Finally got far enough putting the front together, to work on all of the hoses and pipes. The one issue that I ran in to with the aftermarket intercooler pipe that I bought was getting through the passenger side of the radiator support. What I ended up doing was buying a new Ford factory pipe and cutting a section out and welding the beaded end back on with a little tilt downward. Turned out pretty good but had to have a coupe offset HPS connectors. Forgot that the turbo has a 2.75" outlet and ordered a 3", so another part on the way. And don't forget to torque the T-clamps to ~109 inch/lbs or you will blow the connectors off (SURPRISE!). I had picked up a aftermarket intercooler pipe set for the truck and used a lot of the pieces for my custom config but I did have to buy some additional pieces including a 90 degree reducing connector for the Cummins intake to the 3" aluminum pipe.
After finally figuring out what all of the plumbing on the engine was for, I now tackled the heater hoses. One of the pipes that looked like a heater pipe was actually the crankcase vent. I am pretty sure that things would have went really sideways if I plumbed that to a coolant line. Turned out pretty easy as soon as I figured out what to do. The only connection that will be an issue in the future is the pipe that would connect to the bottom of the radiator pressure tank. I put a coolant bypass cap on it but those don't usually last very long. I was able to use regular non-molded hose for the connection to the head and a simple generic 90 degree hose for the return pipe.
For the upper radiator hose, tried to weld my stainless radiator fitting to the hose connector, blew a hole right in the bottom of the area where the cap seals. Now that is trash, nothing saved but the radiator cap. Got online and found someone that had a 1-3/4 connector with filler neck so I got it on the way.Got it installed but still don't know if my plan will work or not. Turns out that the cap is a little lower than the EGR cooling system so now I will just have to test.
Power steering hose took a trip to The Hose Shop. The Ford V10 hose was my starting point but it was way too long on the metal part of the assembly. The Hose Shop was able to take my cut down hose, weld on a fitting, make a short rubber hydraulic hose, and reattach the end that connects to the pump. Looks mostly like a factory hose and appears to work as it should. As for the low pressure reservoir return line, I started with a new Ford 6.4L hose, cut it in the middle (or so) and used a brass barbed coupler to rotate for the directions that I needed, and clamped it.
A/C hoses are not in scope right now since winter will be starting, project for next year.
I do want to call out HPS for having a good variety of pieces and parts that I have needed for this project. Also, it was worth the $130 for the Jegs tubing beader. Not sure it will work on anything heavier than the aluminum tube that I have, but it has been invaluable.
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