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Ok, 2 projects left, to call both the Superduty suspension upgrade, and the aluminum bed upgrade complete on the F250. #1, we need a front sway bar, and that means we need to replace the old drop-tracbar bracket with a 'stock' one. So, enter one new bracket from Sky's Offroad Design:  painted...  ...and installed!  Tracbar angle looks decent, and it means weve now got room to reinstall the swaybar  ...and done! This was the last piece of the puzzle, that now completes the SD suspension swap. Moving on, the final thing i needed to do to finish the utility/dump bed conversion, was to make & install some mud flaps. I welded a piece of 1" angle iron to the bed, and then whipped up a simple mud flap using some scraps i had laying around in the garage:   Nothing left to do now, but drive! Spent the last two days cleaning up the yard. My scrap steel pile got a little big, so it was time to clean it all out  Went over to the scrap yard with it today. 2200#. Dump bed dumped it without a care in the world! Sorry no video, i forgot to check the batteries for the remote before i left (they were dead) so i had to run it from the dash switch. But still, worked like a champ. I was in and out of the yard in under 5 minutes! So my original setup after doing the aluminum bed, i put a set of large reverse lights right in the back  While they do work, the problem is the light isnt very usable, as you cant see that area from the driver seat. Also, i discovered that if i needed to haul something with the tailgate down, that the gate blocks the lights in the bed frame. While its unlikely ill need to do so (it is a 9' bed afterall), it still seemed like a good idea to do something about it. So step one, was to replace the reverse lights with a set of combo STT/Reverse lights. This should solve my potential taillight issue, but also still cast a little bit of light back there for backing up at night.  So now i need proper reverse lights. So i picked up a set of 4" lights from Nilight:  Mounted here, still need to be aimed. Pretty sure these will cast enough light down & out that ill be able to see better in the dark.  Wires run:  ...and terminated with Deutsch connectors so i can still unplug the lights if necessary  I think this will do better  Those should cast plenty of light down & out so i can see, and the two in the middle should be just enough light shining on the trailer hitch in the dark. Also, if you noticed, theres now a backup camera mounted on the license plate. More to come on that soon... Been working on a few projects around the house/garage. First up, we actually used the AL bed to haul a yard of mulch for the garden beds
With how much bigger this bed is, 2 yards should fit in there just fine. Next up was to fix the remote mounted Warn x8000i. After 20 years the cable was sprung, and one of the solenoids was only intermittently working, so i opened it up and swapped them out. 
 ...and finally i also got 2 small projects done in the garage. #1 was adding a light to the drill press  ...and the other was replacing the old bottle jack on the press, with this new pneumatic one  ...and with all that done, its time to start building some new leaf springs for the F250  Used the new aluminum bed a few times now to haul stuff, and im already tired of the spare tire being loose back there. Not that it moves around, just that its big and always in the way. So i took the time to remount the original tire carrier that was in the bed  Simple and effective.
Made a bit of a goofup, seems i designed my sending unit float arm to occupy the same space as the tank rollover vent, so the gauge would only read 3/4 full. So back out it came!  Pulled the rollover valve out, and you can see the problem:  this was a simple fix though, i just added a bend to the swing arm to move it over and away from the rollover valve:  ...and as a finishing touch for the bed, i removed the original 'unleaded fuel only' sticker, and replaced with a new one:  With the bed done id like to get the truck inspected (as i have work piling up that i need it for), but after 15 years, the Banks exhaust i had on here was falling apart and had been patched back together multiple times. Well finally the muffler rotted out and broke:  As a quick fix, i just eliminated it and threw an elbow on there so i could drive it to the exhaust shop
Its a total brodozer look and i hate it, but it was sufficient to drive to the exhaust shop to get a proper exhaust made anyway  So now ive got 4" stainless all the way from the downpipe to the tip, along with a new stainless muffler as well   Nice and quiet, for a 4" pipe anyways. So from there it was just a matter of stopping and filling up the rear tank, so next week i can finally drop the front tank out of the frame rails  I bet you didnt think this would fit, but it totally does, and with room to spare:  And the new rear tank holds an honest 38 gallons  Its way out of inspection (was due in august), and i still need to get my water/methanol injection reinstalled, but at least she's a driver once more!  The next part of the project is lighting. I need to wire up the bed, but i also need a place to put my license plate, trailer plug and reverse lights  I spent some time staring at that space, and started thinking about just building a panel to house my lights & plate, similar to what a traditional dump truck might have  Mocking up in steel:   Brand new Ford wedgelock pins.....  ...means i can rewire a new trailer 7-way, to plug directly into the truck's harness  ...and this gray 8-pin connector is the plug for the original bed's tailllights. The plan is to rewire the bed lights to plug directly into this using some more wedgelock pins and connectors  Running wires  ...and with all wires ran, the panel is now installed!  Why have an 18 gallon tank when you can have a 38 gallon one? Let's go! This is a Spectra F26E tank. Fits right into the frame rail, and comes with longer hardware to reuse the original gas tank straps  I modified the original sending unit to reach another 6" down to the bottom of the new tank, and then replaced the original float arm with a longer one from a bronco sending unit, altho i had to change the shape of it (bend) to get it to display accurately, while also being able to fit it thru the hole in the tank  Sorry i dont have better pics as this is when i broke the lens over my camera, so youll have to wait for the video if you want more info on the sending unit mods. That said, the tank is installed!
As you can see, it fits in there nicely and despite being bigger than the bronco tank, doesnt hang down as far:  This would be the end of the mods for the swap, except dump bed. Seems theres some aluminum in the way:  I had to notch the aluminum frame rail to make room for the filler neck. I also removed the coupling and extension hose to shorten up the filler neck a few inches, and then built a hangar to support the neck:  ...and the finished product!
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