almost 2" of the slip yoke exposed, but at least 3" is on the t case, so I guess it is gonna be ok.

I did manage to get the pass side header installed before the phone rang and I had to go in to work.

I got the rest of my parts today and my new mig welder, so as soon as the weather clears, I'm back to work.
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Old March 24th, 2010, 10:25 PM   #60
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Horray! The headers are installed, the pipes are on and everything is welded up.
Got er running and burned all the paint off the headers. Everything seems to be moving along.

I still need a front bumper and I think I am hearing a lifter. I hope not, but I hear it in the exhaust and don't know what else it could be. Cheap fix, but I don't wanna have to pull off the intake.

I wonder if there is a piece of crud in one of the pushrods. The noise is comming from the passenger side, so I think I'll be pulling off the upper intake so I can at least take off the valve cover and take a look.

2 steps forward and one step back...
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