"Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Hey guys. Been lurking here a while and finally picked up a project of my own this past weekend. Plan is to get the 235 running, yank it and the 3-speed. Then in goes:
5.3 with some goodies
Built TH350 or 400 with manual valvebody
Crown vic front
8.8 rear
'99 1500 steering column
Going to get it low and tuck some 20x9 BMF Novakane's wrapped in either 285/50 TerraGrapplers or 285/55 BFG A/Ts or "gravel chunkers" as my grandpa would call them. Going with 17" Novakanes up front with respective tires in a smaller size.
Exterior wise, I'm just going to clear it after I rehang the doors and take care of a few holes. I'll probably CLR, clear and polish the engine compartment to show off the original dark blue color of the truck. For the bed, I plan on chopping the floor and wheel wells out of an 80's Chevy bed (or whatever bed I can get on the cheap), weld them in utilizing the wheel wells from the donor bed to make clearance for the bigger tires. Then have it Armadillo-lined.
Interior is my weakness. I've figured out what seat I'm going to get but I'll let that be a surprise. Just not sure what colors to go with inside. I've been kicking around the idea of sanding it all down and cold-bluing the whole thing and using some steel wool to give it some grain. I don't really want to paint it because black is so hard to get to look good.
Anyways it should be a fun project for my dad and I. Can't wait to get it done and tear down some caliche roads.
https://scontent-a-ord.xx.fbcdn.net/...53&oe=54F0264F
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https://fbcdn-sphotos-c-a.akamaihd.n...15326f683feeef

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Welcome...Sounds like you been thinking this through...Can't wait to see some pictures

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Yessir, I've had a lot of time to think about things while I was truckless. Now all it takes is a lot of time and a little money (or viceversa :dohh: ). There's a lot of little stuff I can do to it right now to keep me busy while I left my project fund replenish.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Welcome.
Sounds like a neat project.
Keep the pics coming on your progress.
Kim

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Thank you. I've been following your build for a little while now. Nice work. What are the measurements on those tires?? The ones I'm looking at are right around 32". Just wondering how high I'm going to have to cut to get them to fit once I do a spring-under with the 8.8.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

My rear tires are 29" tall.
Kim

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Sounds like a great project!
Keep the pics coming!

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Well, the motor is alive! Runs strong too. It came with damn near everything replaced on the motor except the starter and the water pump. Bought a new battery, rough checked the timing to make sure it was in the ball-park, checked the oil, coil had power, new plugs and wires had spark, new fuel pump was pumping.... Everything was good except the intake bolts were finger tight. Took it and exhaust manifold off and used some extreme temp copper gasket sealant (for the time being) on them and bolted it back up. After 30 minutes of jacking with grounds, we determined the started is just flat wore out. Hooked up a tow rope to it, started down the road , dumped the clutch and it fired right up. Adjusted the idle and let it purr like a kitten for 10 minutes. It was a good feeling. It was the first time I'd ever heard one of these old motors run in person. Gotta love it. Now we get to yank it out.

Found out the yard I'm getting my 8.8 from has 4 running 5.3s. One has been pulled and has no ECU, the other 3 are still in the vehicles. The beautiful thing is, I'm probably going to be able to pick one up for less than half of what I was expecting to pay AND they'll be coming with trannies. I wasn't planning on jacking with an electronically controlled transmission but for the price I guess I'll just deal with the headache. I'll also be able to pull the steering column and pedal assembly.
Need to find a stock gas tank to fit between the framerails and possibly a radiator/fan combo to use. Any suggestions on what to keep a lookout for??

On another note, he's got a wrecked Saleen with a 6-speed in the yard with only 4X,XXX miles on it. Said I can have the whole car for $3K just not sure I want to deal with putting a Ford motor in this old truck. I don't know anything about them, wiring will be some one-off headache that few people (relatively) have done and......I'll never hear the end of it from all of my Ford buddies. Hell, the front and rearend are both going to be Ford, why not the engine and tranny too?? I don't know. I'm on the fence about it. Before I get either motor, I need to get a Crown Vic crossmember situated up front. What do y'all think?

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Fords are for show... Chevys are for go.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

I like your demeanor. The Saleen is an 06 model. I've been looking into it for the last five minutes and there's not much that impresses me. S281, 300hp...yada yada. If it's the supercharged done with 500ish HP I may be interested, but as of now I'd have to pass. The only other the appetizing about it would be if the front end isn't a pretzel, I could chop the frame at the firewall and make it fit. If it's the 300hp model though, I'm 92.667 percent out

On another note, the words "6-speed" has me thinking about an NV-4500. I know they're heavy bastards but has anybody done one with this swap. I know where there's one sitting in a bread truck that I almost swapped into my 350/YJ project.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

The NV-4500 is a 5-speed, isn't it? and with a 5.xx first gear, it's basically a 4-speed now, since you can't really use first gear for more than pulling trees.

I have an NV-3500 for mine and it even has a 4.03 first gear, which would be useless with any decent rear end gear, but it will fit just right with my Jag IRS and its 2.88

Basically, if you want a 6-speed, you will need to pony up the big bucks for a t-56. Around here, they go for around $1200-ish. I constantly monitor the junkyards around here for a Camaro or Trans-Am with one, but all they ever get are auto cars. However, if the day comes, I may be able to score one for $150!!!

Anyways...you got a cool truck, with some great patina. Enjoy your time working on it.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

I'm curious on how you'll mate the crown vic front end. I'm thinking of doing this to a '63 F*&d unibody we have out at our ranch.

Good luck!

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Ah yes. You are right. Not sure why I was thinking it was a 6 speed. If I went with it, I'd definitely be running some 3.55's to make use of the granny gear. The equalizer is that I'll be running a 285/50r20 rear tire. It really soaks up some gear. At 70mph, I'd be turning 1952rpms. Even if I left the stock 3.73 gears in it, I'd be turning 2051rpms at 70mph in over-drive. Would be a great cruiser and still get off the line in a hurry. Here's a great gear/speed calculator I found some time ago when I was building my jeep. http://www.grimmjeeper.com/gears.html

Did a little work yesterday before dark. Got the bed all cleaned out and ready to go back in with the floor out of a donor bed. Located all of the major components today. Motor, trans (if I want it) & steering column out of a 2002 Tahoe, 8.8 3.73 rear end out of an 01 Exploder and front crossmember out of an 04 Mercury Marauder. He's also go a high milage, 2000 6.0L I'm thinking about taking the cable throttle body and pedal assembly out of. Does anybody know if it's a straight swap? I'd like a cable controlled throttle instead of the later electronic controlled one.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

As far as dimensions, it should fit the frame nicely with few modifications. I'm more worries about motor mounts and mating it to a chevy steering column. I'll cross that bridge when I get there I guess

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

To answer your Drive by wire/Drive by cable question, it is A very simple swap. All you really have to do is replace throttle bodies. You take the 3 bolts holding the throttle body off and slip on the Drive by Cable Throttle body. You will also need the correct wiring harness - the Drive by Wire connectors that plug into the computer are red and GREEN. the Drive by Cable Harness ends are Red and BLUE. If you are doing an auto, it is super easy to wire one of these up using a truck harness. Once you get it going, I can promise that you will NEVER go back to the earlier chevy engines. Good luck.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Thank you sir. Sounds simple enough. Any suggestions on someone to tune the ECU/TCU if I go the 4L60E route? I'm pretty sure I can trim all of the unneeded wires, I just need someone to workover the computer.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

If you get a truck pullout (engine/tranny/wiring harness/MAF and computer) all you need to do is send the computer off and have the "theft" and "Rear O2 sensors" turned off. There are several here or on the LS1 board that are good. The complete system thinks it is still in the truck it came from. When you start "mixing and matching" (for ex, LS1 intake or different injectors or hotter cam and headers or different MAF) is only when you need to have it tuned. If you buy the 6.0 drive by cable, make sure you get that computer. The computer for 2000-2002 (camaro, corvette,pick up) for all intents is the same (I use computer service number -last four digits - 0411), only the programming is different. I've done several, and it gets easier each time - but the first time is a learning curve for sure. If you plan to go this route, and want to discuss, you can PM me and we can talk. Hope this helps.

Ricky

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

I did a 5.3 swap into my '69 Suburban, and it was pretty easy. I used www.lt1swap.com for all the wiring harness modification info. I also sent my ECU to Brandan (lt1swap) to have him flash the theft and rear O2 sensors, plus configure the electric fan to come on from the ECU. It was very reasonable for price, and very quick turn around.

I took that motor out of the Burb and will be using it again in my '57...so that should let you know how pleased I was with it. However, this time it will get a pair of turbos and some other goodies.

Oh yeah, and when you get around to the fuel tank and whatnot, definitely use and in-tank pump. I used an inline external for quite some time and they are so noisy that you will be sorry you spent the money on it and will end up spending more to re-do it with an internal pump.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Thanks for the info guys. Hopefully picking up the Marauder crossmember this weekend.
Ricott: Is it hard to get the drive by wire throttle to work? Somewhere I read it was a big headache for one reason or another with the ECU and they ended up just swapping a drive-by-cable TB on it. I guess I've got a few options here because he has a couple 5.3s already pulled with no ECU or wiring harness. I could just pull the TB, intake, wiring harness and ECU off of the 6.0L. I've got a buddy with a built 4L80E with a shiftkit I could probably pick up for 2-250$. It should plug right into 6.0L harness shouldn't it? I'm just not sure what year the 4L80 is. Decisions, decisions..... If the 6.0 had aluminum heads and didn't have 225,xxx miles on it, it would be a no brainer for me.

OneOff: I was on the fence about the pump. I was thinking about an insulated box to fit around it inside the frame rail if I ran an inline pump. You're probably right though, I'd end up doing it all over. What tank are you running in your 57? I was thinking about having a 15ga aluminum one made to go between the frame rails behind the axle. Not sure yet. I've been looking at LT1swap.com quite a bit. I'm sure that's who I'll be using to fix the computer. Just need to figure out what combo of motors, wiring harnesses and tranny will be the least headache. Supposedly he's got another rolled Tahoe coming in by the end of the week. Hopefully it'll have everything I need so I can just swap it all out in one piece

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Well...... it may not look like it but, it feels like we got a lot done this past weekend.
Pulled a 3.73 8.8 Ford that was given to me out of an Exploder.
Picked up a front end out of an 04 Grand Marquis for $450
Cut all the crap out of the bed and halphass cleaned it up
Pulled the front clip, motor, tranny, crossmember, front axle and everything else off of the frame.
Drilled aligning holes and mocked up the Marquis front end.
Cleaned everything off the firewall and out from underneath the dash.

It looks like the Ford "bridge" is going to fit nicely. There is quite a bit of space on the outside and on top of the frame but it shouldn't be a problem. I'm going to weld in some spacers that will extend don through the top of the frame and be welded to the inside of the bottom of the frame. It was hell trying to align the bridge with the frame but we got it as close as humanly possible without high-tech lasers and computers. I'm happy with it :metal:


On another note, I just realized they don't make the 20' wheels I want in a 5x4.5 bolt pattern. Soooo it's back to the drawing board. I'm looking at these AMR wheels in an 18" for the front which will be perfect because of the wider stance of the Marquis front end. The problem I'm having is that I need a 20x9 or 20x10 rear wheel that has 0 offset or slightly negative offset because of the narrower 8.8. Any ideas or suggestions on where I can find some or what brands to look at? As far as I now, the AMRs don't come with the offset I need.

I also locked down a deal on a whole 02 Tahoe that was rolled for $1000. Going to pull the motor and trans, steering column, pedal assembly, brake system and all this week hopefully if weather permits. A buddy of mine has a cam for me for cheap if I want it. I won't pretend to be a cam wizard so I'll let y'all tell me what you think. He says it'll be very streetable with the right converter, and sound good too. It's a Texas Speed 228R 228/228 .588"/.588" 112LSA cam. Says all I'll need is some new springs and hardened pushrods along with (probably) a 3200 stall converter. Plan is to get rid of the electronics on the 4L60E and put a Transgo Stage 3 full manual shift kit in it.

https://fbcdn-sphotos-f-a.akamaihd.n...50162af8146189
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https://fbcdn-sphotos-b-a.akamaihd.n...a02004de500029

https://scontent-a-dfw.xx.fbcdn.net/...db&oe=54D5F692
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https://scontent-a-dfw.xx.fbcdn.net/...34&oe=54E7B87D
https://fbcdn-sphotos-e-a.akamaihd.n...3daa4bf69f5f92

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Looks like a very nice fit!

Can't help you with the cam.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Nice progress.
Kim

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

That cam seems like a good deal if you don't have to pay for it. Cam selection should always be based on what you want to do with your vehicle, so if it is the RIGHT cam for your truck?? That depends on how you plan to drive it.

As far as removing the electronics from the trans...I don't really know if you can do that to a 4L60E. I would highly recommend that you don't if it is even possible. I feel that the only thing keeping those slush-boxes together is the electronics. It would basically become a 700-r4 without electronics, and those things implode with even the slightest mis-adjustment of the TV cable. That leads to rebuilding a trans, which leads one to wonder why they didn't just put a manual trans in it from the start.
Bottom line...get a 5 or 6-speed and enjoy the truck from the get-go.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

I hear ya on the cam. It won't be free but pretty cheap. The cheapest LS6 cam I've found locally is $180. This cam I can get for 200$. As for use, it won't be a daily driver. More like a weekend cruiser, short road trips (3 hours) to car shows, maybe a few trips to the track and a whole lot of terrorizing the local import/ricers that drive around annoying the hell out me.

As for the transmission, for the price in going to run it. I just like th idea of being able to shift it when I want, depending on the situation. I've been doing a lot of reading up on it and opinions seem to be split down the middle.....love it or think it's a bad idea/put a manual tranny in like you said. The NV4500 I'm wanting is going to cost me as much as the whole donor Tahoe. That's another grand if have to spend. Here's just one thread on the topic.... There are several http://ls1tech.com/forums/automatic-...alve-body.html
I'm going to have the local shop go through the tranny and make sure everything is Kosher before I go romping on it. In reality though, as little as I'm going to drive it, I'm not worried about long long term durability.....I may only put another 10,000 miles on it once it's done. If it gives Up the ghost then, I'll either shell out the $2k for a built phoenix tranny or swap in that nv4500. For right now I'm just going to get it on the road with what I've got. Just curious, what do those NV3500s run? I haven't looked. IIRC, they either came stock in some Wranglers or it was a very popular swap into them. I know they were leaps and bounds more reliable than the AX-5 that came behind the 4-banger in my YJ

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Not much to report other than getting the frame sleeved for the 4 thru-bolts. I think boxing it is going to be a SOB with the way the frame tapers slightly from back to front and dips down a little. Then the bottom "rail" of the frame is wider in places. I think I'm just going to take a straight edge and a torch and square everything up as much as possible. Going back in with 1/4" diamond plate because I have half a sheet left over from a bumper project from my jeep.
Currently, we're trying to get the tranny cross-member out. Every single rivet is fighting us tooth and nail. Gave up for the night.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

I found the best method of rivet removal was grinding the head off with a 4.5" angle and using an air hammer with punch tip to drive it out. I'd tried torch, chisel, BFH & profanity before I came around to grinding the heads & air hammer out the stub.

Also: tack a brace into place before you remove any cross members. The trans member you might get away with it but in the rear, the cross member keeps the frame straight. The leaf spring hangers will torque the rails pretty far out there if you don't have it braced.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

I appreciate the help. I like the grinder method too but there's a few holding the spring hangers on that I can't get to with the grinder. ...and I don't have a n air-hammer YET. Looks like I'm headed to Sears tomorrow to get one though. The ol fashioned hammer and punch method sucks! Not to mention, layers and layers of petrified oil and dirt make using the torch a little adventurous. Thanks for the heads up on the rear...it will be next. For the front, the bumper kept everything in check.
I checked out your project. Nice work. It helps with morale to see that others are suffering along with me haha. Keep up the good fight.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

If you know anyone with a CNC plasma or Waterjet, I will give you the CAD files that I just drew up for front boxing plates. Just load them into the machine and slice that sheet that you have. I'll be drawing rear plates with a 2" notch this week to cut out for my own project. I cut the fronts last weekend, and they fit like a glove. They are 40" long and go from the front of the radiator support bracket back to about where the trans crossmember used to be.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

That would be amazing. My buddy runs an oilfield machine shop. Let me see if he has either piece of equipment. I've already straightened up the area that dips for the front of the front crossmember but I could definitely make it work. It'll save me at LEAST 3 hours with cardboard and scissors :metal:

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Well my buddy has a waterjet and a CNC plasma. All it's going to cost me is a fishing trip this winter.
Oneoff: what did you do to the frame where the steering box was? I'm not exactly sure how to tackle flattening it out.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

On second thought, notching the ends, flattening it out and welding it back up wouldn't be too hard at all. I'm just not sure how your CAD drawing addressed it. Don't want to make more work for myself.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

I haven't addressed the little flare for the steering box with the CAD drawing. I am just going to cut out the flare and weld in a flat piece. Seems like the easiest way, since I'm going to be there with the welder anyway.

Here are the plates that I cut for mine. The files are on my computer at work, but I'll grab them before the Thanksgiving holiday. I cut mine into two 20-inch pieces, because I had a metal remnant that was only 21" or so. I will redraw them as one piece and attach that as well. I will also do versions without the little semi-circle cutouts at the front. Those are access holes that I designed so that I can get to my sway bar mounting bolts.

After they are cut, you will still have to do some slight fine tuning with a grinder to dress the edges for welding, obviously.

BTW, if anyone else wants these .DXF files, I'll send them out. Heck, I think this site needs a sticky for open source shares of .DXF files.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

That's sweet. I appreciate it. One idea I had was leaving another 4" of metal on either end of the plate and bending them at a ~45* into the frame so that the boxing wouldn't come to an abrupt stop and it would give me a little more strength (in my mind). Not sure if this is a good idea or not. I'd have to cut access holes in the end to run brakes, fuel, wires etc but that is easy. I also plan on welding in a length of the 3/4" sch80 inside the bottom corner of the frame from the firewall back to the rear to run wires in and help strengthen the frame (somewhat) between the front and rear boxing. I had to buy a 21' joint and only needed 2' of it to sleeve the frame.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

I attached a .zip that has 3 files in it. They are for the boxing plates. One file has the rear 20" section, and it actually has a mirrored image on it so it will make the plates for both sides. The other two files are for the front 20" section. These contain only one at a time, and one has no cutouts for sway bar mount access, the other one does. Cut 2 of whichever one you want for the front part, and then jam them into your frame for 40" worth of boxing plates!

Your buddy should have some sort of editor like Autodesk, MasterCam, Solid Works, or something and should be able to connect both parts together if you want one solid 40" piece or want cutouts somewhere else, or want to add extra to the ends for the 45-degree thing you were talking about. The possibilities are truly endless. Enjoy!

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Thanks OneOff. That's solid. Hoping to get it cut this week. Currently working on mocking up the rear end so I'll have a roller again. I sold the wheels so it was sitting on jack stands. Need to be able to roll it around to put the motor in....using an A-Frame and chain hoist in a caliche driveway to pull the motor out of the donor and roll the 57 under it. What rods did you use welding the plates in? The frame seems awfully soft.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

What's the track width on that crown Vic front end?

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

62" I believe. I plan on running some high offset wheels designed for a ford mustang up from and some 0 or very low offset wheels in the rear because the 8.8 came out of an explorer and is only 58.5" if I remember correctly. The stock steel Crown vic wheels fit inside the fenders as is, the high offset mustang wheels should fit nicely.

The only tough part was situating the mounting holes on the frame. On the bottom of the driver's side, they are just round holes. This put the holes for the sleeves very tight to the outer edge of the frame. The passenger side had all elongated holes so I was able to center the sleeves in the frame.

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Well got a little work done this past weekend. Got the old rear suspension and axle cut out and the new one mocked up. https://fbcdn-sphotos-b-a.akamaihd.n...7496f94dcd6356
https://scontent-b-ord.xx.fbcdn.net/...e6&oe=5546084E
Just waiting on the rear shackle hangers and Jeep YJ shackles to come in. The pinion angle as is is a little high but I plan on correcting it with some shims. I also had to drill and weld up a couple of unforeseen cracks behind the front spring hangers.
In the meantime, I got one of my other toys sold to free up some $$$ and get some goodies ordered. Found a seat on ebay at a steal of a price. It turned out to be one of my few GOOD drunk ebay purchases. It already came in and is going to fit nicely. :metal: https://fbcdn-sphotos-e-a.akamaihd.n...684a7850593f0d
Finally found some wheels with the correct staggered offset I needed and liked. Going with TSW Nurburgrings in the rear and these 18x7.5 in the front https://fbcdn-sphotos-f-a.akamaihd.n...5d8e371ccbcb6f
Dropping the plate off this week to get cut so I can box the front end. Headed to Georgetown on Thursday to Texas Speed and Performance have them program my ECU and pick up some hardened pushrods, springs and longtube headers. I'm going to be running either of these two depending on which ones match up to my measurements the best. https://www.texas-speed.com/p-3410-t...evygmc-v8.aspx or https://www.texas-speed.com/p-4150-t...8-2wd-4wd.aspx I figure it's better to get the headers bolted on and fit the motor than to get motor mounts made and hope they make some that fit my one-off project. Here's the 228 cam I'll be running. Should be fun and sound pretty mean with some dumped Magnaflows. :sumo: https://www.texas-speed.com/p-1148-t...-camshaft.aspx

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

I ended up plating the side of the frame before welding the square tubing to the side. It's been a while since I've welded and those 7018s were a little finicky to get started and even harder to restart, hence the burnmarks on the spring-eye. I wire-wheeled the hell out of the frame before welding it all up.

Just noticed a mess up on the wheels above. Rears will be 20x10 Nurburgrings and those 18x7.5 in the front

Re: "Pinché Caliché" '57 StepSide/LSx/CrownVic
 

Looks good.
What's the seat out of?
Kim