Sadly im just now posting pics of this swap because I am selling the truck and took a bunch of pics.
I wish there was a good place to reference when I did this so hopefully this may benefit some other crazy SOB who isnt content with the 05 swap. Sorry I didnt record any of my measurements for cutting the headlight buckets(use bolts and spot welds for reference instead to get semi close), spacing the fenders, and extending the hood hinges. If youre capable of doing this I am sure you can figure it out with some patience
Did this swap a little over a year ago with a buddy ( shoutout to JimmyTNT, a badass custom paint and body guy in the Bay Area). I wanted a new truck but my 7.3 was clean and well taken care of so we decided to go for it.
I have in progress pics somewhere. Truck was originally white with silver lower accent.
So you found an overpriced tailgate off a new truck and want to put it on. Here you need this little hinge from ford to make it work
Then you get wild and get 08 tail lights and bumper, hell, while you're at it add some of those cool rectangular mirrors too
This is where the fun starts. The guy you bought that rear bumper from also has a front bumper from his 08 AND that big stock chrome grill. He wanted color matched stuff so he sells it to you for cheap with all the brackets and everything.
You call around and locate an 08 hood and fenders, hmmmm maybe this wont be so hard to do.
Only a day or 2 later someone posts a pair of 08 headlights on Craigslist for sale and you grab them. SCORE! Time to start mounting everything.
WRONG. Nothing lines up. One night as we are messing around with it a guy comes to buy my stock front end sheet metal. He could barely speak any English but got the point across that his friend just did the same thing. "yea right I'm thinking." He whips out his phone and shows me a gorgeous swap and the guy was only 10 minutes away. We went over and saw how he did the brackets for the fenders and latches and how he modified the headlight buckets. This was our saving grace for sure.
The hood leveling bumper thing needed to be spaced up as well. The fenders were spaced up 3/4" near the firewall for the body line that goes from the door to the fender to line up and I think 1.5-1.75" in the front.
I was already way past what I wanted to spend so things like new hood hinges and a new wiper cowl and other parts that would be costly from Ford just werent in the cards.
We extended the stock hinges so the front of the hood lined up with the top of the headlights. This took a couple of trips to Home Depot to check out any 08s that were in the parking lot for inspection. What we also noticed was the big gap between the top of the bumper and the bottom of the grill. UGLY. Since we had to modify the bumper brackets anyway we took care of that fitment.
For the wiper cowl youre gonna have to grind down the corners on both sides for the hood to clear. This was easier and cheaper than the 08 cowl because I didnt have to move the washer squirters either. I just have 2 holes where the 08 ones go in the hood.
So you're stoked that your truck is almost done and you go to put the old faded and gross fender liners in....NOT. They dont fit. Well off the Ford to get bent over for new ones. I dont remember why exactly but I bought v10 liners instead of the 08 Powerstroke ones. Maybe the shape was different and I needed a lot a space since my shock hoops ran really high.
Well I was finished with the hard part so I got rid of the old 16s and stepped up to 20s. $2300 for a set of Toyos later I was all done.
There are a ton of little things I'm sure I forgot but ask away and Ill see what I can remember. Hopefully it can help shed some light on what was an almost mythical project to find any solid info about.
Overall Id say the 05 swap is the best bang for the buck since you dont have to mess with the different hood and latch setup. I have it on my 99 for 250k strong so far.