KBPI Radio's Metal Shop 7 Truck Rear End

The Fummins Metal Shop Truck now sits on a 14-bolt 11.5" rear end with a custom fabricated 4-Link suspension. The front end has also been updated with heavy-duty springs and rotors from Jazz It Up. Fuel will held in the fuel cell which is now bolted in-place. Due to the torque that the rear end will see from the Cummins Engine and the low-sitting attitude of chassis, the 4-Link System made sense to put on the back. This will do a good job of keeping the wheels planted and update the old style suspension with new technology. Rear airbags will be added by ATS to help finish the overall package.

Front End Work For The Metal Shop Fummins

Zach, Mike & Devin Mount The
Front-end Parts

With the engine transplanted into the truck, work was able to begin on the front-end assembly of the Fummins. Zach, Mike, and Devin began mocking-up the front radiator and supports. The hood will be placed on the truck and will allow for measurements and fitting to happen between all of the pieces. Once the front pieces are mounted then the detail work inside the engine compartment can be completed.

Next; Onto the 4-Link Suspension and rear end work!

Metal Shop Fummins Truck Second Turbo & Engine Pieces

Zach modifies the firewall
and fuel injection hardware

Zach was hard at work on the Metal Shop Fummins today getting more engine hardware fitted and mounted. The atmospheric or bottom low pressure turbocharger is mounted now and tubing for the rest of the turbo system is being fabricated.

Powdercoated engine pieces are getting bolted in-place such as the valve covers. The P7100 high pressure fuel pump is mounted and fuel lines and fittings are soon to come. Since the Cummins Engine is mounted in a retro truck the P7100 injection pump will simplify things and eliminate the need for other electronics, since it is mechanically timed.

Fabricated crossmember is in-place

Zach fabricated the crossmember and mounting solution for the transmission and has that bolted-in underneath the truck. Suspension parts should be getting mounted tomorrow and will help support the heavier weight of the new power plant.

Powdercoated engine hardware being mounted

Second (atmospheric) turbo is mounted

2011 lbs of Cummins Power in a 1977 lb Package

Is this thing going to fit? 

Yes it did. The 5.9L Cummins Engine is now mounted to the built ATS Diesel Transmission and both are sitting in the 1977 Ford Truck. Body modifications are mostly done to the Ford and provisions were made to support the extra weight of the new diesel engine which is being transplanted.

 The center section of the body has been given a work-over and gotten some nice coats of flat black paint thanks to Camaros Plus Denver Body Shop.

Modifications are underway to the truck's firewall to support the non-OEM engine and hardware. ATS built a heavy duty automatic transmission which will be used to get the new power to the wheels. The factory Ford rear end was exchanged for a 14 bolt 11.5" rear from a newer model Dodge Ram in order to support the high level of torque that the drivetrain will experience.

Last week listeners of 106.7 KBPI Radio chose to have Car Toys supply an Alpine Stereo for the build. This week listeners vote on which style of exhaust will go into the truck. Interior work and suspension are soon-to-come. KBPI continues to award keys to fans in anticipation of the vehicle give-away late this month.

KBPI Radio's Metal Shop 7 - Studio Setup

KBPI Radio's Scoop made the trip to ATS Diesel's HQ today to get the streaming video/photo cameras set up. A handful of cameras were mounted around the build area and up-linked to KBPI's website server to allow the build to be followed online.

The build area studio is setting up.

Scoop gets the video streaming online

Joel sets up the network to stream live shots

According to the KBPI polling it looks like the engine going into the Metal Shop Truck will be a 12-Valve Cummins. Up for voting today on the KBPI website is the paint color and door handle style. Also up for decision is the option to either have the truck in long bed or short bed flavor. More updates coming soon!

KBPI Radio's Metal Shop 7 Truck Build At ATS Diesel

KBPI DJ Willie B. Shows Off The Truck To Be Built

For the 7th edition of KBPI Radio's Metal Shop Vehicle Build, ATS Diesel was chosen to be the 2011 host. Each year the radio station locates a donor vehicle and product sponsors. The vehicle is then rebuilt and modified with performance upgrades. This year's vehicle is a 1977 F-150 Pickup which will receive a diesel engine transplant along with a grocery list of other upgrades which will all be voted-on by the listeners.

Cold Start For The F-150

The Build Area Is Prepped

This week as the build process begins the '77 Ford was dropped-off at ATS Diesel. The crew at the shop began clearing and prepping the area where the build will take place. This week KBPI has a page on their website devoted to allowing listeners to vote on which power plant will be installed into the truck in place of the 460 gas engine. The engine options are the 5.9L Cummins from the Dodge Ram, 6.6L Duramax from GM Diesels, and the 7.3L Ford Power Stroke.

Whichever engine is decided-on, the truck is going to need some serious help on the front end to support the additional weight versus the 460 gas unit. Body work and interior upgrades will also be happening along the way and this truck should look a lot different very soon.

Co-Pilot For 6.7L Dodge Ram Solves 68RFE Transmission Issues

Co-Pilot For 68RFE Transmission

ATS has released the most advanced version of the Co-Pilot Controller to assist the durability of the 68RFE Transmission in the 6.7L Dodge Ram Diesel. This truck is capable of impressive power and performance and serious towing weight, but has been lacking in the transmission longevity department. This new transmission system uses computer control to govern hydraulic clamping pressure and shift /lockup strategy (similar to the Allison Transmission in the GM Duramax Trucks).
The combination of mechanical limitations and factory computer programming has left truck owners who are towing heavy loads or tuning for improved performance with a void and in-need of an aftermarket solution. The Co-Pilot Controller for the 68RFE Transmission plugs into the OEM electrical harness and monitors the load being placed on the gearbox.  The hydraulic pressures, shifting, and torque converter lockup strategies are modified to prevent the pressure from dropping to an unsafe level and therefore avoiding slippage of the internal clutch packs. Many issues stem from hard acceleration damage that occurs to the 'low-sprag' or 'low-roller clutch' inside the transmission. The Co-Pilot is programmed to engage the low clutch pack to distribute the torque load more effectively.
The Co-Pilot on its own creates much better longevity inside of a properly functioning transmission, but may not be a 100% solution depending on the application. If internal transmission wear/damage, extreme towing weight, or significantly increased power are factors, then mechanical upgrades to the transmission's internals are needed in-conjunction with the Co-Pilot.

With easily selectable programs available in-cab to the driver and exclusive strategy for keeping the 68RFE Transmission alive, the Co-Pilot is a great solution for 6.7L Dodge Ram Owners who tow, snowplow, street-rod or compete with their truck.