49/51 3100, 4bt Turbo, ZF-5, Classic

[andreas_kc]

I've had a 51 pickup in my garage for 10 years now, but after long hibernation I am getting it going.

General plans are to make it close to classic/stock look as possible. I'm planning a 4bt Turbo, manual zf-5, 4-link, 9 inch rear, and mustang ii heidts kit.

I've pretty much decided to swap my 51 cab for a 49 5 window my gpa has that is in much better condition.

[andreas_kc]

Here are some pics from donor bread truck

[andreas_kc]

Frame pics. Had it blasted and painted with por-15

[iowaboynca]

Looks like most of the fun work is almost done! Good luck.

[andreas_kc]

Had a junkyard find for a Torino 9in rear end, only $50... even came with a seized axle bearing! Spent $300ish on axle bearings, gaskets and third member rebuild kit.

Got the rear housing mounted on 4-link today and put third member in. Used one of those fancy lubelocker gaskets. I assume some of the brass/copper rings around the third member bolts were crushed washer parts?

Have to wait til tomorrow to get axles in. Need to find someone to press the bearings on.

Wondering tonight what to do with the breather hose. Not sure if I can run a long hose and clip it somewhere or if I need to attach an actual filter/cap/vent.

[andreas_kc]

Had axle bearings pressed today and finally have 4 wheels! Filled rear end with royal purple. Wheels are just spare 14" rims for temp use. Hope to find 16" wheels that are more perm as I need the space to fit calipers.

[joedoh]

I am interested to see the length difference of the 4BT vs the 6BT, the 6BT guys have a YUGE firewall cut.

what a great donor, I might have tried to use the chassis too and make a wacky hauler.

[andreas_kc]

Rough measurement of 4bt engine is about 38" needed from front pulley to transmission adapter. Seems like it will fit without any serious wrangling. But who knows until it happens! I'm also switching to an electric fan too which is thinner than what's currently attached to the pulley.

I can't allow myself to think about reusing the "taco truck" (what my neighbors have nicknamed it). But sheesh, could get a super cheap 6bt that would likely fit the original mounts... would only need a transmission adjustment... and some cab that has the length.

[andreas_kc]

Some transmission pics, ZF-5 from a small block ford. Ordered new clutch kit, should hopefully bolt to 4bt flywheel wo significant brain damage.

[andreas_kc]

Cut out x-brace on radiator support and got new radiator/shroud fitted. Kit ordered from Brothers Trucks.

[andreas_kc]

Cut out rear crossmember for tire and welded/painted some angle iron to fit fuel tank. Unfortunately depth of 4-link made it a few inches short to fit a replacement tank. Using por15, brush and topcoat black spray can from por.

[andreas_kc]

Test fitting some fuel line plumbing from Speedway. Adding a little fuel breather/vent. 1/2 inch fuel line with aluminum lines and ridiculously expensive AN fittings. 3/8 return line will require drilling a hole in top. Expecting to place the return hole near the sender.

[andreas_kc]

Meanwhile, the 4bt engine is still in process of being pulled out by a local shop. At a bit of a standstill until that happens and then can borrow their hoist to figure out where the engine mounts need to go.

[andreas_kc]

Sheesh fuel tank took all of Sun afternoon. Needed a fuel return line (3/8) that I cut out near the sending unit. Did most of the drilling upside down to keep most of the aluminum out of the tank.

Getting the holes drilled where the tank attached consumed most of the time. As much as I tried to get the holes to line up, sandwiching a band of welded nuts w washer, lock washer, frame, and tank was often off by 1/16 and enough to not tighten.

[andreas_kc]

Made and connected grounding strap to sending unit while oldest made an art table out of the gas tank.

[andreas_kc]

Brakes! Picked up some rear disc brakes that fit my Ford 9" housing. It even has an integrated parking brake without the crazy drum parking brake. It looks like it will line up well with the old stock emergency brake bar that comes out of the frame.

Downside is the 15" rims I've been using don't clear the caliper

[dieseldude4bt]

Looks good can't wait for more.

[andreas_kc]

Brought home the 49 5-window cab. Certainly needs some work but think it will be less work than the 51 cab I have.

[HUSSEY]

I sure don't know my diesels, I had to Google what 4bt was, I had no idea. A 3.9 four cyl. diesel sounds like a cool idea, probably a good fit under the hood too. Looking good!

[andreas_kc]

Did a little painting. Sprayed the rear calipers and engine mounts. Cab door hinge made a great place to hang something to dry

[andreas_kc]

Trying to figure out parking brake cables. I think I'm going to weld a brake clip to one of the running board supports to run the cable to and use that to connect to the old parking brake bar.

[NeoJuice]

Originally Posted by andreas_kc

Trying to figure out parking brake cables. I think I'm going to weld a brake clip to one of the running board supports to run the cable to and use that to connect to the old parking brake bar.

I'm very interested in your parking brake setup. I will be doing the same thing to my truck soon. I have a simular rear disc setup with the cable guide lever & spring on the caliper. I want to hook it up to the stock cross shaft and I'm interested in what parking brake cables your using as well.

[andreas_kc]

Originally Posted by NeoJuice

I'm very interested in your parking brake setup. I will be doing the same thing to my truck soon. I have a simular rear disc setup with the cable guide lever & spring on the caliper. I want to hook it up to the stock cross shaft and I'm interested in what parking brake cables your using as well.

I stopped thinking about this and ending up calling Controlcables. For $60 I am getting a completely custom set of cables that go from the brake calipers to the intermediate parking bar with all the appropriate ends. Will certainly update when I get them and also when installed.

[andreas_kc]

Engine pulling time! Pulled engine out of old bread truck, pretty clean pull as there are not many wires. 4bt is an all mechanical beast, 30 inches tall and 28 inches long.

Made some engine blocks for towing engine block around. Taking it this weekend to have engine mounts welded, driveline set and basic alignment.

[joedoh]

Originally Posted by andreas_kc

well looky there! cant wait to see this in the frame