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Old 10-03-2020, 04:31 PM   #31
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Check the front frame rails just back of the bumper and the area under the battery. Also pull out all the body plugs inside all the fenders at the lowest point of the body and clean out the muck.

The doors have drain holes too. The front fenders have a drain at the bottom of the stamping forward of the wheels. Spray water in the cowl to get them cleared out.

If you carry on with the van spray it with Corrosion Free. Good enough for the army. Creeps everywhere unlike Waxoyl.
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Old 10-03-2020, 05:32 PM   #32
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Once I make sure I have it fixed I'll start on things like rustproofing and soundproofing before the actual buildout.
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Old 10-04-2020, 06:09 PM   #33
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Sprayed the greasy/oily parts of the undercarriage with degreaser today and will let it sit and hit it with the pressure washer. That's all I got done since I'd helped neighbors split their firewood. They had given me most of the tree so it was the least I could do.

I'll spray with preservative later and check all those drain holes and suspect areas.
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Old 10-07-2020, 05:03 PM   #34
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Well, I hit a snag today. I was not going to report on the mechanical issues, only on the build-out but I removed the heads and discovered the expected bad spot in the head gasket, this on cylinder #2 that was one of the two at 0 PSI in the compression test.
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The surprise came on cylinder #4. No signs of other damage; all the valves look good so no telling what caused this. Now I need to figure out how to proceed. Short block? Used engine? Replace that one piston and proceed as planned? Abandon project completely?
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I'll let you know what happens.
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Old 10-08-2020, 09:35 PM   #35
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I'd put a compression tested used engine in it.

Do the Hughes engine plenum gasket kit, their deburred timing chain set, and the V6 chain tensioner.

Cheer up. A 6.0 Ford diesel repair would cost more than your Sporty.
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Old 10-10-2020, 04:47 PM   #36
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Got the piston out today. It's kinda scuffed but the cylinder looks okay. I'll hone it and decide after that.
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Old 10-11-2020, 01:19 PM   #37
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Funny coincidence.

The 5.2L Magnum I swapped into my 84 B350 had a stuck intake valve from sitting for years. I forced it to turn over with a bar before installation.

It ran on 7 cylinders until I pulled the head and replaced the valve. Worked fine after reassembly. The jam left a small mark on top of the piston.

In cylinder #4.
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Old 10-11-2020, 06:38 PM   #38
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It's the curse of #4, I tell ya!
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Old 10-17-2020, 09:09 PM   #39
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There's also a curse on #6. I had to order a second piston but the cylinders should hone nicely and be okay.
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Old 10-18-2020, 08:28 AM   #40
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Quote:
Originally Posted by Pntyrmvr View Post
I'd put a compression tested used engine in it.

Do the Hughes engine plenum gasket kit, their deburred timing chain set, and the V6 chain tensioner.

Cheer up. A 6.0 Ford diesel repair would cost more than your Sporty.
There's all sorts of truth and good advice in this post. I bet there are lots of these engines to be had in yards since these vans are getting more and more rare.

I don't speak Dodge but I'm sure this engine is common to lots of trucks and other Chrysler-y things.
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