Electrical System: Schematic (Last Updated 4/2004)

-Batteries

* 3 battery system w/ battery isolator.

* Primary battery is for engine starting and running, headlight and heater, wipers….

* Secondary battery is for radio, and other high amp draw stuff

* Third battery combines with 2nd Battery to produce 24 volt for Stobe System

-Starter

* Reworked solenoid on starter to jump it off and relocated to upper engine compartment with ford style.

* Reduced the length of the wire run and increased the size of the wire to #2.

-Alternator upgrade to 135 amp

-Rewire of entire vehicle with increase in wire size to key areas;

* i.e. headlights, starter motor….

-Relocated headlight bright switch to shifter, w/ momentary

-Indicator light bank w/addition switching of lighting system

Power Train:

-Head upgrade:

When I had the heads done, I asked the guy to upgrade the valves and valve springs, and install valve seats. When I got the heads back, he had install a racing type double spring setup on the valves. They no longer float at high rpm.

-Welded rocker assembly replaced with Boat style rocker assembly

-Headers: Stan’s Headers

-Timing: Mallory Unilite distributor with hotter coil and spark plugs gaped at 70

-Removal of emission system

-Holley 500 CFM carb with a large jet. Not sure exactly what size (maybe 73), but I over did it and need to reduce it a little(maybe 53).
    :Winter 2002/2003  Found the best jet size to be 66

* Spring 2004 Installed K&N Air filter on Carb with riser to extend clearer into hood cowel

-Power steering: The manual steering was the worst, and the wife wanted to be able to drive Buddy, so we bought a pump and gear set, rebuilt them and had to modify the existing spine, rag joint setup to accommodate the new pump. Also had to fabricate a bracket setup for the pump to attach it to the motor. Works great now.

-Clutch: Custom pressure plate made with ceramics and upsized both to 12 inch. Also increased the spring tensions to force the plate to stay in contact with the disk.
    Summer 2003 While playing around, I popped the clutch and snapped off one of the little finger bolts that ride on the throw out bearing. Some welding was needed.

-Removed the single speed chain drive transfer case and installed a 2 speed transfer case
    Winter 2002/2003  While playing around, I popped the clutch and twisted the drive shaft in 1/2. That was a costly repair, but found the original was not up to specs, so we upgraded the mil and the diameter.

-Entire engine compartment taken down to metal and repainted

-Radiator hold down re-engineered to clamp down style w/ shroud support modification

Body:

-Permanent removal of the hard top

-Custom convertible half top (Terra style)

*Fall 2003 Reworked Hard top front section into half top

-Back deck w/ gas support shocks
    Spring 2003 Covered the deck with same vinyl as the half top

- Spring 2004 Installed Hood Cowel induction system.

- Spring 2004 Painted Exterior of truck yellow

-Door Hinges: increased door adjustment

-Rally wheel centers w/ custom IH logo

Suspension

-Shackle support modification:

Early Summer 2003 Dropped the rear shackle support down 3”

Summer 2004 Reverse Shackle Modification Pic / Doc File on front springs

-Total Suspension lift of about 3"

-Front stabilizer shock, Rancho

-Rear stabilizer bar

-Rancho 5000 Series Shocks all the way around (Summer 2003)

Interior:

-Power windows

* window regulator and motor from late 80’s Ford van reworked to fit IHC regulator.

-Power locks

* installed power lock motors on both doors and back deck (tailgate in future) with keyless entry pad and high tech alarm system w/ remote

* Alarm system-commando 501-S w/ starter cut-out.4 additional horns installed for added db output.

-Gauge package

* Thornsen digital gauges for oil and water temp, main and secondary volt gauges, tach and clock and a mechanical oil pressure gauge.

-Custom paint of all interior pieces (original brown)

-Seats

* Summer 1993 Escort Bucket seats
    * Spring 2003 Replaced Seats with 1999 Sunfire Buckets

-Chevy 14” steering wheel w/ custom IH logo

-60 watt Fosgate w/Pioneer Supertuner
    * Spring 2003 Replaced with Bolt Lighting Amp w/ 2-10" MTX & 2 Kenwood 6" Mids in Custom Box

-CB w/kicker

-GPS

Other Stuff:

Repaint of all removed parts

Note:

All or 90% of the interior work was done when I got the truck, 1991, with the rest of the work done recently to accommodate rework of systems or new modifications.

Most of the engine work was done 1999 and is still on going.

The body and suspension were only taken into consideration these past few years and are in the plans to be redone.

I have no intension of making this truck show or anything close. I will settle for looking and running good. Nothings perfect and Buddy is certainly that.