When Ford introduced the "Super Duty" line of trucks in 1999, they were billed as a heavy duty work truck. Ford had no idea that the new body style would be so well accepted and that they would become so popular with the people who didn’t even need a truck at all. They have become as much a status symbol as a workhorse. Then they added to that, the awesome powerstroke diesel engine and people went crazy over it. Not because they needed all that horse power and torque, but because they wanted it!

Since the super duty was built to be a work truck, Ford offered it with several cab and box combinations that appealed to that crowd. All of the single cabs produced by Ford had the longer frame rails so that it could be outfitted with an 8’ box, flat bed or utility body. Never a short box, unless it was an extended or crew cab.

Ford has enjoyed great popularity with the F150 Lightning, that rivaled the Chevrolet SS454. Both being a single cab short box, 2 wheel drive sport truck. But now that the diesel engine has come of age, it’s time for something new and exciting.

We first had the idea to build this truck in 1999. After seven years of planning we finally decided to make it become a reality. We wanted to build a truck from the ground up and build it just how we wanted it. To get the project started, we needed a cab shell and a frame, from a regular cab truck. Ford hasn’t made any significant changes to these since their introduction in 1999 to current production. We went on the search, and finally found what we needed. It was a 1999 F250 4 wheel drive that was equipped with an 8’ flatbed and had spent it’s life on a Texas ranch about 50 miles north of here. It had a powerstroke diesel engine that had been badly abused and showed 154,000 miles. Remarkably, the sheet metal was still quite nice and the frame was still good. That was all we needed. We wasted no time getting started, and pulled the cab and bed off and set them aside. Next went the motor, transmission, transfer case, axles, wiring and plumbing until the frame was bare. After much calculating and measuring, we split the frame where the cab and bed meet and shortened it 16" welded it back together and plated the inside for reinforcement. Each frame rail now has eight 3/8" Huck rivets (an industrial grade 8 fastener used in big truck and trailer construction with uncompromised strength) that secure the reinforcing plate. The factory quite often puts frames together in this same manner; we just do a prettier job of it. The end result is an extremely tough joint that is stronger than before the cut was made. If this frame ever gets damaged, it will bend anywhere else before it bends or breaks here. The frame was then cleaned and undercoated to protect it.

Next was the suspension. The front end was lowered by installing a dropped I beam kit from DJM performance and then a set of Ford spindles and hubs from a 2000 donor F250 2 wheel drive. The rear was lowered with a set of DJM lowering spring hangers and a set of 4 degree pinion shims to keep the driveshaft angle proper. A new crossmember was installed to support the 26 gallon fuel tank from a short box truck and another crossmember was modified to create clearance for the new shortened driveshaft. The rear axle was replaced with a low mileage unit from a 2000 F250 and has 3:73 open gears (non locking) Everything was detailed during reassembly, 4 wheel disc brakes with fresh blacked rotors, silver caliper brackets and silver bolts. All front steering and suspension is painted silver and gray with blacked frame and both front and rear calipers and shocks are red to match the body color. Wheels are 20"X8" Juice by Pacer and wrapped with General Grabber UHP 285/50 R20 tires. That completes the rolling chassis.

Next, we needed the perfect engine. We located a 2000 F450 that had the 7.3 Litre Power stroke engine and had been wrecked on the right side. The truck was wrecked in 2001 and only had 22,000 miles on it. It had been tied up in an insurance lawsuit for the last 5 years and we finally persuaded them to sell it to us with a bill of sale. The right valve cover had a dent from the wreck and we removed it to push the dent out. The inside of the engine looks like brand new. There was no other damage to the engine. The F450 had a manual shift transmission and we wanted this truck to be an automatic so we purchased a remanufactured 4R100 and coupled it to the engine and installed the unit into the frame. Then with no cab on the truck we installed a 4" stainless steel exhaust system by Magnaflow from the turbo back and deleted the muffler then finished it off with a monstrous 6" chrome resonator tip that exit’s at a 45 degree angle behind the right rear wheel. After all with a name like the "Thunder" it just can’t sound Wimpy. An end result is a deep throaty tone that commands attention and bellows the whine of the turbo without becoming obnoxious and keeps cab noise to a minimum.

Now we turn our attention to the cab. The cab was completely gutted and stripped of every removable part. Each individual panel was meticulously smoothed of any dings and imperfections and factory flaws. The doors, fenders, etc. were then refitted to the cab with much more finesse than the factory had ever intended. Once the body had finally met our approval, it was primed and painted inside and out. Nearly 3 gallons of "Viper Red" base coat was applied to the cab, bed and bumpers before applying 5 coats of urethane clear. The empty cab shell was painted inside and out all at one time just like the factory does it with no tape lines anywhere, no wrench marks on any bolts and no overspray on any parts. After curing for 7 days, the truck was color sanded down to 2000 grit sandpaper then buffed to a high gloss luster. This is some of the finest paint work around and far exceeds any factory job. We purchased a pull off, short box (61/2’) from a 2004 F250 and it got the same attention as the cab. The box was then taken to "Gatorback" for a superbly done spray in bed liner in black. The bottom side of the cab and bed were both completely undercoated for protection and good looks too.

The cab was then lowered down onto the new chassis with a refurbished original engine compartment wiring harness. Then the front of the truck received the new 2006 headlights, XLT grille and headlight mounting panel. The front bumper is from a 2006 F550 and was filled and smoothed before finishing it inside and out with the matching viper red paint. Emblems are new 2006 issue and custom "Thunder" appliqués, then smoothed and painted door handles complete the exterior of the truck. Windshield was replaced and a privacy manual rear sliding glass was installed.

On to the interior. The original blue interior was discarded and replaced with a graphite gray interior from a 2002 F250 including the dash and wiring harness, door panels with power windows and door locks where the manual ones had been. The instrument cluster that went with the engine was installed in the new dash, reflecting the actual mileage of the power plant (now at 23,000 miles) All factory Ford parts, no aftermarket junk. New visors and headliner complete the roof. Seats transplanted from a 2002 F250 are 40/20/40 with fold down center console and seating for 3 adults. Drivers seat is 6 way power and they are covered in custom leather from "Katzkin" with perforated red leather inserts and custom monogrammed with "Thunder" in the headrests, then finished in gray leather and red piping. Then outfitted with custom carpet from "Auto interiors" Interior refinements also include, cruise control, tilt wheel, automatic transmission with overdrive, air conditioning, AM/FM cassette, keyless remote entry system and drivers and passengers side air bags, all fully functional as is the factory anti lock brake system.

The internally stock engine received an added boost of power thanks to the "Bully Dog" power pup programmer that allows the driver to increase the horsepower by up to 120 hp and is fully adjustable and can be returned to factory settings. The downloader and software go with the truck as does the bully dog "Outlook Monitor" which allows the driver to keep an eye on the engine’s vital statistics and a whole array of other functions.

Every aspect of this truck was well thought out and planned. There is nothing about it that is inferior in any way. Every option is at least as high quality as factory specs or better. Many things are a lot better.

We have been building custom trucks since 1978 and I have never been more happy with a finished product. Nor have I ever driven anything that I enjoy more. All that I ask is that if you buy this truck, please don’t clutter it up with aftermarket garbage that will only distract from the clean appearance that took so long to achieve.

Sincerely, T.J. Marnell Tumbleweed Trucks

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