I ordered a distribution block. Ziptied everything for now as i lay out the power cable




Routed the power cable out the bottom left corner of my cab






[side tracked project]
I built a proper amp rack finally, and cleaned up the wiring for the amp






Location area of the distribution block






I ended up flipping the amp rack, put the wood behind the aluminum angle strip. Looks cleaner, and fits better after test fitment of the back wall trim panel

 

my distribution block showed up. got it installed

more to come this weekend hopefully

 

Got my 150A fuse holder installed on the second half of my amp rack. Really like how it turned out







This is the power wire coming off the back bottom corner of the cab. Put it in split loom and taped it to protect it where it is around possible rub areas








Power wire taped and routed over the frame just behind the leaf spring hanger. Getting close










started routing the frame rail harness along the inside of the frame. With the 2003 EVAP vent hose deleted, I was able to use the factory clip to secure the new harness in a few places

 

Threw together a video going over some of my recent progress:

 

I got the FPDM mounted, I also got the main ground cable installed from my kill switch to the frame

 

this is a awesome thread!




great job patman!!

 

Thanks

 

set back the BJB to make a template for my firewall bolt on panel

[also seam sealed the welded area on the firewall after we replaced the RF upper rail] will paint over that before hanging the sheet metal for the last time




This is the body harness going into the cab on the passenger side. Will have to de-pin these connectors to push the wires through the grommets







Test fitting with the 2003 PCM grommet for the firewall






installed threaded inserts for bolting the panel to the firewall




Drilled and test fitting grommets. I'll have two grommets for the body harness, and the bottom one for the main power cable for battery relocation





Shot in flat black primer for tonight. Ill probably paint some more tomorrow before installing it







I went ahead and ordered a factory 2003 wiring diagram book for my truck. I've got it electronic copy already, but having it in a hard copy will make it much easier




This really sums up how much more complicated 2015 vehicles are compared to 2003. Almost twice as thick!

 

I know it doesn't look like much, but I now have 9 hours in fabricating this plate, and the associated wiring with the plate. Depinning the 59 pins in several different connectors, and routing the harnesses through the two grommets

Im super happy with the way it turned out. On to the next mini project.

 

I emptied the bed and began working on the battery box and finalizing that wiring










Nothing gets thrown away. This is the original 2015 battery cable which I cut off to add a crimp connector to. It will now be reused in the battery box. The battery terminals that came with the relocation cable kit are too tall to fit under the box lid. I would have had to change the hardware out and/or modify them. Using factory terminals streamlined that process for me.





I made this cute little power wire




It was much easier to mock up cable routing with the battery box out of the truck. And then the final install would go much more smoothly





Ford 450A Mega fuse and holder, courtesy of my time working at Land Rover, we used to remove these as part of the new car inspection as they were taken out of transportation mode (limited functions to preserve battery), and moved into regular service




Final install. I put threaded nut inserts into the floor on each corner. And used extra OE Ford fender bolts since they have a nice big washer built into the head







And I also hung up the front end sheet metal. Took a little while to get it all adjusted where I was happy with it. I now have front end parts from 4 different vehicles.

2003 Original drivers fender
2003 Donor core support
2001 Expedition Fender
2001 Lightning hood


Im super pleased with my progress this weekend, it feels like its coming together nicely. Now its time to heavily focus on the interior.

I also still need to finish the fuel tank/lines/pump situation
And I still need to order a driveshaft as well


Until next time

 

Patman, I haven't been active over here in a long time but I have been following your swap and I have to say it is a thing of beauty. The amount of talent and patience you have poured into this project is really impressive. I cant wait to see you finish this thing up.

 

Thank so much for the genuine/sincere comment. It really does help keep me motivated and encouraged

 

Pulled my 2003 cluster out, and comparing it to the 2015 cluster

Both with bezels and lenses removed






Just a little trimming




Just look at all those weight savings! Every little bit adds up




Sat the bezel on top of the now heavily modified cluster. I'm also cutting up the back of a spare 2003 cluster I have to be [hopefully] able to use factory dash mounting points.....


As a side note if anyone cares, I'm 238.5 hours into the swap project as of the end of tonight's work

 

Excellent work. Your ingenuity and attention to detail is top notch.

 

I only subscribed to this, because I have nothing to add. However, this is phenomenal work. I considered swapping a coyote into my 2005 when the 5.4 dies, but this is making me reconsider! Nice work!

PS, good thing the fuel door is on the same side on both trucks! That would be a silly detail to have to work out