For the most part, hooking everything back up was simply the opposite of disconnecting it all. In a few spots, I added self fusing silicone tape around hoses or wires to improve their protection against the hot engine compartment conditions.
See captions below each photo for comments and explanations…
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- `93 D-250 Driver’s side firewall photo – the largest circular holes to the right of the brake booster must be transferred to the `82 Crew Cab firewall.
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- `82 Crew Cab Firewall – cutting the holes. Compare this photo with the firewall photo from the `93 and you will see exactly why I needed to cut. The hole nearest the booster needed to be enlarged, and the other (really big) hole needed to be cut from scratch.
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- This image shows the larger of the two round holes cut into the Dually Crew Cab firewall. The big hole has a big rubber grommet/plug which enables any custom wiring to pass through the firewall. From the factory these grommets had few if any wires going through – the hole was mostly for upfitter purposes on the later trucks. You may also notice in this photo that the other round hole nearest the booster is marked but not cut yet. The existing hole just wasn’t big enough.
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- With large grommet installed in big round hole, and with smaller hole near booster already cut. The grey stuff around the edge of the smaller hole is the foil backed insulation material I glued on from the inside.
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- Both round firewall holes cut, deburred and painted white to prevent rust.
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- The `93 D-250 Donor Truck was now able to move outside. Image shows storage of spare parts in pickup bed.
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- `93 D-250 Donor Truck now outside the shop. Beautiful weather, not sure why I was inside the shop working!
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- Hooking everything back up – the radiator position as well as the position of all the other items fit perfectly into the older Dually Crew Cab truck.
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- Photo of passenger side as things were going back together.
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- Driver’s side of truck – mostly wiring and the battery tray on this side. Any cracked or dilapidated wiring got a few wraps of self fusing silicone tape to improve longevity and reduce stress on the assembly.
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- Another photo of the passenger side, from the front of the D-350.
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- With radiator, intercooler and A/C condenser bolted back in.
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- The truck was really getting close to finished at this point.
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