Haven't posted up for a bit but have been slow and steady on progress.
Ran into issue with donor rear axle being from an Excursion and not an F250/350, workable but didn't want to go that route (spacers and different brake setup) no Frankenvan for me. And since the first axle was a train wreck anyway I grabbed another, correct axle. Live and learn.
Progress so far...
New rear leafs SD (43-1033HD) 4+1 2250# rather than the original 2+1 1625#
3" blocks and trimmed down u-bolt excess
swapped rear pinion yoke from flange to u-joint style
used 13 to 14 series u-joint to bolt up OE driveshaft (temporary until Xfr is in)
new brakes all the way around, pads/calipers/rotors/hyd lines
Reamed out OE pitman, again temporary, need to move projects around
All brackets torqued down to spec
Steering components in and locked down
Track bar in and very snug, need to torque to spec
Diff oils changed front and rear (donors were very clean)
Was able to drive it out of the shop, so yeah, stage 1 of the build is complete and I am able to get it outside and get a sense of 1)how it sits 2) how it looks 3)how it feels. I like it all!
I have a new to-do/want list...
Swap out the 31s for 35s (the 31s with wheels were $140 and considered temporary for now)
Front and rear bumper changes (rear with tire carrier)
Fuel tank, man I struggle with this one. Don't want to give up the 5gal to clear the trnsfr and keep the midship and the large rear tanks are very expensive.
Still need to do transmission work to bolt up transfer (once I get transfer) May opt for compatible rebuilt trans to avoid doing the work. I've had enough of transmissions lately. (Rebuilding my second 4L60E for something else currently)
Definitely want the shackle flip instead of blocks. (I have only tack welded perches because I know changes are coming, so not driving, gently moving from here to there only)
Does the exhaust for the 5.4 need re-routed? May help me choose fuel tank options.