Rod's 84 BabyBajaF100

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AussieRod
Posts: 2804
Joined: Sun Sep 05, 2010 1:43 am
Bronco Info: 81 Bronco XLT, 250 alloy head crossflow 6, NP435/NP208, 4:10 gears, 31-10.5R15 M/Ts.
Location: Downunder

Re: Rod's 84 BabyBajaF100

Post by AussieRod »

Monday April 10:
Well, it started raining about 4 pm Saturday and didn't let up until early this morning. Saturday, I refitted the front springs for now, removing the front quad shock mounts. I'm going to run singles behind the coil for now until rego, then fit my Autofab buckets, etc. and the Fox 10" coil-overs (minus coil seats and hardware)I have sitting there doing nothing along with the leveling springs. I also did a detailed leak inspection and have some work to do. The pinion support on the 9" is weeping at the join, so that might need removal and re-sealing. The t/case rear seal leaks, I pulled that tonight to order the correct one after work tomorrow. The front t/case seal is damp, but I will do that one when I change the fluid after 2 - 300 miles of driving to clean and flush out any shit inside. No sense wasting all that new fluid just yet. The other leak is the heater hose that goes to the nipple pressed into the block under the alternator. It WAS rusty when I put the engine in, and it weeps water once pressure builds up, so that will need to be replaced. I'll order a brass replacement later this week and fit it when I find a few hours to tackle it. Sunday I spent finishing off the wiring connections to the trans cooler fan from it's solenoid and the wires for the radiator fans. I also ran the BajaHID HID harness across the front in preparation for the headlight inserts, etc.If the weather fines up, I'll sand and paint the grille and headlight surround accents satin black and get them ready for the headlight inserts install.
The driveshaft guy swapped the front uni in my driveshaft for the correct one tonight after work while I waited, so that's ready for duty, and I pick up my 2 1/4" mandrels tomorrow, so I can make a start on the Y pipe.
Some pics:
Driveshaft:
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Radiator and trans cooler wiring:
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Choke mechanism on:
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BajaHID at work:
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P clips holding the heater hoses:
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I'll take more as it progresses.
Cheers.
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AussieRod
Posts: 2804
Joined: Sun Sep 05, 2010 1:43 am
Bronco Info: 81 Bronco XLT, 250 alloy head crossflow 6, NP435/NP208, 4:10 gears, 31-10.5R15 M/Ts.
Location: Downunder

Re: Rod's 84 BabyBajaF100

Post by AussieRod »

Good Friday, April 14th:

With a few things to do at home (vacuum all the cobwebs from the eaves in the rooms, and do the floors, sofas etc., clean the toilet and help prepare food for dinner visitors), I didn't have a lot of time to work on the truck today. However, I found time to install the new rear t/case seal and re-fit the polished and cleaned yoke, finish connecting/soldering in the few wires behind the cluster that needed doing and get all the exhaust bits together to try and make a start on the Y pipe. I was off sick again Wednesday with viral runs, so not a lot was managed there either. Thursday, I picked up the new seals after work, got the manifold stubs expanded to match the mandrels better and sorted through some odd stuff in the shed for an Ebay sale. I've also noticed that now the pinion support bolts are tight, the weep has stopped (for now).
Tomorrow, after the Handbrake goes to work, I will remove the bench seat, clean and secure all the dash facsia, and try and make the radio work (it won't at the moment), then make a start on the Y pipe. I scored a few 3" bends from work, leftovers from another job we did, which should allow me to get the Y pipe mostly done so I can start thinking about routing the muffler and side pipe. If the weather holds for the next few days, I will try and get the tub prepped for paint before we head off in May for a holiday to Alice Springs. Until I get the U bolts, it isn't drive-able, so other things can be done until then. I'll cut material for the seat frame and get that well and truly under way before the next weekend, although I still don't have a shifter cable to be able to safely shift the auto yet. I might even sneak into work tomorrow (Saturday) and see if I can get some used garnet to start blasting my towbar/bumper and get that ready to fit. I can also give the side tank a quicky blast to remove any dirt and surface rust and get some paint on that ready for a fit-up once I can order the stuff for that. I'm determined to keep momentum on this to get it done.

I'll post pics tomorrow night and keep y'all updated.
See ya.
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AussieRod
Posts: 2804
Joined: Sun Sep 05, 2010 1:43 am
Bronco Info: 81 Bronco XLT, 250 alloy head crossflow 6, NP435/NP208, 4:10 gears, 31-10.5R15 M/Ts.
Location: Downunder

Re: Rod's 84 BabyBajaF100

Post by AussieRod »

Saturday April 15th:

Well, I didn't do any work inside the cab, instead I did some re-wiring in the carport to re-position some lights. I have 2 flouro tube lights that are dead, so one of them got the flick and I re-positioned another that still works to throw light better on the back of the truck. Previously, it was above the cab and wasn't much use. Now that the days are shorter and light is disappearing fast in the afternoons, I need to get the lights up to scratch so I can work longer.

After I did that, I got started on the Y pipe. I trimmed some excess of the 45 deg bend and added it as filler for the 90's. The picture is lousy, due to it getting dark, the camera always does this is poor light:
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I also installed a 25 amp Deutsch plug on the radiator fans loom end, ready to make the connector harness to the fans after install:
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I'll start on the inside tomorrow, when the light is better, after I install the Y pipe and test run it.
More tomorrow.
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Tchajagos
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Rod's 84 BabyBajaF100

Post by Tchajagos »

The 16 gal side tank fits the 4x4 x-fer case if you are running the shorter C6 trans. Most of the early step side 4x4 f150-f100 short bed single cabs had only side tanks. I'm switching mine to the e4od and the trans is long enough to where I can't run the side tank. You will notice all the later 4x4 F150 single can short bed trucks only have a rear tank because of this.
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AussieRod
Posts: 2804
Joined: Sun Sep 05, 2010 1:43 am
Bronco Info: 81 Bronco XLT, 250 alloy head crossflow 6, NP435/NP208, 4:10 gears, 31-10.5R15 M/Ts.
Location: Downunder

Re: Rod's 84 BabyBajaF100

Post by AussieRod »

Tchajagos wrote:The 16 gal side tank fits the 4x4 x-fer case if you are running the shorter C6 trans. Most of the early step side 4x4 f150-f100 short bed single cabs had only side tanks. I'm switching mine to the e4od and the trans is long enough to where I can't run the side tank. You will notice all the later 4x4 F150 single can short bed trucks only have a rear tank because of this.
Short beds with 4WD here are a rarity, usually only F250's were available in that combo and I've only seen one, so I was unable to find out visually if the t/case would fit or interfere, that's why I went with the rear tank, for that purpose only. I've actually now put my side tank under the truck and verified that it does fit with my combo (AOD and NP208) in a short bed. I have about 2 - 2 1/2" of clearance, more than enough to work without interference. Everything bolted up no problem (trans and t/case) without having to re-drill any holes. The only mod was to the t/case selector. I will run both fuel tanks, along with the propane tank for maximum range, as I plan to do a lot of trips into central Arse-tralia where propane isn't readily available. When I can find one that's affordable, I''ll fit the 38 gal tank in the rear to give me even more range. Postage on these things kills me, seeing I have to pay 4 of our south pacific pesos to 3 of your $.
Get into yours, I want to see it going! :D
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AussieRod
Posts: 2804
Joined: Sun Sep 05, 2010 1:43 am
Bronco Info: 81 Bronco XLT, 250 alloy head crossflow 6, NP435/NP208, 4:10 gears, 31-10.5R15 M/Ts.
Location: Downunder

Re: Rod's 84 BabyBajaF100

Post by AussieRod »

Sunday April 16th:

Y pipe fitted. It has a slight leak at the flange bell, but I will fix that later:
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I have other pics, just need to resize them a bit. Later.
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AussieRod
Posts: 2804
Joined: Sun Sep 05, 2010 1:43 am
Bronco Info: 81 Bronco XLT, 250 alloy head crossflow 6, NP435/NP208, 4:10 gears, 31-10.5R15 M/Ts.
Location: Downunder

Re: Rod's 84 BabyBajaF100

Post by AussieRod »

More (re-sized) Y pipe pics:
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Turned the chassis bolts up the other way so they don't interfere with the side tank re-install:
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New t/case seal:
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I'll attack the inside tomorrow, measure up for the seat frame, console and shifter mount, make some ballast mounting plates etc. Still have plenty of little things to do, still waiting on stuff to arrive and need more money.
I'll keep the updates coming.
Cheers.
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AussieRod
Posts: 2804
Joined: Sun Sep 05, 2010 1:43 am
Bronco Info: 81 Bronco XLT, 250 alloy head crossflow 6, NP435/NP208, 4:10 gears, 31-10.5R15 M/Ts.
Location: Downunder

Re: Rod's 84 BabyBajaF100

Post by AussieRod »

Thursday April 20th:

The t/case U bolts arrived today, but I was tied up with a doctor's appointment and cleaning up the back shed to do anything before it got dark. However, after dinner, I went out and installed the rear driveshaft and everything fit nice. I will have to get a Bronco rear CV joint and graft it on later, as the angle is already acute and with any lift, will get worse and cause interference at the t/case yoke with the driveshaft, unless I clearance it. I'll just have the CV joint installed later on, that will fix the issue permanently.
I'm going to finish the seat cradle before I drive it. I've made mounting brackets to bolt on the floor, and I will cut the tubing and angle for the cradle proper tomorrow at work, but I won't get anything done until Sunday. Once the driver's seat is securely mounted, I will hook up a shifter and take it for a spin around the yard to drive it for the first time in 5 YEARS. Sunday, I;ll do an update with pictures and report further.
Cheers.
Dust
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Re: Rod's 84 BabyBajaF100

Post by Dust »

Has to feel good to be so close to the yard spin stage!
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AussieRod
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Bronco Info: 81 Bronco XLT, 250 alloy head crossflow 6, NP435/NP208, 4:10 gears, 31-10.5R15 M/Ts.
Location: Downunder

Re: Rod's 84 BabyBajaF100

Post by AussieRod »

Dust wrote:Has to feel good to be so close to the yard spin stage!
It is. I'm being patient, though. I want all the little things finished before I drive it, so I can appreciate it all the more. :D
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AussieRod
Posts: 2804
Joined: Sun Sep 05, 2010 1:43 am
Bronco Info: 81 Bronco XLT, 250 alloy head crossflow 6, NP435/NP208, 4:10 gears, 31-10.5R15 M/Ts.
Location: Downunder

Re: Rod's 84 BabyBajaF100

Post by AussieRod »

Wednesday April 26th:

I made my seat cradle. I had it all tacked up yesterday, but ran out of mig gas before I could weld it up proper. So, I took it into work today and welded it up during my break. It's now fitted in the truck with the driver seat mounted, I"ll have to do the rest when I get back as I have no time now other than pack it away.
Mounting brackets:
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tubing sitting in place:
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Driver's runners tacked in, passenger runners being tacked:
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Prior. Screwed up the hole centre measurment for the tracks, redrilled:
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tacked up, ready to take out and weld up:
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If I have time tomorrow, I'll snap the seats in place, just have to fab a mounting plate for the centre console, weld it on and fab the shifter mount (once it arrives). Once the shifter is mounted, the cable installed and the electrics done, I can drive it.
I'll update in a week or two. Check out my trip report after Saturday, I will post up when I have internet access.
Cheers.
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AussieRod
Posts: 2804
Joined: Sun Sep 05, 2010 1:43 am
Bronco Info: 81 Bronco XLT, 250 alloy head crossflow 6, NP435/NP208, 4:10 gears, 31-10.5R15 M/Ts.
Location: Downunder

Re: Rod's 84 BabyBajaF100

Post by AussieRod »

Sunday May 14th:
Well, I'm back. 6,000 km in 15 days is enough for me for a while. The trip was breathtaking, and busy, but we fitted a lot in for the time spent. Really needed another week, but I'll take what I can get.

Got the F100 out of the garage today, after cleaning up it's usual rest area. Had to pull it up the drive with ratchet straps, as I count NOT push it up on my own now the driveshaft is in.Gonna measure up the mounts needed for the console box and shifter mount tomorrow night so I can finally drive this thing. It's been 5 years, a few more days won't hurt (much). :roll:
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AussieRod
Posts: 2804
Joined: Sun Sep 05, 2010 1:43 am
Bronco Info: 81 Bronco XLT, 250 alloy head crossflow 6, NP435/NP208, 4:10 gears, 31-10.5R15 M/Ts.
Location: Downunder

Re: Rod's 84 BabyBajaF100

Post by AussieRod »

Bloody 'ell! I've been busier than a one-legged man in an arse kicking contest and haven't had any time to work on the truck. Also, I've been hammered by bills, and I'm still behind. Hopefully I'll be caught up by next payday or 3, then I can get back into buying the last few bits so I can drive my bloody truck! I might have to rob a few things if we need them for Mike's bronco, but I'll wait and see. More soon (hopefully).
VintageIronFab
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Re: Rod's 84 BabyBajaF100

Post by VintageIronFab »

Keep the faith Rod! LOL
http://www.vintageironfabworks.com

77- "Victoria"
71- "Annie" Halfcab
73- "Heloise"
96- "Cheryl"
95- Marilyn (F150)
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AussieRod
Posts: 2804
Joined: Sun Sep 05, 2010 1:43 am
Bronco Info: 81 Bronco XLT, 250 alloy head crossflow 6, NP435/NP208, 4:10 gears, 31-10.5R15 M/Ts.
Location: Downunder

Re: Rod's 84 BabyBajaF100

Post by AussieRod »

Halloween 2017:
Time for a minor update.
Well, I am 95% going for my 400M engine into the F100. I can use Mick's old Bronco engine rebuilt, but the extra 50 cubes, 50 - 75 extra HP and 100+ LBS- FT of torque are really pointing me in that direction. I've found out by carefully measuring the engine mounts, the 400M will fit the small block mounts, but will set the engine back 1/2 an inch (or forward 1/2 an inch depending on which mount goes where). Anyway, since I pulled the 351 out for Mick's Bronco, and I'm not comfortable using someone else's engine in my truck, I'm going to suck it up and rebuild my own. I'm having trouble finishing this post because I'm so f-ing tired, so I'll update further later this week.
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AussieRod
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Bronco Info: 81 Bronco XLT, 250 alloy head crossflow 6, NP435/NP208, 4:10 gears, 31-10.5R15 M/Ts.
Location: Downunder

Re: Rod's 84 BabyBajaF100

Post by AussieRod »

July 27, time for an update:
It's been a hectic year, with early on, almost everything that could go wrong, has. However, with the new work away job, I've managed to get back on top of things very quickly. As of last swing away, I've shifted to 2 weeks on, 2 off, so now I have some real time to get a lot of things done. The first few months were focused on Mick's Bronco, which so far, is going great guns, except for some brake gremlins. Mick is very happy with the end result and now I am freed up to start back on the F truck. Up to last swing, I've literally doubled my income and then some, so I've been buying bits and pieces for the truck and storing them for the day I have time to use them. The main focus has been freshening up the old 351C out of the Bronco and getting it ready for install. First, I cleaned up the block and de-glazed the bores. The crank showed some damage from the lack of oil pressure, with the back 2 crankpins measuring 0.004" under, so I had the big ends ground down to 0.030 u/s and the mains polished. The next cam up from the Elgin cam in the Bronco and new lifters, Rollmaster timing set and new Melling std volume oil pump with Milodon drive completed the bottom end. To top this off, we have used the old mechanical open chamber heads from the XB Falcon we used to drag race. These had been pocket ported and matched, machined for screw-in studs and guide plates and PC seals, all I did was have them tanked, new Ferrea 2V stainless race valves and new seals, with the inner Isky 8005 spring removed and on they went. Mick splurged on some new hardened 5/16" Speed Pro pushrods, Manley guideplates and Scorpion roller rockers.
After getting the truck out of the garage where she has been for the last 5 months, I wheeled the engine to the doorway for a final clean and freezeplugs before taping it up for a coat of Ford Blue:
Some of the stuff I bought.
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The new power unit 1
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The new power unit 2
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I spent the afternoon fitting the water pump, alternator, etc and generally getting it ready for install. The rockers have all been adjusted, the intake will get washed tomorrow and installed, along with the distributor, and once I find the bloody seperator plate, I'll sling it up, fit the plate and flex plate and start the install. The plan is to fit this engine, run it in on gasoline and get the truck finished while I organise my own new engine. I'm saving for a Pavtek 393 stroker DIY kit, and getting my own block machined at the same time. This will have a Comp 270S solid lifter cam kit and topped with 2V AFD alloy heads and Edelbrock Air gap Performer.
Oh, I almost forgot. I managed to get hold of a nice set of Alcoas from an importer in QLD. They came off a 94 F150 and came with nuts and caps, so I will fit the 32's to those and see how they look. I have 2 steel rims for spares, these will get powder coated silver and wear the same boots.
Anyway, more updates to come, as I progress during this stay home.
Cheers :D
Dust
Posts: 781
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Location: Central Oregon

Re: Rod's 84 BabyBajaF100

Post by Dust »

I was just thinking about this build yesterday.
Good to see you back on it!!
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AussieRod
Posts: 2804
Joined: Sun Sep 05, 2010 1:43 am
Bronco Info: 81 Bronco XLT, 250 alloy head crossflow 6, NP435/NP208, 4:10 gears, 31-10.5R15 M/Ts.
Location: Downunder

Re: Rod's 84 BabyBajaF100

Post by AussieRod »

New heart, ready for install:
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Installed, waiting for it's Autofab race engine mounts:
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Stuff waiting to be installed:
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Starting to get excited, hopefully it will be running and I can drive it before going back to work.
More soon.
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Nick
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Re: Rod's 84 BabyBajaF100

Post by Nick »

I'm happy to see that you're still working on this!
"If at first you don't succeed, it may be cheaper to buy it."
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AussieRod
Posts: 2804
Joined: Sun Sep 05, 2010 1:43 am
Bronco Info: 81 Bronco XLT, 250 alloy head crossflow 6, NP435/NP208, 4:10 gears, 31-10.5R15 M/Ts.
Location: Downunder

Re: Rod's 84 BabyBajaF100

Post by AussieRod »

Nick wrote:I'm happy to see that you're still working on this!
Thanks, Nick. Don't worry, every time I've walked past it in the garage I've had guilt pangs because I'm not working on it. Now I have both time AND money to (hopefully) finish it. :oops: ;)
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