Hadn't posted anything in a while so I figured I'd post an update. Truck is still going strong and I've put a bunch of miles on it since the swap.
I did have a bit of a problem with the engine that I started noticing in Fall 2020. I initially noticed that every time I shut the truck off after running it for a bit the cooling system would gurgle. It ultimately started pushing coolant out of the system. I did a block test on it multiple times and I never got a positive result. I knew it had to have been a head gasket but wasn't really willing to accept it. LOL. After all, I was running relatively low boost on a fresh head, new gasket and ARP studs.
After I finally accepted the reality of the situation, I decided to pull the head in Feb 2021. Found a 3/8" blown out section of gasket between #6 and a cooling jacket. This explained everything... but how did it happen? I torqued the studs to spec and felt I prepped everything correctly. The one thing I didn't do (because the ARP instructions specifically said not to) was a hot retorque on the studs. I don't think I had adequate torque on some of the studs after a few heat cycles and that ultimately led to the failure.
Decided to have machine shop oring the head for some additional pressure on the fire ring to hopefully avoid the same failure. I also decided to hot retorque the studs after the first heat cycle, and again after about a week. Both times yielded additional rotation on the nuts, maybe 1/7th of a turn or so. Interesting, but I haven't had any issues since.
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Truck has been performing its towing duties great since the head gasket work. In June, we loaded up and headed to Rapid City, SD for BerettaFest 2021. It's an event that's been going on since 1997 and we all get together in a different location each year. Drive was great, no issues. Got between 12-14mpg depending on headwind. Ended up putting about 3000 miles on it during that trip. Highly recommend checking out the Badlands and the Black Hills if you've never been!
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Going to haul the camper this weekend. There are a couple minor bugs to fix and items still left to do but overall the truck has done great since the Cummins swap. The biggest item left to do will be a solid axle swap. With the weight of the Cummins up front, the torsion bars feel like they are holding on for dear life. I'm on the lookout for a 2005+ F350 dually axle and will ultimately complete that swap. I think that's all for now, just wanted to make a quick update.