1987 F350 4x4 Crew Cab Diesel Dually! Project Brutus, The Bulletproof Garage!!!

1987 Ford F-350 Custom

NO RESERVE AUCTION for this 1987 F350 Custom crew cab long bed dual rear wheel project truck, also known as Project Brutus. Brutus was originally configured as a 2WD 6.9 liter IDI diesel dually with the ZF5 S42 transmission. It now has a completely rebuilt 7.3 IDI turbo diesel, 4x4 conversion with a rebuilt Dana 60 solid axle, rebuilt Borg Warner 13-56 transfer case, and a completely rebuilt ZF5 S47 4x4 transmission. FYI – if you want a 4x4 crew cab diesel dually from this generation of Ford trucks, you need to build it or find one that’s been converted because Ford never made a truck in this configuration. Yes, there's still some work left before it's road worthy, but the hard work has all been done.

More details below, but this truck is also the star of my YouTube channel, The Bulletproof Garage. I can’t insert a link here, but just go to YouTube and search for The Bulletproof Garage and you’ll find 25 episodes on the work that I’ve done on Project Brutus in the past year.

Before I forget - $1,000 deposit due within 48 hours of auction end (PayPal is fine for the deposit). Full payment due within 7 days of auction end by wire transfer (preferred) or cash in person. Truck must be picked up within 7 days. Truck does roll and steer, but I do not have the capability to transport the truck, so please plan to take care of shipping arrangements on your end. Clean Virginia title.

I have at least $17,867.86 invested in the truck (it’s more than that; I’m sure I forgot to include some purchases), and of course that doesn’t account for hundreds of hours that I’ve spent working on it. The new owner will get all the receipts.

I’m selling the truck partially completed because I have simply run out of time to get it done. I am retiring from the Army after 26 years of service in a few weeks and I’m moving from northern Virginia back to Texas to rejoin my family. Once I get back home to Texas, I have 5 project cars in line to be finished, and it would take me forever to get to Brutus, so my loss is your gain.

The original 6.9 IDI was seized and had rust in several cylinders, so I sourced a 1988 7.3 IDI that only had about 30,000 original miles (plow truck). The engine was in beautiful condition internally but I still completely rebuilt it. Also, one cylinder got water in it at some point, so I had a sleeve installed so it would remain standard bore. The crank is standard/standard, and I installed Total Seal gapless rings for the second ring. I also installed R&D IDI head studs; I believe these are sourced from ARP. The heads are from a 1994 IDI turbo engine, and they been fully rebuilt, too, with new valves, new Comp Cams 910 springs, full valve job, and new positive seals on the intake and exhaust. The engine also has an aftermarket camshaft from Justin at R&D IDI, and billet fuel return rails from R&D IDI. It also comes with a new R&D IDI 4” turbo downpipe and a new exhaust crossover pipe.

The induction is a Stage 1 drop in turbo from R&D IDI along with an R&D IDI 90cc injection pump and Stage 1 injectors. According to Justin at R&D IDI, this combination should make 250 hp and 550 ft/lbs of torque at the rear wheels. FYI – this isn’t a hotrod motor; it’s a conservative and mild build with an emphasis on longevity and reliability.

The truck comes with three sets of front dress/accessories – one full serpentine belt setup, and two complete V-belt setups. The cooling fan is an aftermarket manual fan, and the fan clutch is new. The water pump is new and the radiator is original but it does have a small leak. I do not have radiator hoses.

The engine build was finished a few months ago but I have not installed the turbo, injection pump, and I have not started the engine. It also needs the overflow line run to the tank, the starter wired, batteries purchased and installed, and the glow plug controller and CDR installed. The engine does have the turbo valve covers with provisions for the CDR and glow plug controller mounting. You will also need exhaust run from the downpipe. The complete engine rebuild was documented with numerous videos on my YouTube channel if you’re interested. I have $7,501.23 invested in the engine; that’s all parts except for a $565 machine shop bill.

The transmission is the stronger S47 version of the ZF5 that I sourced from a 1995 F350. I fully rebuilt the transmission with new bearings and synchronizers; it's installed and shifts well. The single mass flywheel, clutch, and pressure plate are brand new from Luk. I posted videos on the disassembly and rebuild of the transmission on my YouTube channel. I have $2,855.33 invested in the transmission/clutch/pressure plate/flywheel.

The transfer case is a Borg Warner 13-56 with the correct provision for the speedometer on the transfer case. It's also the F350 version with a provision for a PTO. It was in really nice condition, but I also fully rebuilt it with new bearings and posted a video on my YouTube channel. I have $532.67 invested in the transfer case.

As I noted above, this truck started life as a 2WD, so it’s been converted to 4x4 using a solid axle and front shackle reversal swap kit from Sky’s Offroad Design. The front differential is a kingpin Dana 60 with 4.10 gears that I sourced from a 1990 F350. I completely refreshed the front differential, and it’s riding on new Super Duty X code front springs and new Bilstein shocks. The adjustable track bar is also from Sky’s Offroad Design. The 4x4 conversion is detailed in a video on my YouTube channel. FYI – I have not installed the front swaybar but it’s included. I have $4,015.93 invested in the front differential and suspension.

The rear differential is the original Ford Sterling 10.25” that should have 4.10 gears (I have not removed the rear cover to verify). It’s riding on stock springs but with lift blocks from PMF suspension and new Bilstein shocks. I also have new swaybar end links but I have not installed them. There’s a video on my YouTube channel detailing the lift block installation. I have $474.68 invested in the rear differential and suspension.

The rear driveshaft is the original driveshaft that’s been shortened with new u joints installed, but it may have been shortened too much. The front driveshaft is new, and it has the correct double cardan joint. I have $707.67 invested in the driveshafts.

The frame is rock solid with only minor surface rust. However, the truck will need a bit of metal work – the cab corner on the driver’s side will need to be repaired, and there are a few smaller holes in the floors on the driver’s side and passenger side that will need to be patched. The bed is very solid with no rust through. The radiator core support will need to be repaired or replaced; it’s rusty as well. The inner fenders, bumper, front grille, etc, are included but not installed. The passenger rear fender has some minor damage at the rear bottom. There is no tailgate. I did replace the core support mounts with nice new ones from Jeff’s Bronco Garage. I also have a firewall reinforcement kit from Jeff’s Bronco Garage. I have $293.43 invested in the parts from JBG.

The truck is a Custom -- it does have A/C, but came with manual windows, manual locks, and a rubber floor mat instead of carpet.

The front brake calipers are remanufactured and the front rotors are new. I have new front flex hoses, but they’re not installed. The front hard lines will need some minor repair because they broke right at the fitting when I removed the old soft lines. The master cylinder is original, but I do not know if it’s still good. The rear brakes are all original, but I suspect they will need at least new wheel cylinders. I do have a new soft line for the rear but it's not installed. I have $259.29 invested in the brakes.

There are a BUNCH of extra parts that come with the truck, including two engine wiring harnesses (I have not closely inspected), tubs of spare engine parts, drivetrain parts, etc. It also comes with the front frame sections from the 1990 F350 that I sourced the Dana 60 from; it’s been very helpful in the 4x4 conversion, and you’ll likely need these pieces to check for placement of the swaybar end links, since I’m sure it’s different than the 2WD frame. You can also cut the reinforcement out of the front inner passenger side frame on the 1990 frame and weld it into the 1987 frame since the original 2WD frame doesn't have this reinforcement. All the loose parts are labeled or bagged and tagged.

The odometer reads 34,605 miles but I am sure it's rolled over once or twice so I have it listed at 234,605. Based on the inspection sticker expiring in 2008, I suspect it's been off the road since 2008 or so.

As you may notice on if you watch my videos on this truck, I take my time and don't cut corners -- things that need to be replaced are replaced, and if I rebuild something, I do my homework and do the job right. Bottom line -- there's still some work to do on the truck, but I'd be quite surprised if you needed to re-do anything that's already been done, other than the rear driveshaft, as I mentioned above.

Sorry for writing a book, but I have a lot of time, energy, and $ invested, and I want to ensure any prospective buyer understands what's been done and what remains to be done.

You’re more than welcome to come see the truck in person, and please let me know if you have any questions.

• Make: Ford
• Model: F-350
• Type: Crew Cab Pickup
• Trim: Custom
• Doors: 4
• Year: 1987
• Mileage: 234605
• VIN: 2FTJW3514HCA93499
• Color: Blue
• Engine size: 7.3L Diesel V8
• Number of cylinders: 8
• Fuel: diesel
• Transmission: Manual
• Drive type: 4WD
• Vehicle Title: Clean
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