I just read through this thread...amazing work!!

 

I've never had my truck torn down this far before. Can the portion of the front highlighted in red be removed without actually cutting it out? It looks like it was cut in previous pictures but I wasn't sure if it was due to the accident damage. Really looking forward to see how this turns out. Fantastic job!

 

thanks!




it is spot welded to the structure of the truck. Short answer is no it can not be removed easily

 

 

I believe we left off talking about the need to modify the fan shroud, and upper radiator hose. Here's the progress in that area....


Here's the fan shroud with all the plastic corners filled and glued




Fan shroud mounted on the radiator





Modified and re-indexed upper radiator hose







Hell yea this is looking sweet!

 

Looking good! It's nice to see a swap being done so clean.

 

Thanks Erik

 

dropped the 2003 fuel tank out today. a few comparison pics and see what my goal is here. Doesnt look like the 2015 tank will easily fit (haven't tried yet) just comparing the two tanks

still may end up doing a custom 10-15 gallon fuel cell. still undecided

 

I know it doesn't look like much progress. I decided to use the 2003 gas tank for simplicity. That being said I've got the 2015 pump sitting in the 2003 carrier. Made a conversion bracket to get the 2015 sending unit to play nice on the 2003 carrier as well



I just realized that this picture is the original 2015 sending unit version. but has already been changed again since this picture.....



Just ordered another big round of misc parts. And I will hopefully get the 2003 fuel tank modified (chopped) soon



I kinda am expecting that progress will be slowed with the upcoming holidays... Hoping to find some time to keep plugging away at it

 

Holy cow man! This has been incredible to watch as you progress. This appears to be a daunting task, but you are doing great work. Can't wait to see the final product either; keep it up! I will be beginning a lightning swap on my 2001 Supercrew in the near future.

 

Thanks. Just got the 2003 tank modified and welded. Gonna get it sealed up and it should be just about ready to go back in.

Overdue on pic updating. Sorry about that.

Also have a really neat sub-project that will be starting soon now that the tank modification is complete

 

Using a laser level to ensure i get a straight line






Welding





Gorgeous MIG welds





New back of the tank prior to trimming and cleanup




Going to seal the inside and outside of the tank tomorrow and do a rough install so I can start on my next sub-project......

 

Started in on the tank sealing process on Sunday and found a leaking weld. Gonna have to address that before I can continue sealing the tank up. Here's the pics from this weekend

And that's my new sub-project. Flush/floor battery box


Cut a big hole out. No turning back now lol




Measure twice cut once. Made sure it would clear everything under the truck, and play nice with the shortened gas tank

Diamond plate lid. Has two small Allen screws that hold the lid down


I will probably end up putting some velcro on this top help keep it down when it's not in use




I am really happy with how this turned out. Most people will never know where the battery is hidden at.

Also this helps with front to rear weight balance, as well as lowering the center of gravity a bit too

 

holidays came and went. not much time to play with the truck. hoping to get a lot done this weekend tying up loose ends on the fuel system, and start making a plan with all this wiring going into the truck.

I did get the tank rewelded in the few spots that were leaking, and then sealed. I'll try and get caught up on pics after this weekend

 

Tank sealer mixing






Real test fitting under the truck with the battery box and the modified gas tank. Still need to paint the exterior of the tank, and finalize the fuel pump lines/wiring situation





Removed all the 2003 EVAP junk off the bottom of the truck