1968 Dodge A100 re-born ...again....

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kiwigtx

Big Dummy
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FABO Gold Member
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(Also available for your viewing pleasure at FBBO) :)

Hi guys, follow this link to another of Joey's great sites, and you can read a little about my first rebuild of the '68 A100 pickup.
https://www.fortrucksonly.com/truck...ibute-to-the-little-red-wagon-pic-heavy.4179/

Not so much in words, but I am happy to answer questions about the process. As with any restoration or rebuild, there are always things that can be improved upon, and this truck is no exceptions. It really was a 90 day build, and it was ready only hours before setting off to what has become a very famous annual event - The Whangamata Beach Hop. Held every year around Easter time'ish, it draws car nuts from all over the world, and showcases a lot of new builds. There is always something new that opens eyes, and gives great inspiration.

This year has been no exception. I have been holding something back from the masses here, and have only been sharing this with a very tight bunch of friends - guys who I can rely upon for solid advice and vision. Don't feel left out....I wanted this to be totally off the radar and low key just on the off chance something went bad. :D And besides, with too many differing opinions, it would only serve to confuse me, and possibly make me do something irrational here on site. :p

So, I am going to give a shout out to the guys involved....I'm sure they won't mind - (in alphabetical order) @Budnicks @conv67bdere @Ghostrider 67 @HEMI-ITIS @MarPar @moparnation74 @Richard Cranium @super-bee_ski
These guys have become good friends and I know I can rely upon the information they share - thanks guys. :thankyou:

Second shout out is to a Vendor here - @Johnny Mac and his team at BluePrint Engines in NE. I started talking with Johnny at the start of this year....and asked him to keep it to himself :) Johnny guided me through what became a hassle-free purchase and an all round pleasant experience. I selected the engine combination I wanted, and Johnny put his team to work on building it for me. The trouble with trying to build an engine in NZ these days is quality and supply of parts. Unless you have someone trustworthy enough to do the research for you, and actually build the engine in a timely manner, it just becomes another headache. BluePrint Engines took all the problems away for me. I am more than happy to recommend them to anyone wanting the easy route to re-powering their car....or truck.
Thanks Johnny. :thankyou:

Here it is - the engine I chose.....
BluePrint Engines 408CI Stroker Crate Engine | Small Block Chrysler Style | Dressed Longblock with Fuel Injection | Aluminum Heads | Flat Tappet Cam

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The type of EFI changed just before I purchased, so I am now the proud owner of a Holley Sniper system. Man it is way better than any carb system I have ever had. Once you get to understand how these work, there is no way you could ever go back. My buddy Cliff is so impressed, he is looking at putting a Sniper in his Ram.

Choosing the 408 was a no-brainer really, as it slots straight into where my 360 was, and the original mounts and brackets, transmission...everything just bolts back up together.
Sure, I made a few mods along the way....but who doesn't? :lol:
More about the mods in subsequent posts.

Rest assured....the engine is awesome, and way beyond my expectations. :thumbsup:
 
Started the project back on 4th of June this year....by removing the engine and transmission for inspection.
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The engine looked OK inside, and will eventually make it's way into my buddy Cliff's truck. Transmission was taken straight to a local specialist who has a passion for MoPar work. Tony gets so much Jappa junk and odd-ball transmissions, that this was a dream job for him. Started by tearing it down and cleaning all the parts. Installed a street shift - I opted to go small, as it's hard to wind the clock back once you go big. :D Also installed a slow bleed valve from the torque converter - meaning the fluid doesn't bleed out within hours or days....since the truck might sit for longer periods than normal. Replaced the neutral back-up switch while we were there. I had a local Engineer repair the damaged holes for the dust cover and two mounting holes as well. The welds and re-threading is so good, it's hard to tell it was done. :)
 
Forgot to upload this - this was just prior to removing the engine and transmission.....



:lol:
 
Transmission valve body lever was badly worn , so a call out for help netted a good used unit from '65 Dartman' at FABO. Thanks for helping out Don...much appreciated. Once that part was worked into the mix, the trans was completed and ready for installation.

Before.....
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A new neutral safety/backup switch was installed along with a new loom to the relay - actually one from a 1970 Plymouth B-Body :D ....who said it couldn't be used for something else. :steering:
 
While the transmission was being rebuilt, I took the headers in to get cleaned up....blasted and coated ....
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Which led to the next issue - gaskets. Some of you may remember me asking what gaskets you guys used. Well, turns out there were a lot of great suggestions. When I made inquiries locally, I was pointed towards a Custom Gasket facility just down the road from a fellow FBBO member - @Chargerjase . I marked up a set of new TTI gaskets for the Edelbrock heads, and sent them down by urgent courier. The guy had the new gaskets made and repackaged on the Courier the same day he received them. Now that is service!!! The place is called gaskets BOP Ltd - Gaskets | Mount Maunganui | Gaskets BOP - a small family run business that is hot on service.
The gaskets are double steel outer (both sides) and soft heat resistant material inside. Simply fit dry and tighten up on the manifolds or headers. I swapped out the old header bolts for studs with star washers and quality nuts. So far all sounds great...no leaks.

Template marked up...
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The new gaskets...
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Getting them made locally was still cheaper and faster than buying something exotic from overseas. :)
 
A new custom hanger bush was made for the tail of the transmission, as the one fitted looked very home-made and was extremely worn out...too many burnouts me thinks. :D

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While the transmission was being rebuilt and toughened up, I sent the rear end 8-3/4 head for a rebuild and a gear ratio swap-out. The previously fitted 2.76:1 ratio was replaced with a 4.10:1 ratio and Sure-Grip unit. Fresh gear oil was then installed along with a new gasket. Brakes were still in great condition, thanks mainly to the diligent work years ago by our very own Dr Phil - a brake specialist here.
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Now was about the time also when the driveshaft was checked over and swapped out for the spare with a bigger yoke for the 4:10 gear set. I have two driveshafts to cover whichever head I'm running. Took a while to source a spare, and I ain't letting either one go. :)
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Now that the engine was out, we could start to line up all the new brackets and pulleys for the new engine.
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Time to un-box the new engine from BluePrint Engines......packed extremely well IMHO :thumbsup:
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Someone call for a Taxi....2 mile journey to the workshop where the operating theater is located...
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Time to start hanging all the new goodies on the new engine....
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Mock-up time now....
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Bouchillon performance eventually contacted me, and everything is great - very nice product and a fair price. You can't make this stuff yourself without a lot of aggravation.
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Very pleased with their products. :thumbsup:
 
Next item on the agenda is the fuel system. Starting with the tank, it needed work to bring up to EFI specifications. After exploring the options, of which there were few, it was decided that a new custom tank would be needed. Given the time frame and shipping costs, I found a local specialist engineering company who manufacture custom tanks for boats and Hot Rods etc. So I gave them some dimensions to work to, and the old tank as a reference, and gave them a time-frame to complete. Only 4 days over budget, but it was a great looking job that they made. New capacity is 92 litres....approx 24 US Gallons. Complete with internal baffles and a BSP fitting for a VDO sender unit, the tank has a Return fitting, Supply and a drain also. The guys also made some stainless straps for securing the tank in place. A bit of fiddling around with the truck bed floor, and the tank was fitting nicely. Utilised the original J-Bolts also with the aid of threaded sockets to allow a bolt to be the tightening medium. The only part missing was a fuel gauge to match my choice of sender unit - a quick order into Summit got me a replacement gauge. Took a couple of hours to complete the swap-out.

Old tank setup as was previously fitted...
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Problem was the level of fill vs the filler tube entry...awkward and slow. Also a little ugly....
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Floor exposed underneath...
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The new tank almost completed in place.....
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Filler tube and alterations inside the rear quarter was next to make the tank work better. Filling was always an adventure...very slow because of the uphill tube into the tank. Our expert exhaust fitter called in to help out here again...

The old filler tube - done in a hurry 10 years ago..
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Time to mock up the entry ....
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Dr Phil in action...
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Getting tricky to put all the parts together and hidden...
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Certification label - these guys are actually about 2 miles from my home....
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Breather cap in place....(old fittings welded up and made safe)
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I had already converted the original dash and gauge to an Autometer branded gauge - it was the closest size and depth to fit behind the glass etc....you could say it was a no-brainer using Autometer. Recently swapped out the stock fuel sender unit and tank, so the new gauge had a different range and required the dash mods. Simple, I just bought the correct range for the sender.

Start with a little dissection...hacksaw time...
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The gauge needs cutting open to get the internal parts out....
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A small mod to the original gauge - this was done 9 years ago....
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Mounting studs replaced with nuts & bolts...
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Fuel gauge swap-out continued....
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Be very careful with the cardboard tube surrounding the turn-signal lamp...
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Fuel line work was next...before the engine and transmission are installed...
Used a bunch of Earl's fittings and braided hose for ease of disassembly on the side of the road etc....just thinking ahead. :D
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Below there is a 3-inch bulkhead to pass through, so a frantic search on the Innerweb found a company in Arizona...a phone call and a transaction was done. Within 6 days I had the bulkhead fittings required....thanks guys.
http://www.purechoicemotorsports.co...ct_id=346/category_id=74/mode=prod/prd346.htm

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We actually ended up having major problems with the flash new Holley billet pump - failed within 10 minutes of road test....a second one also failed within 10 minutes on the road test. The solution was to remove the Holley pump AND Filter/Regulator, and run a Bosch pump, and the return line directly from the Sniper. There appears to be some confusion in a Holley bulletin suggesting you can save on a return line by using a Filter/Regulator - this is the wrong way to pipe out a Sniper. The return line MUST run direct from the Sniper to the tank....no exceptions. This gives full pressure to the Sniper as well as allowing a cooling effect on the Throttle Body itself with the flow of fuel. As we didn't have anyone local to tap into for knowledge, this really was a 'Learn as you go' experience. All sorted out now, and the engine runs great.
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I have included the picture above to show that we had to dissect the Holley pump to determine the problem...the biggest problem appears to be a poor design.
 
Back to hanging the goodies on the new engine...
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Bit of a dilemma....no special tool for the water pump bypass fitting, so we improvised by using a bottle opener....
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And to torque it up....
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Chassis boxes for the engine mounts were cleaned up - sandblasted, rustproofed and sprayed with semi-gloss black after I had brushed the rust-proofing on. Forgot how good the camera is at picking out faults....:rolleyes:
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Installed new exhaust studs as these are easier than header bolts, and IMHO much more secure...
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New gaskets in place, and start the tightening process....
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Of course I love seeing/hearing that BluePrint Engine! but I'm super impressed with your gauge work also! Re-facing the autometers with the OE faces, thats the stuff of genius!
 
Of course I love seeing/hearing that BluePrint Engine! but I'm super impressed with your gauge work also! Re-facing the autometers with the OE faces, thats the stuff of genius!
Thanks....kind of born out of necessity. :thankyou:
 
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