“Thunder” 1998 Expedition Build Thread

[MISTERgadget]

TJ, badass build! Sometimes I wish mine were 4x4 just so it could hook on all 4 tires, that would hurt some feelings on the street! We have two very similar builds, great color choice too!

Can you elaborate on how you fit the mini H1s into the Lightning headlight shell? Also, what size (mm) of XBS 2.0 Switchback Halos did you use?

Thanks and great thread.

The halo was a 100mm halo. Getting the projector in is very easy. I reccomend using knockoffs of Lightning style housings, as they usually use butyl sealant instead of so-called "permaseal", and it makes for a very easy removal of the lens with a few passes of a heat gun around the edges of the lens. After removing the clips around the edges, heat up the seams, and once you visually see the sealant turning soft from the heat, pull the lens right off.

The Mini H1 7.0 is a tight fit depth-wise, but it can be installed using the threaded shaft and just barely clears the front lens. You have to cutoff part of the ring around where the bulb normally sits to make it easy to tighten everything down, it's very straightforward once everything is apart.

If I were doing it again today, I would use diode dynamics' new HD halos that just came out, they are much brighter, and the best part, made in USA!

Here's a picture I have of the backside that shows more detail:

 

[MISTERgadget]

Some minor updates, it's mostly "hurry up and wait" at this point on the cylinder heads to get back to the engine builder.

Finally stopped being lazy and after sitting on this guy for a few months, pulled the original short rod out of the hydroboost and replaced it with this adjustable unit from Tallon Hydraulics (no fun doing it once the HB was installed,I took the driver's seat out and laid on my back on the floor)

In the picture you see the new adjustable rod as well as the pulling tool for removing the fixed length rod.


image.jpeg3024x4032 1.94 MB


Less than an hour later, start to finish, I had already installed and adjusted the new rod, inckuding a mishap where I accidentally bent the piece of rod I tried using with the puller for my first attempt, and then trying to get it dislodged.



The superduty has a different geometry to the pedal setup so it uses a short rod from the hydroboost to the brake pedal. In an F-150/Expedition, this leads to a low brake pedal that sits below the accelerator pedal and feels like it doesn't have much room to go before hitting the floorboard. The longer rod brings the pedal back up, and having it threaded for adjustability lets you put it exactly where you want.

In months of driving the truck I never actually ran out of pedal travel, and perhaps it's just psychological, but once the pedal height was corrected, the brakes immediately felt even better and more confidence inspiring. Perhaps lifting the pedal back up corrects the geometry to give you more leverage. The pedal height feels right now and no need to adjust going from one truck to another. Now all 3 have the same pedal height and hydroboost, it's a real pleasure to drive.

 

[MISTERgadget]

and just because, a few pictures of the truck around the house after a fresh coat of collinite insulator wax.

and yes, the EB flares desperately need to be color matched!

 

[whitelightning99]

looks nice

 

[MISTERgadget]

Got the heads back from the porting wizards at Performance CNC (cncport.com)

Fully CNC Ported exhaust/intake runners and combustion chambers, 1mm oversize valves, new valve seals, new guides, new valve seats, upgraded crower springs and retainers.

 

[eluther3]

Are you color matching the fenders yourself? I just got a set of fenders from the junkyard to add to mine. Used the Duplicor Perfect Match in Oxford White and the 3 in 1 primer. It was a piece of cake

 

[MISTERgadget]

Dropped them off at a bodyshop last week actually, I should have them back friday and on the truck this weekend!

 

[MISTERgadget]

Got the paint matched fender trim on, way overdue!! It totally transformed the look of the truck.

 

[MISTERgadget]

The Expy also took a trip with me to the West Coast of FL to see family over the holidays

 

[Tjhoward84]

Absolutely beautiful but I am a little bias.

What's next for this beauty?