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I hit **** with sticks!
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Discussion Starter #1 (Edited)
Decided to put up a restore thread over here on my 1993 Dodge D250; Cummins Turbo Diesel...this truck is like the Intrepid to me; and is getting a very similar restoration that my Intrepid did back in 2005...a bit more on this one though.

A little history, the 1993 has been in our family since 1996, I remember when she was clean as a whistle, with just 40k miles.....my dad bought it for me as a graduation gift...I drove it daily until around 2003, when my dad needed it more than me for hauling, work at the farm, etc...so I went to a Toyota Tacoma, and gave him back my old Dodge...regrettably....I eventually sold the Toyota, got into the car hauling business, borrowed the old 93 for a couple years, then in 2007, purchased a 99 Ram 3500 to handle the towing...dad got the 93 back at that time.

Fast forward, I sold the 99 Ram 3500 in 2012, with over 270K miles, it was needing some major work...and I was done with hauling, so it was best that it was sold......this June, dad decided to buy a new car, no longer needs the 93, and gives it back to me....

Ohio winters have not been good to it, I live in NC now....had it shipped down...bed is shot, fenders are shot...cab is shot...holy rust....but she still runs like a top...tight as ever....drivetrain and frame is good...so...being the most reliable truck we have ever owned, and sentimental value and all...I am going to restore it, with the help of this 89 D150....its clean as a whistle, not a speck of rust....so here, the project begins...

Hard to tell in the pics, but the only good panels left on the 93 are the hood, front rad support, and the drivers door...LOL....

Many pics to come during the restore...pictured here is the 93, and the first of two parts trucks, a 1989 D150, in grey on the right.
 

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I hit **** with sticks!
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37,343 Posts
Discussion Starter #3 (Edited)
Just picked up this pile of bolts, for parts, a 1991 D250 diesel, it will contribute some good rust free parts along with the 1989....

Down to the bare frame;



 

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I hit **** with sticks!
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37,343 Posts
Discussion Starter #4
Next step is to prep the frame for sandblasting/paint, just have to swap over some rusted out brackets and crossmembers with some clean ones, and she'll be ready.....

This truck is also kind of a bastard, it has proven very hard to find parts for. It is actually a 1 ton truck, badged as a 3/4 ton....with the engine/trans combo it has, it is 1992-93 only apparently the way it is set up...very very hard to find certain parts...I have ran into several issues with the cab and frame, but no worries, now I have enough parts around to get her back together nicely...
 

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Keep the pictures and updates coming. You will definitely put that compressor to work and spend some $$$ on sandpaper and sand grit.

Was the rusted side drivers floor pan from wet shoes?
 

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Nice project, will keep you busy for a while. I'm betting the result will be awesome !!
Make sure you take care of the "death pin" before you stuff that "B" back in......
 

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I hit **** with sticks!
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Discussion Starter #9
Keep the pictures and updates coming. You will definitely put that compressor to work and spend some $$$ on sandpaper and sand grit.

Was the rusted side drivers floor pan from wet shoes?
Yep, the compressor is sure to be tested...hopefully doing the sand blasting next weekend after some prep this weekend.

Yeah, floor pan is gone from the snow/salt seeping thru I am sure....plus it had the salt treatment on the bottom as well from the road spray.

How did the drivers door survive? With northern winters you would expect extra snow/crap to sit around the rocker area and rust out that and the lower couple inches of the door.
There is a little bit of rust on the seam at the bottom. Thats it. Easily fixable with a quick sand blast and some POR 15. The passenger door is completely gone on the bottom..no idea why...maybe it was something to do with the passenger door seldom being opened, and the salt/snow/crap could sit between it and the cab and fester.

Nice project, will keep you busy for a while. I'm betting the result will be awesome !!
Make sure you take care of the "death pin" before you stuff that "B" back in......
Yep, plan on doing the KDP before the install....never an issue with it, but just to be safe.
 

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I hit **** with sticks!
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Discussion Starter #10 (Edited)
As of now the frame and several other pieces are at the powder coating shop. They should be done any day now....and reassembly can begin.

When it gets back, first step will be to get it back to a rolling chassis. Suspension will be installed, then brake/fuel lines, chassis wiring etc, then the body. Piles of parts here waiting.

I have begun tearing the parts trucks all to pieces and getting the donor parts ready in the mean time.
 

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I hit **** with sticks!
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Discussion Starter #11 (Edited)
Here is the latest.....got the frame and all the parts back from the powder coat shop....now on to re-assembly. I spent most of the day putting new bushings in all the axle components...hoping to have a rolling chassis here in the next couple weeks.



Here is the following week, got the axles in; shes just about a roller;
Front and rear suspension is on! Hoping to have a rolling chassis before the week is out.

 

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I hit **** with sticks!
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Discussion Starter #13 (Edited)
The color looks perfect to me, how's the finish??
It turned out pretty nice. There are some ex-rust pits still visible near the axles; that was expected; nothing can be done for that really; but overall, I am satisfied with it. Semi-gloss finish.
 

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I hit **** with sticks!
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Discussion Starter #14 (Edited)
Shes starting to look like a truck again. Got the cab mounted up today.



Next step is to install the fuel tank, chassis wiring, and the bed. Then; lots of bodywork. Stay tuned.

The parts truck is looking a little skinny after all of this:




It will see the bad side of the junkyard soon. We were thinking maybe a 318 powered go-kart in the mean time.
 

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How many people did it take to move the cab on to the frame? Where the doors still on?

BTW - will there be lounge space for the meet?
 

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I hit **** with sticks!
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Discussion Starter #17
How many people did it take to move the cab on to the frame? Where the doors still on?

BTW - will there be lounge space for the meet?
5 of us, we moved it without the doors. Its a bare shell, except the glass; only weighs maybe 250lbs. The doors themselves are pretty heavy, close to 70 lbs probably.

Yes, there will be plenty of space for the meet; putting this truck together will get all the parts up out of the garage so we have room...truck can be pushed outside.
 

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I hit **** with sticks!
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Discussion Starter #19 (Edited)
Well, I figured it was time for an update...I dug into the body work pretty hard the last couple weekends getting ready for paint. Removed all the old trim and sealed up the holes from it, and removed the titties holding the plastic trim retainers on. Removed all the old seam sealer on the cab, and sand blasted the drip edge. No rot found, just surface rust luckily, its gone now. Also, I removed the low hump (automatic tunnel) and replaced it with the proper high hump manual trans tunnel:

One of the trim holes disappearing:




Trim all removed, started sanding the body:


Automatic Transmission Tunnel coming out:



Trans Tunnel from the original cab [NO RUST...thanks to oil from leaky Cummins valve covers]...


Installed, ready to weld in on Monday...this was a big job, not the easiest panel to replace.


Took all the glass out and sanblasted the drip rail and windshield frame, all clean; ready for new seam sealer.


Manual Trans tunnel all welded in and done...


So far, this has been a ton of work....I've questioned my reasoning in diving in this far to an old truck; but damn, it will be worth it when its done. Next step is get her all back apart and down to bare metal for the body and paint prep.
 
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