1966 F100 EcoBoost Engine Swap (EcoBoosted)

[TimeWarpF100]

1966 F100 EcoBoost Engine Swap & 1966 427 Project

I had a couple requests in another post to show my EcoBoost project so thought I would start another thread.


I love the 65-66 Ford body style and have since my Dad pulled into the drive way back in October 1965 with a brand new Red/Red 1966 F100 352 w a 3spd on the column.

A few months back found a near twin to my dad's from back in october 1965.
He gave me the truck in fall of 1984 and I sold it when I moved to Phx back in January 1986 for a measly 100.00 because I could not afford to take it with me.

Replacement truck 2012 300.00 ! AZ truck to boot.

I have 5 65-66 Trucks and thought it would be nice to have something other than a gas guzzling FE powered one that I could take on trips and use as a daily driver with a few late model comforts like A/C in the Arizona Heat.

I did very little research and measurements because if I found too much negative for doing the swap I probably would not have attempted it.

Only thing I did research ahead of time was the wheelbases possible on the EcoBoost. Knowing my truck was a 129" wheelbase and the shortest EcoBoost F150 was 145" I had my work cut out for me any way you slice it.

I thought about doing a 5.0L Coyote engine but seemed there were too many people already doing those swaps and Ford had a harness avail to do so.

So It was decided to search for a possible donor of a F250 with a 6.7L Power Stroke or a 3.5L Twin Turbo F150

March 28th I picked up a 2011 F150 EcoBoost that was hit hard in rear.

The search had been ongoing since the beginning of March to find a suitable donor EcoBoost to swap into one of my 66 F Series Trucks.

I was able to find many wrecked EcoBoost trucks across the country and bid on a half dozen or so. Difficult to find close by that were not wrecked in front end as most were.

This is the truck I found:

This truck happened to be a SuperCab with a 145" wheelbase. Because I wanted everything up in front was not that concerned about back sheetmetal or frame section knowing I needed little of it other that the rear axle assy. This one a 3.15 geared 9 3/4" was toast from the hard rear hit.

April 7th I started to tear apart my '66 Truck to see if this was even possible.

I pulled the cab and moved it aside. I then pulled the cab off the 2011 Eco so I could use that chassis to check fit under the 1966.

 

[1steve]

Yes this will be a very interesting. Need lots of pictures if possible. Thanks for starting this thread.

 

[dankicksass]

Subscribed. Pics of the classic sheetmetal?

 

[JMcFly]

This is going to be awesome.

 

[TimeWarpF100]

This Silver EcoBoost had only 6430 Miles on the clock when purchased.

The owners manual, Window Sticker etc were found in glove box!
along with original purchase invoice.

Original price was 34,200.00, I picked it up for less than 10% of that.

Seeing as though I have done very few cars that were not Nut~Bolt type restorations thought it would be a nice change to do something that could really test my abilities and way beyond yet not break the bank doing so.

My food for thought was;

A neat FE with a few mods like a crank kit, rods pistons etc, a bit of machine work, a set of edelbrock aluminum heads and a Performer RPM intake and a carb would set me back 5500.00 if I built it myself. Only to get a measly 10-13mpg tops, the truck had a 4:10 gear so if I wanted something else it could mean a Gear Vendors overdrive for another 3200.00. So that is 8500.00 and I still do not have a transmission yet and big bucks for the resto of suspension including updated brakes etc.

I felt even though it seemed big bucks the late model swap would save me a bunch of money in the end.

I could easily spend 20k in building the truck and still have a gas guzzler that I already owned 4 of.

At this point & 2wks into the build am pretty hopefull I can make this work. If not I can turn it into a sand rail of sorts and have fun that way as the basic cab of 2011 is still intact.

Here I start to dig into the 1966.

 

[rockchucker]

Absolutely AWESOME! Good luck with the project. If you have a Sand Rail also just make it swappable into the Rail. You could use all of the peripherals and just swap it over when you wanted to. You could get 2 Wiring Harnesses and it would be pretty to swap.

 

[TimeWarpF100]

Yes this will be a very interesting. Need lots of pictures if possible. Thanks for starting this thread.

Subscribed. Pics of the classic sheetmetal?

This is going to be awesome.

Wow That was fast! Thanks!

English was not one of my better school classes so it may seem a bit bunched together. My brain and fingers do not work well together... LOL One is always ahead of the other.

I did purchase a decent camera so I could photo document and video as I go along.


Here is the mangled mess of sheet metal I bought.

I had to cut off the rear section of truck in order to get it off trailer as it was loaded on with a forklift. A portion of left bedside had to be cut off as it was sticking out so far to be road legal on the trailer. A purchased cordless sawzall did the trick as I was 700 miles from home.

 

[jonb347]

that is an awesome idea...defintely will follow this

 

[TimeWarpF100]

Anxiously waiting to see how fit would be I rolled the wounded 2011 chassis under the '66 Cab. Much to my amazement the '66 to '11 body mounts were in proper location! 46yrs apart . . . Using the '11 mounts on '11 chassis it dropped into place, except for of course the rear of cab on the '66 was too narrow so I just kept tail of frame down to double check fit and proper centerline of front axle into wheel opening.
Also note the steering column of '66 was right in line with the '11!

 

[TimeWarpF100]

To help things out I picked up the entire shop manual set for the '11 Eco along with the Wiring supplement and a CD/DVD.

I found a set of brand new take off 2012 F150 Lariat wheels with caps for 1/2 price of a single wheel less cap!

Actually today stopped by costco to check on tires and found I will probably go with a 255/55R18 Tire, decent rubber with a little lower sidewall than the stock
265/60R18's.

I installed a fender to check wheel opening with cab in place.

The light blue truck is one I almost used but paid big bucks for a nice original AZ truck and thought I would be better suited to use the 300.00 special. Maybe on the next one..

 

[Garys Garage]

I may have missed it, are you trying to repair and use the Eco boost frame?

 

[SCscoutguy]

I may have missed it, are you trying to repair and use the Eco boost frame?

Yea I was wondering the same thing?

 

[HOTFR8]

Will be following this with interest. Great project.

 

[mtnkrake]

I gotta see how this turns out.

 

[csargents1546]

Glad you went with a ecoboost, I do not think a 6.7 PS would fit. This is going to be an awesome build. Subscribed!!!!!

 

[1steve]

Yea I was wondering the same thing?

He is going to use the front section.

 

[HOTFR8]

He is going to use the front section.

A Chassis graft ?

 

[TimeWarpF100]

I may have missed it, are you trying to repair and use the Eco boost frame?

Yea I was wondering the same thing?

Will be following this with interest. Great project.

I gotta see how this turns out.

Glad you went with a ecoboost, I do not think a 6.7 PS would fit. This is going to be an awesome build. Subscribed!!!!!

He is going to use the front section.

A Chassis graft ?

Thanks All for your interest!

Before I had a chance to explain what I am trying to accomplish I lost my internet connection right in the middle of a post. Turned out the Ethernet cord went south.

I started this project 2wks ago on saturday. The initial plan was to just drop in the ecoboost engine and trans. Problem is there is not a standalone harness avail for the ecoboost yet. I spoke to a Ford engineer nearly a year ago and was promised they would have one out in approx 1yr. Well a couple weeks ago the update was: It will be at least another year yet and they plan on doing a ecoboost harness for swaps but its possible the 2.0 or 1.6 eco engines could have a harness first.

What make this complicated is the type of injectors used for the direct injection. Knowbody makes a harness and what is required is most of electronics as the F150 has Securilock anti theft and a bunch of other **** in order to make truck even start. This truck has the upgraded instrument cluster so it would be an issue unless everything is up and working.

So my plan simply changed because I did not want to give up on project as really love the eco engines.

Once I found that the engine position in chassis was going to work and cab spot was close with stock mounts I then decided that maybe I could install the 2011 dash into the '66 cab to make it a plug and play. Problem with that the '11 cab is HUGE in length and height compared to the '66. The '11 seats I planned on using would nearly touch the ceiling in he '66 cab and just looked too far out of place. Remember the '11 Eco only has 6430 miles on it so the interior was pretty much mint and not damaged with exception of the side air bags. Seat and dash bags did not deploy making this a good candidate for the swap.

I found that the 5.0L Trucks were avail in a 125.9" wheelbase so it got my brain turning that maybe I could just pick up another frame. Using my frame stretcher to get it to fit my 129" Wheelbase '66.

I took a HUGE chance and ordered a NEW 5.0L Frame from Ford as the only thing in partsbook was wheelbase and did not mention engine size. I figured if I had to I could just use the mounts off the original frame and already had them just in case.

In the mean time I removed the floor out of the '11 thinking it would be best to use that so the dash, HVAC etc would be a direct bolt in.

A lot to say here and this will take a bit of time to catch up on whats been done so far and where I hope this is going.

 

[TimeWarpF100]

When I looked at my other 4 65-66 trucks I found the front wheels seemed to be 1" farther forward that what looked correct. I figured a 1" there and somehow 2" gain in rear by moving springs or lengthening frame I could get there. Thats when I ordered the frame. The new frame came in this past wednesday! Only to find it was all faded out and had obviously been sitting outside for quite some time even though the date on frame was october 9th of 2011 the same month the truck was built!

Of course crossmembers, cab mounts etc were i n a different location from the supercab frame.

Prior to the new frame showing I drilled all the spotwelds and cut the firewall and floor pan out of the '11 to see if that was a viable option to install it in the'66 cab.

Because the '66 cab frame opening in back was only 41" and the '11 frame was just under 46" wide at back of cab it was back to the drawing board. The '66 frame is 34" wide.

A few pics of '11 floor pan and firewall in place on '11 chassis with '66 cab overhead to check for possible grafting together.

 

[TimeWarpF100]

as one can see the firewall of '11 is way farther forward to accommodate the HUGE '11 dash, electronics and HVAC.

The '11 dash weighs in at a hefty 150lbs. Just a plug and play module with a few bolts holding it in place.

I then did a temp install of the '11 dash into the '66 cab after a quick measurement told me it was within 1/2" or so in width.

Drilling out what seemed like another gazillion spot welds I did a trial fit of the '11 dash into the '66 cab. This is what it looked like.

 

[TimeWarpF100]

In order for the HUGE '11 dash to fit or even part of it as I need pretty much all the electronics the '11 firewall would have to be added to the '66 cab. It being approx 8-9" further forward than the stock '66 firewall. Another hurdle.

Because when I did the temp fit of '11 dash and found it was way too deep even when 4" shy of being in correct position it was another curve ball in hoping for windshield wipers and defroster ducts. Both a must have.

This is going to add some serious weight to the truck but I would rather have it heavier and working than waiting for someone to make a standalone harness over the next few years. This could be a total failure but some how some way hope to make it happen and do not plan on giving up that easily.

The satisfaction of taking this around the block for 1st time driving on its own will be a awesome accomplishment. Getting to be a old fart so need to keep the brain active somehow.

As long as I can keep the motivation factor up and not let the snags get to me I will be ok. At this time am much more excited about this project than any other I can remember.

 

[TimeWarpF100]

A few of '11 teardown and what that dash fit like.

Also the '11 windshield is 35" heigh vs 21 or so on the '66. That makes the cowl area on the '11 with tons of room and also the '11 wiper assy fits in cowl in front of windshield. Completely unknown at this time how I will adapt wipers to this project. Arm out window with rag seems to be viable for now.

Because the '11 cab is so much taller inside it makes for more dash room. I may end up just making new dash of metal for '66 and installing components from the '11. This is a plan as I go project. I relate it to making plans written on sand @ beach on a windy day. The plan gets erased and you start over often. Eventually the winds will die down I hope! LOL

 

[TimeWarpF100]

A few random pics. Note the size of HVAC unit that has to fit behind the HUGE dash.

I told myself I this truck does not have A/C here in the ARIZONA heat I am no longer interested. Wiper's I can live without but not A/C as its already reached 100deg here and its only April!

 

[jabberwoki]

Wow this is better than a tv show! Hurry up i need more.

 

[Adam McLaughlin]

BOY am I interested in this one. See my Avatar?

357 CI V8, AOD, 3.73 w/ Detroit Locker into the 1992 Ranger... Smog Legit in Calif

Adam

 

[TimeWarpF100]

To save $$ I plan on using as many parts from the '11 as possible. Pretty much to learn. If I build another it will be to see how much weight I can take out and more of a performer than one that rides quiet etc.

Also interesting is I plan on using Quiet Steel in the firewall to minimize the noise in cab. It will be up to the 50yr old door rubber design and shape of cab to determine wind noise which will probably be pretty loud. At least engine noise and road noise will be quieter than in '66.

Here is the new 2012 Standard Cab Short Bed chassis under the '66 cab with the '11 floor installed for a test fit. This is pretty much catching up with where I am at with this project. Updates as they happen.

Note the new rear axle housing and new leaf spring. Still waiting on the new rear suspension parts so I can assemble the chassis.

 

[TimeWarpF100]

Wow this is better than a tv show! Hurry up i need more.

BOY am I interested in this one. See my Avatar?

357 CI V8, AOD, 3.73 w/ Detroit Locker into the 1992 Ranger... Smog Legit in Calif

Adam

You got it jabberwoki! More to come and real soon . . .

Adam neat project.

Back in 1996 (the last time I dove deep) I bought a brand new 1996 Ranger Step side super cab in plain white then dropped in a supercharged 5.0. Had a bit of fun with the OBDII but was a fun project. This one is a bit deeper than that. The ranger had 2040 miles on it when i dropped in the 5.0L. I am hoping to match the MPG of 25-26 with the ranger with this one. Do not think it will be an issue?

The B A R E 2011 standard cab short box frame is 520lbs! OUCH . . . This truck will be heavier than a stock '66 by far. Not initially what I wanted but so be it.

 

[bmwpower]

Can you retrofit the new dash components into the old dash? That might be a slicker (and easier) install. Just my 2 cents... Looking good!

 

[TimeWarpF100]

A bit more of plan in works but unknown how much of this I can really make happen.

2012 '66 F100
A total high tech 1966

Things I plan on integrating into this project:

HVAC

Easy Fuel Capless Filler System

Fail-Safe Cooling

Fully Boxed Hydroformed Frame

Electronic Power Steering

Tire Pressure Monitoring System

Built in Trailer Sway Control

4-wheel Disc Brakes w/ABS

Advancetrac w/Stability Control

Steering wheel and Pass AirBags

Quiet Steel Firewall

Power Adjustable Pedals (fly by wire)

Sync Voice Activated Systems

Navigation System

Satellite Radio

26 Gallon Fuel tank for those 650 mile trips without stopping for fuel

YAW sensors with steering input that is part of Roll Control

Power Seats

Unknown if I will adapt the '11 power windows, door locks etc.

This is just a dream but will see how much of it I can integrate into this truck.
If its going to be heavy I may as well have creature comforts right?

I am hoping it will be between 500-1000lbs lighter than the stock SC '11 Eco.

I also plan on installing a Traction Loc unit in the rear and keeping the stock
3.15 gearing and 33 spline axles.

Towing capacity should be around 9000lbs with a bumper pull.

Brakes will be 14" + front and rears 13.75" Rotors

Tires will be 255/55R18 and wheels the stock Lariat 7.5x18

 

[CreekRat]

Wow that's an awesome build!

A double thanks for showing the F150 as you strip it out. I drive a 2011 Ecoboost so I love the "behind the scenes" shots of the F150 as you disassemble it.

 

[TimeWarpF100]

Can you retrofit the new dash components into the old dash? That might be a slicker (and easier) install. Just my 2 cents... Looking good!

Simply not much room.

The '66 dash is approx 11" and the '11 is 15" plus another 1' for HVAC

I agree maintaining the '66 dash would be much better looking.

If I can somehow get it all to fit in the '66 dash with working A/C then yes but at this time does not look possible.

That would be my goal to have all this in the '66 dash.

Will see where the next couple weeks brings this project.

I need to see how and if the '11 floor, firewall, HVAC is going to fit.
I do not want to buy an aftermarket HVAC for 1500.00 when this one is free. Then I do not have such a mix n match of parts just 1966 & 2011.

Even if I have to compromise on what I really want to use to save $$ since I have the entire '11 truck on hand.

Next up is fitting the '66 Cab to chassis to find firewall location etc. I have started the cut of back of '66 cab to fit the chassis. Goal is to make it look like it belongs that way. All metal finished of course...

Rear cab mounts I think I may have figured out by moving the cab mount from outside of frame to inside.

Another issue is the height of frames from '66 to '11. I do not want much if any of the frame to show when looking from the side. I need to section the cab to do that. Exact location unknown. If the floor is raised it will even make for less room for the '11 dash.

More real soon!

 

[TimeWarpF100]

Wow that's an awesome build!

A double thanks for showing the F150 as you strip it out. I drive a 2011 Ecoboost so I love the "behind the scenes" shots of the F150 as you disassemble it.

Thanks for your interest!

Sure learning a lot about the 2011-12 F150's! Pretty much taken completely apart at this time.

I have 3 trucks torn apart right now so what a MESS! not much for elbow room in such a small garage. Getting too hot for much outside work.

This is where I am at right now with cab mod in back. Frame no fit but a little massaging should do it.

 

[geologist]

This is amazing. I'm learning a hell of a lot just from your thread. I had a custom S10 that I slammed about 10 years ago (working with my Dad) but that's nothing compared to what you're undertaking.

 

[DFW-LSX]

This is awesome. You have some skill! Subscribed!

 

[Kevin54]

Wow!!! I am impressed and I am subscribed. If I were closer I'd be over to help you out all I could. It sure looks like it's going to be a fantastic project.

Patiently waiting for future updates

 

[jrherald420]

In for the long haul!!! Keep up the good work!!

 

[allinon72]

 

[54FordPanel]

Fantastic build! Thanks for making a thread for it. I admire your workmanship and your perseverance......lots of obstacles in what you are trying to do, and you aren't giving up. Keep on doing & posting.

 

[DarrenF]

Awesome. Subscribed

 

[bams50]

Another big fan of what you're doing- and another subscriber!

As it gets spread around the 'net this thread may be destined for the Guinness book as the most-subscribed EVER!

Best of luck- I'll be watching AND learning!