F250/Cummins Swap

Found some gates hoses at oriely's to finish up the passenger side hose connections. That lower radiator hose is just over 2.1" which is perfect for the Ford quick connect. The other end is 2" to mate to the 3rd Gen inlet. It has an internal spring to prevent collapse. The 2" side needs between 1.5 to 1.75 inches cut off to clear the frame with the DCS engine mounts. The destroked mounts put the engine to the driver side. I'm going to use a gates shrink band at the radiator end.

The heater hose is a 90° quick connect into a gates hose with two 90's turned out of phase. I'm mating this to the Ford heater hose and clamping it with oetiker clamps like OEM. This puts both heater hoses coming to the rear of the alternator before they diverge.

Has anyone had trouble with the Ford radiator hoses not wanting to clip on to an aftermarket radiator?
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Barely. I got the wiring harness bracket made up and attached to the frame. It mounts the engine to chassis connector to the modified Ford location.
I found some sweet isolator blocks for the trans lines, and I'm having some brackets to mount the lines to the pan rails made up. I'm also having a log manifold made to mount the coolant resevoir line to the engine.

I beta tested a device to change the 47RE range into a signal the Ford can use. This let's the ford's ignition system crank the Cummins engine, as well as display the position on the dash as it should. I'm also working on replacing the pressure line for the power steering with AN line to resolve a clearance issue at the PS pump
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Got to play with the throttle valve last weekend. Hoping to have something to convert the TV into a useful throttle input for the cummins
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Also checked out the tach converter from swap helper. Com

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Got more done.
Picture are really out of order.
Replacing the 8 pole oem connector for the AC Clutch and sensor. I evidently sold the wiring harness and related AC parts still on the 5.4 engine, so now I get to build the harness.

Wired the bussman-cooper relay. This provides the fuse holder for the ecm constant power, and the relay side will supply the air dog. The air dog V+ supply is 12ga and passes through the cam-lock connector along with everything else engine related.

Got my water manifold in to get the coolant from the reservoir to the tubing around the back of the engine. Couple of holes to drill and then I think black ano finish.

Trying to decide if I should send It out or do it myself.

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Installed the AC Clutch wiring and pressure switch wiring. Installed a shield on the 60 pin ecm connector. Realized that with the gas engine AC high pressure switch, there is no control over the engine fan. I added the wiring for the fan switch since the repair connector has 4 wires, but the switch is only a two pole, and the switch from a 6.4 is a rectangular connector body. I will sort all that out later.
Installed the log manifold so I could see what type of molded hose I'm searching for. I think I'm going to try and anodize that thing purple some time in the near future.
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Ano attempt #1 was a fail. Too much current and not enough time. It has just enough purple on it to know it was dipped.
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biggy238 said:
Ano attempt #1 was a fail. Too much current and not enough time. It has just enough purple on it to know it was dipped.
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Click to expand...

How do you anodize aluminum?

You’re sure doing a great job on the wiring, and it’s a reminder to me why I’ll probably never Cummins swap anything this new! LOL Keep up the good work, and keep posting progress pictures please.
 
bracker8040 said:
How do you anodize aluminum?



You’re sure doing a great job on the wiring, and it’s a reminder to me why I’ll probably never Cummins swap anything this new! LOL Keep up the good work, and keep posting progress pictures please.
Click to expand...
That camlock connector was a "oOoOOOooo, I like that kind of thing. I had two goals there:
Make it so the wiring would let the cab come up
Make it so I can run the engine independatly of the chassis.
Even the power supply to the airdog passes through it.
I was just having a conversation about what bulkhead connector to use to pass into the cab.
I think I'm going to use the TE HDP

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Installed the transmission line brackets. I'm going to end up building some steel transmission lines. I finished everything down the sides of the engine that I intend to do, so I put the cooling pack back in.
OH yeah. I anodized the coolant manifold purple. Well, supposed to be purple.
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Looking good. Stuff like those trans line brackets are so time consuming, but so worth it.
I like that raspberry colored coolant manifold. :lolly:
 
Don't wrench wrench when you're tired kids. Hoses get cut too short, plans get shat on......

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Well. I finally, after like 4 months, got a set of oeticker clamps for the heater hose. I clamped everything together, wrapped it in heat shielding, and sealed it with speed tape.
Tig welders are the devil BTW. I welded all of one weld on that charge air tube, and then a piece the size of a dime decided to evaporate.
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Anyone know who offers the swaged hoses that are in this photo?
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OK, next challenge,

7/8" coolant hose with a 60° bend.
I looked at the hps parts but never saw a 60 degree elbow.

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