PROJECT OBSESSED

Introduction to the build-up of a ‘96 F350 Ford Power Stroke
The Old Body Style (OBS) ‘94-’97 Ford is one of those trucks that will never go out of style. Like the ’68-’72 Chevys, the OBS Ford is timeless. There’s just something about that 7.3L Power Stroke that drivers continue to love. Whether you owned one, your dad owned one, or your neighbor owned one, many of us have a memory of these old trucks.

With that in mind, it was time to start another big project, and with the overwhelmingly good feedback we receive from readers any time we focus on an older truck, starting on the overhaul and updating of a ‘94-’97 Ford F350 seemed the perfect fit. After months of searching, this ‘96 F350 was located not far from home and showed a promising future. The used-truck market is nuts right now, and we were finding these old Fords in the $15-20K range regularly, so when this one popped up at $12K, it was worth the second look. Meeting up with the owner who had been driving it for over 20 years, we were impressed to find it virtually rust free and with a relatively clean interior. After driving the truck and giving it a good once over, we had an idea of what kind of work was going to go into it and felt comfortable making an offer. It had 224,000 miles on it, which was more than we wanted, but the engine ran strong and the oil and transmission fluid were in good condition.

The previous owner had used the truck as his daily driver and weekend tow rig for more than 15 years before replacing it with a newer Dodge pickup. Since that time, the truck had spent a lot of time sitting and was going to need some basic maintenance and love to be truly ‘daily driver’-worthy again.

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When it comes to finding parts for ‘94-’97 F250/F350 trucks, there is one go-to shop that specializes in everything OBS Ford. Located in Jasper, Texas, Complete Performance (CP Addict) is run by brothers Chris and Paul Rutledge, who have nothing short of a sickness for the OBS Ford trucks. They’ve built an entire business around their love for these trucks and are known nationwide for their expertise. So, it seemed like a no brainer to spend some time on the phone with them and surfing their cpaddict.com website for a list of stuff we’d need for this build we’re calling Project OBSessed. To replace the faded grille and lights, the Rutledge boys suggested their six-piece headlight package in our choice of clear or smoked lenses along with some new chrome headlight bezels and all-new chrome grille shell. Because our local laws do not allow smoked lenses, we opted for the clear lens package, which will improve the looks of our old Ford while offering better lighting. All the parts were direct-fit pieces and fit perfectly. We also opted to replace our faded taillights with some new, original red tails from CP Addict.

In next month’s installment, we’ll do some basic performance modifications including a new cold-air intake, exhaust system, and custom tuning to help breathe a little bit of life into that old Power Stroke engine. We’ll be turning this truck inside out with one goal: to build one of the finest OBS trucks on the road. Call us crazy, but we expect to see this old Ford achieve the power of a newer truck, with similar ride quality and the versatility to be a reliable daily driver and weekend tow rig. Anyone can buy the perfect truck, but we’re seeking that sense of pride you feel when you build one with your own hands—and the help of the best aftermarket shops in the country. Stay tuned: Project OBSessed is going to be a fun one.

DW-1910-OBS-01 — The ’94-’97 F250 and F350 trucks were extremely popular and for good reason. That 7.3L Power Stroke made great power, and who couldn’t love that spacious crew cab? The OBS has become a classic in the truck market. It has a timeless look that done right is still as stylish as it was 20+ years ago.

DW-1910-OBS-02 — While the exterior of the truck is in great condition, with a straight body, glossy paint, and shiny chrome, the under hood shows signs of neglect. It appears to have spent a lot of miles running down dirt roads and never a minute at a car wash. The engine runs strong and the oil and transmission fluid appear in good condition, but there will be some parts to replace and some elbow grease needed to clean it up.

DW-1910-OBS-03 — We thought the truck was completely stock, other than the cheap air filter mod under the hood. However, these two gems were found stashed under the front seat and instantly took us back a decade or two. The Gold PCM chip and Max Microtuner from Superchips were by far the most popular tuner upgrades for these 7.3L Power Strokes back in the early 2000s. While they do work, tuning has evolved and we will be replacing them

DW-1910-OBS-04 — First priority for this build was replacing a few of the exterior pieces that were showing the truck’s age. The factory grille shell and that camouflage bug shield had to go.

DW-1910-OBS-05 — Along with the faded grille shell, the bubbles under the plastic chrome layer made the entire front end need refreshing. And let’s not even mention those lovely yellowed head lights.

DW-1910-OBS-06 — With the ever-increasing popularity of these OBS trucks, there is a growing need for good replacement parts that add some flare. Complete Performance of Jasper, Texas, has dedicated their business to OBS trucks and specialize in everything ’94-’97 Ford. While we’ll be ordering up a huge laundry list from them for this build, we started off with the front-end package that includes a grille, light bezels, 6-piece clear head and corner lights package, and new taillights.

DW-1910-OBS-07 — Swapping taillights on these old trucks is simple: a couple Phillips head screws, two small bolts, and they pop right out. While the factory light was removed, we took some time to clean up the bulbs, wires, and added some di-electric grease to the light sockets.

DW-1910-OBS-08 — While the original taillights weren’t cracked or busted, 20-plus years of sitting out had taken a toll. The red lens was faded and hazy and the clear reverse lens was discolored as well. While Complete Performance offers clear and smoked taillights, we opted for the factory red tails.

DW-1910-OBS-09 — Up front, the swap is a little more labor intensive and will require some more time to get the headlights, blinkers, and clearance lights traded out. The original chrome-light bezels are being swapped for new shiny parts as well.

DW-1910-OBS-10 — With the factory headlights removed from the truck, you can see how yellow and hazy the lens has become. You can also see the moisture that resides within the light.

DW-1910-OBS-11 — Think these new, clear, reflector-style lenses will look any better hung on the front end? There is no doubt, but another advantage is the added projection you’ll have with the new headlight technology. We’ll be installing some new LED bulbs as well, which will really bring this old truck into the 21st century.

DW-1910-OBS-12 — Going back together now, the new headlight lenses can be mounted first, then the corners and bezels, and lastly the grille shell. Remember, you’ll have to go back and adjust the headlights for the correct light pattern on the road, which is easily done with a few small adjustment rods on each headlight.

DW-1910-OBS-13 — Going back together now, the new headlight lenses can be mounted first, then the corners and bezels, and lastly the grille shell. Remember, you’ll have to go back and adjust the headlights for the correct light pattern on the road, which is easily done with a few small adjustment rods on each headlight.

DW-1910-OBS-14 — The new factory replacement grille sitting next to the original shows just how much life has changed that old girl after 20-plus years. The factory chrome is a dull and the gray centers have faded out. Complete Performance’s new grille is a perfect fit and will make such an improvement to the truck’s overall look.

DW-1910-OBS-15 — The new lights look so much better, and for what little investment and time was spent swapping them out, you’d think this was an all-new truck. The clear lenses look great on the front of this white truck and took away 23 years of tarnish and wear.

FREQUENTLY ASKED QUESTIONS

What are the differences between various engine block years and their features?

Understanding Engine Block Variations by Year

When exploring engine blocks across different years, it’s essential to recognize the unique features and characteristics that distinguish them. Here’s a detailed overview:

1994.5 – 1996 Engine Block

Design Features: This period saw the introduction of blocks with open lifter valleys. The open design allowed for easier maintenance and optimization of engine cooling and performance.
Compatibility: These blocks were often paired with specific components that harmonized with the early advancements in engine technology.

1997 – 2003 Engine Block

Timing Cover Adjustments: During these years, the timing cover underwent significant changes. Notably, engines from this era had timing covers that supported oil pickups positioned on the passenger side of the vehicle.
High-Pressure Oil Pump (HPOP) Reservoir: From 1999 to 2003, the HPOP reservoir designations became a standard feature. This enhancement contributed to the optimization of the oil flow and pressure within the system, providing better performance for the vehicle.

Key Takeaways

Open vs. Closed Lifter Valleys: Early blocks, such as the 1994.5-1996 models, featured open lifter valleys, whereas later versions may feature varied designs depending on improvements in engine cooling and maintenance.
Passenger Side Oil Pickups: Starting in 1997, the placement of oil pickups on the passenger side became a defining characteristic, reflecting broader design philosophy changes to enhance engine efficiency.
HPOP Developments: The inclusion and refinement of the High-Pressure Oil Pump reservoir in later models helped meet increasing demands for engine performance and reliability.

By studying these distinctions, you’ll gain better insights into how engine technology evolved over the years and how specific features were introduced to address contemporary automotive challenges.

What is the configuration of the turbo and engine setup for the truck?

The turbo and engine setup involves a motor accompanied by an s436 turbo, specifically tailored with dimensions of 80/86. Initially, it was paired with injectors boasting 400% nozzles. However, the current plan is to experiment with injectors equipped with 300% nozzles. The intent is to optimize performance with this configuration and, with a well-executed live tune, achieve efficient turbo spooling.

What challenges were encountered during the restoration process, such as rust issues?

During the restoration process, a significant challenge was the extensive rust damage this truck had sustained over the years. Originally a former plow truck, it had accumulated considerable wear and tear. By the time I began the restoration project back in December 2009, the truck was in dire need of a complete overhaul.

The Process Unveiled:

Discovery Post Sandblasting:After sandblasting, the true extent of the rust became apparent, much worse than initial estimates. The frame, once hidden by grime and old paint, revealed areas that were severely corroded.
Rusted Components:Specific parts, like the brackets on the frame, were rusted through and required replacing. This wasn’t just a superficial issue—it involved critical components that are crucial for structural integrity.
Unexpected Setbacks:Each step seemed to uncover additional rusted areas, leading to more time spent on repairs than originally planned. This unpredictable nature of restoration was a challenge both logistically and financially.

Overall, the battle with rust proved to be a daunting aspect of bringing this vehicle back to life, turning what started as a simple restoration into an extensive rebuild.

How was the frame of the truck prepared and treated?

Frame Preparation and Treatment Process

The truck frame underwent a comprehensive preparation and treatment process to ensure durability and longevity. Initially, the axles were carefully removed to allow easy access to the frame. Once detached, the frame was transported to a sandblasting facility.

Sandblasting:
This step was essential to remove old paint, rust, and any other surface impurities, revealing the bare metal underneath. The frame remained at sandblasting for most of February.
Painting the Axles and Components:
While the frame was away, attention turned to the axles and other components. Thorough cleaning and painting were performed, ensuring each part was ready for reassembly.
Inspection and Repair:
Upon the frame’s return, a detailed inspection uncovered areas affected by rust. Some brackets were found to be rusted through, which were promptly replaced to maintain structural integrity.
Final Painting:
Despite the dislike for painting, it was recognized as a crucial step for protecting the frame. The frame was carefully painted to shield it from future rust and corrosion, ensuring that the painstaking work was worth the effort in the long run.

What concerns were raised about the new engine block?

Concerns About the New Engine Block

When examining the new engine block, several potential issues have been identified that raise concern. Here’s a breakdown:

Smooth Piston Walls: Unlike the typical cross-hatching found in most piston walls, this engine block’s walls are smooth. This could be indicative of several underlying issues.
Possible Causes:
- High Mileage Wear: The absence of cross-hatching might suggest excessive wear, possibly due to higher mileage than reported.
- Fuel or Coolant Issues: Excessive fuel or coolant can lead to piston wall wear. However, since no coolant was found above the pistons after removing the heads, coolant leakage seems unlikely.
Performance History:
- The engine may have been operating under demanding conditions, such as using “400s with 400% nozzles,” which can add stress and cause premature wear.
- The presence of gapless rings could also impact the condition, although their specific effect requires further investigation.

Overall, it’s crucial to consider these factors when assessing the engine block’s condition to understand its potential longevity and performance implications.

What steps were taken during the disassembly of the truck?

Disassembling the Truck: Step-by-Step Process

Stripping Down the Exterior:The disassembly began with removing major exterior components. The bed and fuel tanks were taken out the night before rolling the truck into the garage, setting the stage for more detailed work.
Dismantling the Cab:Next, the cab was carefully detached from the frame. This step was crucial for accessing the truck’s interior and underlying structures.
Removing the Interior:The interior of the truck was stripped out, leaving behind an empty cab shell. This allowed for an in-depth inspection and potential replacements.
Frame and Axle Preparation:With everything else out of the way, the truck was reduced to just the frame and axles. The front axle had already undergone an upgrade with a Dana 60 prior to these efforts.
Axle and Frame Separation:The axles were stripped from the frame, leaving the base structure ready for transport. The frame was then sent off for sandblasting to remove rust and old paint.
Painting and Frame Treatment:While the frame was being sandblasted, a renovation team painted the axles along with various frame components. Once the frame returned, rusted brackets were replaced to ensure structural integrity.
Reassembly Preparations:The final step involved taking the frame back into the garage. Traction bars were mocked up, and a gusset was added to the frame for reinforced strength during future assembly.

This meticulous approach laid a strong foundation for further restoration efforts and performance enhancements.

What is the background of the 95 F-250 restoration project?

Background of the 1995 F-250 Restoration Project

Back in December 2009, a daily-driven 1995 F-250 single cab with a long bed and 4×4 capability was retired from regular use to undergo a significant transformation. Originally serving as a workhorse in harsh conditions as a former plow truck, it had accumulated considerable rust and wear over the years. Recognizing the need for extensive care and attention, the owner decided it was time for a complete overhaul.

The truck’s restoration journey began with plans to simply return it to its stock condition. However, circumstances shifted when the owner acquired another truck for everyday driving, allowing more time and focus on the F-250’s revival. This led to an ambitious new vision: transforming the vehicle into a formidable performer for both street and track, aiming for an impressive horsepower output in the range of 650 to 700.

Through this project, the owner hopes to merge the rugged durability of a classic truck with the high-performance thrills of modern engineering. The restoration not only seeks to preserve the heritage of the F-250 but also enhance it for future adventures.

How can oil rings affect the lubrication of engine walls?

How Oil Rings Impact the Lubrication of Engine Walls

Oil rings play a crucial role in the overall health and efficiency of an engine by controlling the flow of oil onto cylinder walls. Their primary function is to ensure a thin layer of oil is consistently present to lubricate and protect the engine walls from wear and tear.

Key Functions of Oil Rings

Regulating Oil Flow: Oil rings are designed to permit just the right amount of oil to reach the cylinder walls. This lubrication minimizes friction between the piston and the cylinder, reducing wear and extending engine life.
Heat Management: By maintaining proper lubrication, oil rings help in dissipating excess heat generated within the engine. This is essential to prevent overheating and potential damage to engine components.

Potential Issues and Effects

Wear and Tear: If oil rings fail to function correctly, either allowing too little or too much oil to pass, it can lead to insufficient lubrication, resulting in increased friction and accelerated engine wear.
Overheating: Improper oil flow can also lead to overheating, especially if excessive oil causes the engine to run hotter than desired. Consistent overheating could degrade engine parts and lead to failures.

Proper maintenance of oil rings is critical to ensure they perform their function efficiently, thus safeguarding the engine and maintaining optimal performance. If engine temperatures seem unusually high or if unusual wear patterns are noticed, it may be time to inspect and possibly replace the oil rings.

What are some potential causes for smooth piston walls in an engine block?

Potential Causes for Smooth Piston Walls in an Engine Block

When examining an engine block’s piston walls, discovering a smooth surface can raise concerns. Here are some potential reasons for this occurrence:

High Mileage Wear:
- Over time, regular engine use can naturally lead to wear and tear. High mileage is a common factor that can result in smoother piston walls due to consistent friction and movement over thousands of miles.
Excessive Fuel:
- Running an engine with too much fuel can wash away necessary lubrication, leading to accelerated wear. This condition, often referred to as “fuel wash,” can smooth out the crosshatching over time.
Coolant Leaks:
- While there might not always be visible coolant on the pistons, past exposure to coolant can cause corrosion and wear the walls down, leading to a smoother surface.
Modified Engine Components:
- The use of specific modifications, such as high-capacity fuel nozzles (e.g., 400% nozzles), can alter engine dynamics. Increased fuel and power output may impact the longevity of the crosshatching.
Aftermarket Parts:
- Installing components like gapless piston rings can change how the engine operates. While these rings might improve performance or efficiency, they can also affect wear patterns differently from standard parts.
Incorrect Mileage Information:
- If the engine has more mileage than initially reported, this could explain the extent of the wear. Verifying accurate mileage is crucial in diagnosing the condition of the engine.

Understanding these factors can help diagnose the condition of an engine block’s piston walls and guide any necessary repairs or modifications.

What modifications and enhancements are planned for the truck?

8-foot Bed: Rust and dent-free, this will give the truck a fresh, sturdy look.
Newly Built Motor: Packed with all the essentials to aim for an impressive 700 horsepower.

We’ll be turning this truck inside out with one goal: to build one of the finest OBS trucks on the road. With these enhancements, not only will we upgrade the truck’s aesthetics, but we’ll also significantly boost its performance. Stay tuned as we bring this powerhouse to life!

What is the condition of the new parts?

The new bed is described as free from rust and mostly free from dents, indicating good condition.

What is the intended performance goal?

The goal is to reach 700 horsepower with the new motor.

What specific parts are being added or modified?

An 8-foot bed and a newly built motor are being added.

How does the community respond to updates on the restoration project?

The community’s response to our restoration updates has been nothing short of enthusiastic. Readers eagerly subscribe to our progress, expressing excitement with comments like “subscribed!!!” and “can’t wait to see what’s next!” Their enthusiasm is palpable, creating a vibrant atmosphere of support and anticipation.

Our updates have also sparked engaging technical discussions. Readers often delve into specifics, asking questions such as, “What turbo are you running?” and offering advice on setups. This interactive dialogue showcases not only their interest but also their knowledge and willingness to engage in detailed conversations.

Moreover, the community frequently shares words of encouragement and praise, with responses like “Looking good!” and “dang, great job!” These affirmations are a testament to their appreciation and enjoyment of the project’s progression.

In addressing technical aspects, community members have also provided insights, such as discussing the purpose of the oil ring and its influence on engine performance. This level of constructive interaction highlights the depth of expertise and shared passion among our readers.

As we continue to document this restoration journey, the community remains a vital part of our narrative, fueling our drive to deliver more updates and share the intricacies of this beloved truck’s transformation.

How engaged is the community with the project?

The community is actively engaged, with members expressing eagerness to see future updates and subscribing for ongoing progress reports.

What kind of feedback or advice does the community offer?

The community offers technical feedback, such as insights on engine components and possible causes for mechanical issues, based on their expertise.

What technical aspects are the community interested in?

The community shows interest in the turbo setup and engine modifications, asking about specific components and configurations.

What is the community’s reaction to the project’s progress?

The community is highly positive and encouraging, expressing enthusiasm and support for the project’s progress.