Lindsey Fisher March 26, 2024 F Series Builders Guide
Photos by Solomon Lunger
Crawl over rocks, speed through the desert sand, and take a beating over long stretches of often off-camber, rolling divots in the form of “whoops” all while trying to follow a specified route between Point A and Point B and do so as quickly as possible—that’s what racing in Mexico on the Baja Peninsula is like. If this sounds like a good time, you’re in good company, including that of off-road aficionado Jerry Souza of Gilroy, California.
There are a handful of very well-known races that take place on the Baja Peninsula every year, every one of them having their challenges, as well as amazing aspects. For Jerry, it was all about racing the NORRA 500 and he needed the perfect rig to do so. Enter this gorgeous 1976 Ford F-250 crew cab.
OK, so we may be getting ahead of ourselves a bit—let’s rewind. Jerry’s original purpose for building this truck was to have a rig he could take off-road, whether that was weekend wheeling or attending various off-road events. But he didn’t want just any old truck. He had his heart set on a classic, built to be as capable off-road as it was on pavement. Three and a half years of work and we’re looking at that very truck.
“For Jerry, it was all about racing the NORRA 500 and he needed the perfect rig to do so.”
Building a capable off-road truck is more than just slapping on a lift and some sticky tires. Rather, every aspect of the build has to be weighed against how you want that truck to perform and on what kind of terrain, how you’re going to keep from breaking just about every mechanical component possible, and how you’re getting home at the end of the day safe and sound. Therefore, many people start with the chassis.
To achieve his ultimate build, Jerry opted to stick with the Ford’s original frame to start things off, but he had it cut and notched by M-Fab. A cage was then integrated into frame that goes throughout the truck for added rigidity and safety.
“… every aspect of the build has to be weighed against how you want that truck to perform and on what kind of terrain, how you’re going to keep from breaking just about every mechanical component possible, and how you’re getting home at the end of the day safe and sound.”
From there, M-Fab added Eibach springs and King shocks dialed in by KDM on all four corners to give the truck longer wheel travel while increasing the ride quality substantially from what the truck boasted stock. A Red-Head F150 ported steering box and PSC hydraulic-assist steering stabilizer were also added, boosting the handling of the truck tenfold.
Under the truck you’ll find 17×8.5-inch Method MR704 wheels wrapped in differing rubber depending on the situation, with Jerry going back and forth between 40×13.5×17-inch Toyo MT tires, and the pictured BFGoodrich Mud-Terrain T/A tires.
Looking for some decent power to push this beast forth, Jerry went against the purist grain and outfitted the truck with a 2008 GM 6.2L V-8 he salvaged from a junkyard. To that, he added custom 1 7/8-inch headers and a custom 3-inch exhaust system with side dumps, as well as a Speartech harness before handing it over to ZMOD Performance for the perfect tune. Other than that, the engine is as it came from the factory, fed by a Fuel Safe fuel cell behind the truck’s cab.
Tied to the 6.2L V-8 is a CBR-cooled 2012 GM 6L90 transmission touting heavy-duty NP205 transfer case with a Offroad Design Magnum underdrive, adding up to a 5.33:1 final low-range drive ratio. This low gear is the perfect “crawl gear” for Jerry’s off-road adventures, while hardy Tom Wood’s front and rear driveshafts give the truck’s drivetrain extra fortification for the same task.
As far as the axles go, Jerry also went tough here, with a 2014 Ford F-350 Super Duty Dana 60 in the front, and a 2014 Ford F-350 shaved Sterling 10.5 in the rear. Both axles are equipped with 4.88 gears and electronic lockers for targeted dual wheel rotation at the touch of a button.
Ford Super Duty brakes both front and rear give the truck some powerful stopping power, fed by a GM Hydroboost master cylinder and upgraded with a proportioning valve and line lock.
“Tied to the 6.2L V-8 is a CBR-cooled 2012 GM 6L90 transmission touting heavy-duty NP205 transfer case with a Offroad Design Magnum underdrive, adding up to a 5.33:1 final low-range drive ratio.”
While Jerry built his truck to be highly capable off-road, he also wanted it to stand out in a crowd. Thus, using his automotive painting skills to his advantage, Jerry gave his truck a one-of-a-kind look, featuring Ford Vineyard Yellow paint with custom black and white “cartoon-like” accents.
A 1975-1977 Ford F-Series grille, custom tube bumpers and rock sliders, and a custom integrated spare tire rack over the truck’s bobbed bed add to the build’s rugged appearance. Cutout wheel wells make for better tire clearance as well as less rubbing and denting of body panels from off-road shenanigans. Speaking of off-road shenanigans, Jerry’s upgraded lighting system, which includes 7-inch KC HiLiTES Gravity LED Pro headlights, a KC light bar above the truck’s cab, and 30 rock lights throughout the body help light the way for just about any after-dark adventure Jerry may want to go on, including those races in Baja we spoke about earlier.
Inside, the truck is just as custom, with brown and tan PRP suspension seats, as well as a matching center console, door panels, and dash, bringing the old-west vibe of the truck’s exterior from outside in. As discussed before, an M-Fab rollcage is continued throughout, while a full Rugged Radios communication system with headsets guarantees proper communication between the driver and the passenger, whether they are out night wheeling, enjoying an event, or racing in Mexico. Other interior features include AEM Electronics digital gauges, a MOMO California Wood Heritage steering wheel, and an on-board refrigerator/freezer.
Purpose-built and gorgeous all in one package, Jerry’s vintage crew cab is one impressive truck, so much so that in 2023, Jerry and his team raced the NORRA 500 and pulled out a third-place finish in their class in the truck’s first race. If that isn’t a testament to the capability of this truck and its owner, we don’t know what is.
1976 Ford F-250 Crew Cab
Owner:
Chassis & Suspension:
1976 Ford frame cut and notched by M-Fab, Custom integrated cage, 144-inch wheelbase, Custom 3-link suspension lift by M-Fab, Eibach front and rear springs, King front and rear shocks, custom tuned by KDM,Red-Head F-150 ported steering box, PSC hydraulic-assist steering stabilizer
Wheels & Tires:
17×8.5-inch Method MR704 wheels, 40×13.5×17-inch Toyo MT tires; BFGoodrich Mud-Terrain T/A tires, 4.25-inch backspacing front and rear
Engine & Drivetrain:
2008 GM 6.2L V-8, Custom 1 7/8-inch headers, Custom 3-inch exhaust system with side dumps, GM E38 ignition, ZMOD Performance tune, Speartech wiring harness, Fuel Safe fuel cell
On-board ARB air compressor, 2012 GM 6L90 transmission, 14×16-inch CBR transmission cooler, Heavy-duty NP205 transfer case with an Offroad Design Magnum underdrive adding up to a 5.33:1 final low-range drive ratio, Tom Wood’s front and rear driveshafts, 2014 Ford F350 Super Duty Dana 60 front axle, 2014 Ford F350 shaved Sterling 10.5 rear axle, 4.88 front and rear gears, Electronic lockers both front and rear, 2014 Super Duty brakes front and rear, GM Hydroboost master cylinder, Proportioning valve and line lock
Body & Paint:
1975-1977 Ford F-Series grille, Custom tube bumpers, Custom tube rock sliders, Custom spare tire wrack integrated into the rollcage, Cut-out wheel wells, Bobbed bed , 7-inch KC HiLiTES, Gravity LED Pro headlights, KC HiLiTES light bar, 30 KC rock lights, Ford Vineyard Yellow paint with black and white “cartoon-like” accents, all done by Jerry
Interior & Stereo:
Custom brown and tan upholstered PRP suspension seats, Matching brown and tan center console, door panels and dash, M-Fab roll cage, AEM Electronics digital gauges, MOMO California Wood, Heritage steering wheel, Full Rugged Radios communication system with headsets, On-board refrigerator/freezer
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Editor’s Note: A version of this article appeared in TREAD Mar/Apr 2024.
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