DNFXDLI's 79 F150 Build Part1

[DNFXDLI]

Did more cleaning/prepping today...kind of made a grim discovery...at one point I would guess a bearing failure in the pinion as the case has a nice gouge in it. The front pinion bearing is a non OEM type and the race is galled. The ring gear looks original looking at the stamping on it and didn't get damaged. I'm thinking that it happened at low speed and the owner at the time stopped right away.
Going to go and pick up the transmission case tomorrow as well to start cleaning it up.

Pinion race:

Bearing:

Fits the ring gear nicely

 

[m78]

The 205 is easily capable of handling that kind of power...and with that converter, driveline shock load should be minimal...don't forget, I'm only going to run a 31''-32'' tire...no bigger.

The 1980 CJ-7 I had , had a 300 transfer case. Its similer to the 205. It handled the Chevy 350 & muncie 465 that I put in it just fine. I did spin axles, spun up both drive shafts and broke in two, broke several yokes.

 

[DNFXDLI]

Got the transmission case back, started to clean up the case castings:

Damn crappy castings...got pieces flaking off, but best to catch it now before powdercoating:

Still cleaning up the axles:

 

[DNFXDLI]

Ordered up a complete overhaul kit for the 205 from Quad4x4.....also ordered up all bearings/seals for both axles from the same place....http://www.torqueking.com/NP205 rebuild kits.htm
Still cleaning/deburring/blasting stuff.

 

[bucks77ford]

Quad 4x4 is a nice place to deal with. I've had good luck with them. Your powder coater should be giving you a heck of a deal with all the stuff you are coating. When you get this truck together, you'll have to do a write up and submit it to a 4x4 magazine or something. Can't say it enough, this is a heck of a build and should be recognized. Off topic a bit, but have you or anyone else ever used a DIY powder coat process. I've thought about getting a small oven and one of those eastwood kits for small parts like brackets and what not.

 

[DNFXDLI]

Thanks Buck...I just want to get the truck as perfect as I can. I haven't heard of anyone that I know taking the DIY approach to powdercoating, it seems to get sent out to be done.

 

[Truckin4life]

as well documented as it is, i think you could make a submission...

 

[m78]

Is there an easy way to fill those casting holes ?

Harbor Frieght has some inexpensive powder coating supplies. It would be a cheap way to see how it would work.

 

[5.0Flareside]

Is there an easy way to fill those casting holes ?

Harbor Frieght has some inexpensive powder coating supplies. It would be a cheap way to see how it would work.

there arent Harbor Freights in Caniduh..... lol..... they have Princess Auto's


EDIT: thought you were talking to D...

 

[m78]

fixed it

Off topic a bit, but have you or anyone else ever used a DIY powder coat process. I've thought about getting a small oven and one of those eastwood kits for small parts like brackets and what not.

Harbor Frieght has some inexpensive powder coating supplies. It would be a cheap way to see how it would work.

 

[DNFXDLI]

I have filed/dremeled/grinded most of the casting holes away.

 

[m78]

I have filed/dremeled/grinded most of the casting holes away.

Dosn't that thin out the case ?

 

[DNFXDLI]

Dosn't that thin out the case ?

Maybe a tiny bit, but most of the imperfections have been very shallow or simply extensionso of the mold in the casting process. There is one however that is on the top just below where the converter would go that has an actual crack inside which was factory ground...I will be having that TIG'd up just in case although it's been like that since day one.

 

[m78]

I forgot about this stuff . I have some in the garage.

http://aluminumrepair.com/land/index.asp?src=google&gclid=CNfR9vX4tagCFch-5QodNkD5Bg

 

[DNFXDLI]

Interesting Mark!. Got the case done to the point to take it to the powdercoat place. Degreased the transfer case reasonably well, going to go drop that off so I can get the case back for grinding as well.

 

[smokey]

It's slowly all coming together
I have some of those aluminum repair rods I picked them up at Carlilse car show.
They work great have used them to repair many different things.

 

[Ranger429]

Can't wait to see this finished.

 

[LEB Paul]

Great work Duncan, x2 on can't wait to see it all done!!!

 

[Dirky]

That C6 case looks real nice. Good work!

 

[DNFXDLI]

Thanks lads...still have a bit more left on the case. Picking up the frame in the morning and dropping off the case to get that little crack TIG'd up. I did look at that repair rod that was mentioned, but I would just rather go the TIG route.
Quad4x4 has got all the bearings and seals together now for both front and rear axles.