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  #1  
Old 05-30-2014
markusfmeyer markusfmeyer is offline
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Default Next project - non bird

Since you guys love projects, thought I'd share what I've been busy with ths winter and spring. Not the Bird! First I bought my daughter a used Taurus that needed the entire suspension rebuilt. Didn't take pictures unfortunately. Front went easy, rear was a pain. Had to cut one of the control arms out, the bolt was seized in the metal sleeve inside the rubber bushing. Anyhow, no pictures so enough of that story. Thought I could relax now for a bit, but after coming back from the long weekend away in the Bird, I was looking at my truck that we had taken with us wondering why the front was leaning on one side. I think the pictures explain it, you can see which side is still ok and which isn't. Of course Ford didn't bolt those spring cradles to the frame, they riveted them in place. And then they ran the brake lines through them too. This is going to be interesting!
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Markus Meyer
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  #2  
Old 05-30-2014
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exxis exxis is offline
Thomas Rembert
 
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Glad I don't have to drive on salted roads.
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  #3  
Old 05-30-2014
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patticake patticake is offline
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Quote:
Originally Posted by exxis View Post
Glad I don't have to drive on salted roads.
I agree on that. Especially since in my son's business, we install kits that raise p/u trucks up from 2 to 8 inches, and that would be one we would not touch. We have done them from brand new, to a truck with over 300k on it.

That just looks like a frame replacement or a newer truck is needed. In other words, what else is rusted out.
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  #4  
Old 05-30-2014
markusfmeyer markusfmeyer is offline
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Rest of frame is solid, just surface rust, already looked it over. The passenger side cradle is still solid too, but I'll do both anyway. Considering its a 20 year old northeast truck, not bad. I've seen a lot worse, earlier than 20 years.
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  #5  
Old 06-28-2014
markusfmeyer markusfmeyer is offline
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Now that my son is graduated, the entire family was here (15 people at the house, my wife and I slept in the Bird ), we had our trip to Myrtle Beach, its time to get back to this project. Today I started on the driver's side where the shock mount was damaged. First I removed the shock. Then I took the bolt off the hold down strap at the top of the spring, then let the suspension hang and the spring popped right out of the way - first picture shows these two things done. I ground the 5 rivets out, removed the one bolt and the unit was off the frame (second and third pics shows this). Tried to get the brake lines off cleanly but the threaded nuts were rusted/frozen to the lines so they snapped. Time to get new brakes lines now, probably a good idea anyway at almost 20 years. Getting the rivets out of the holes was a little challenging, some holes no issue, others I had to grind some more than pound the stud thru, one I still have left underneath is giving me an issue. Found the new mounts online (brand new OEM Ford) and ordered them, brake lines have to be made since they are steel. Good news is the frame is solid, just surface rust, you can see that where I ground the rivets away and you can see nice clean fresh shiny metal (last few pics). Still have the passenger side to do.
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  #6  
Old 07-04-2014
markusfmeyer markusfmeyer is offline
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New parts arriving. Here are pictures of the new OEM Ford spring/shock towers/cradles and the grade 8 bolts I bought to attach them with. I ran into an issue with the place I took my old steel brake lines to. Originally they were going to make up new ones for me, but called the next day to say they wouldn't do it without the vehicle being there to ensure the connections were tight and wouldn't leak. That was a blessing in disguise as it forced me to do more research and I found a place online that will replicate all your brake lines in either steel or stainless, in my case for $160 or $190. I wanted stainless anyway so ordered them, but will have to wait to have them made and then shipped from Michigan. This is ALL lines, not just the two I broke, so as always this will turn into a slightly bigger project but with all new hoses and lines I should be good to go for a while, especially with stainless lines, no more rust to worry about.

This is the place I ordered from. Read some good reviews from the guys on the Bronco and F150 forums:

http://www.inlinetube.com/
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  #7  
Old 07-04-2014
cemjam cemjam is offline
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WOW that is a project!!! Glad you were able to correct it.
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  #8  
Old 07-06-2014
markusfmeyer markusfmeyer is offline
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A little grinding, a little scraping, a little wire brushing, a little cleaning, and a little chassis painting later, I had much better looking frame rails and radius arms. I also decided to take out the old springs and get new ones, using a 1 1/8" socket with some long extensions and breaker bar took care of them. Put the new shock/spring mounts in place, and ordered the new springs. Got a good deal on those - Amazon had free shipping since my wife has the Prime account, and they applied by Discover bonus points so the whole thing was free!

New springs should be here mid week so can install those and the shocks I took out (Bilsteins that I replaced about two years ago), then just waiting on the new brake lines to arrive.
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  #9  
Old 07-08-2014
markusfmeyer markusfmeyer is offline
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Love Amazon two day free shipping. Sure enough, new springs were waiting for me when I got home today, so I popped them both in. Of course I forgot that I needed to bolt the bottom in first without the top in place, because there is no way to get the socket and extension in there if the top of the spring is in the mount, so I had to take it out again on top then bolt it in, but no biggee. For some reason I needed the spring compressor only on the passenger side, couldn't get it down low enough to just slide the new one in. I bought heavy duty springs, not regular duty, so they were just a little taller than the old ones.
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  #10  
Old 07-12-2014
markusfmeyer markusfmeyer is offline
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New brake lines arrived Wed. I installed the two I broke and tried to bleed the system using the Mityvac. Didn't go so well since the master cylinder and lines were empty to start. To add to the fun I snapped one of the bleed screws off and in looking at my records, saw the calipers were replacements to new calipers only a few years ago. So instead of getting another set of free replacements of what obviously is junk, I went to NAPA instead and bought new ones, along with ceramic pads (first time trying these). I took Thursday off as I needed a break from this project and needed to finish mowing the lawn. Yesterday I completed things. Replaced the rest of the lines and had my wife help with the old two person bleeding method.

Pretty happy with the brake lines. I have tried bending/flaring in the past on another car and it didn't go so well. I spent enough time cussing and struggling with other things that I wasn't about to try that again here. So having the lines already made was worth the price to me. As you can see in the pictures they did a pretty good job of mimicking the factory twists and bends.
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