Zach Hidalgo, a 22-year-old design engineer at Cognito Motorsports, didn’t set out to build a diesel-swapped classic, but that is exactly what happened. While scrolling through listings, he spotted a 1965 Dodge D200 crew cab hiding in the background of another vehicle photo. The former Forest Service truck looked rough, but it was too complete to ignore. One conversation later, a deal was done and a seven-month transformation was underway.
Rust Everywhere, But The Foundation Was There
The Dodge was far from roadworthy. The wheels were seized, the floor pans and doors were rusted through, and the entire truck showed its age. Still, it was mostly intact. The key remained in the ignition, the previous owner’s belongings were scattered inside, and the service bed was loaded with parts. For Zach, it was the perfect foundation for a killer build.
Cummins 12-Valve Power With Compound Boost
Rather than revive the old gas drivetrain, Zach went all in on diesel. He picked up a 2008 Ford F-250 frame for just $500 and used it as the foundation for the build. Between the framerails sits a built 5.9-liter Cummins 12-valve running a compound turbo setup. The primary turbo came from a John Deere combine. Other features include a ported and polished head, ARP head studs, an upgraded injection pump, and a three-piece exhaust manifold. The combination delivers a dyno-proven 550 horsepower.
Cooling is handled by a Cold Case aluminum radiator designed for second-gen Dodge applications, paired with an OE Cummins clutch fan. A custom 4-inch-diameter exhaust system with a Coffin muffler handles spent gases, while dual Optima RedTop batteries provide amperage.
Allison Strength And Proven Driveline Components
Backing the Cummins is a Merchant Automotive–built Allison 1000 six-speed automatic transmission, a proven choice for handling serious torque. A rebuilt NP273 two-speed transfer case from Zumbrota Drivetrain transfers power to both axles.
Speaking of axles, Zumbrota Drivetrain also supplied those. Up front is a Ford Dana 60 equipped with a Yukon Grizzly Locker and Yukon manual locking hubs. Out back, a Ford 10.5 axle carries another Yukon Grizzly Locker. Both ends are geared to 4.10:1.
Modern Suspension With Trail-Ready Hardware
The suspension setup brings the old Dodge firmly into modern territory. Up front, a coilover conversion uses Icon Vehicle Dynamics 3.0 remote-reservoir coilovers along with Icon 2.5 piggyback secondary shocks. Cognito Motorsports radius arms, Apex Chassis billet steering links, and a Carli Suspension torsion sway bar kit complete the front end.
Out back, Carli 1-inch-lift leaf springs are paired with Icon 2.5 piggyback shocks. Each 2.5 shock features Icon’s Compression Damping Electronic Valve and Intelligent Control system, allowing for advanced adjustability. A Hellwig Products rear sway bar and Cognito adjustable traction bars help keep everything planted.
The truck rolls on 9-inch-wide Icon Alloy Recon Pro wheels wrapped in 35×12.50R17LT Toyo Open Country M/T tires, giving it a stance that matches its capability.
Custom Fabrication From The Ground Up
Finding replacement sheetmetal for a truck like this is not easy, and Zach confirmed that firsthand. After sandblasting the body, he fabricated multiple components from scratch, including floor pans, cab corners, and rocker panels.
The Ford chassis was shortened by 8.5 inches to match the Dodge body. Once everything was aligned, Zach built a custom 12-inch high-clearance rear service-bed bumper and modified the service bed’s wheel arches. Additional upgrades include a custom front bumper, Baja Designs lighting, and a coat of Chevy Cypress Gray paint.
Vintage Style Meets Functional Interior Upgrades
Inside, the truck blends old-school character with modern usability. TMI front and rear seats provide comfort, while GlowShift gauges are integrated into the factory dash. A modified factory steering column is paired with a Peterbilt-application steering wheel, adding a unique heavy-duty touch.
The firewall and bed tub are coated in Raptor Liner for durability. The interior also features an aftermarket audio system along with custom plaid door inserts and headliners that give the cabin a distinctive look.
Built Around Diesel Reliability And Power
When asked to choose a favorite feature, Zach kept it simple. “The 12-valve Cummins swap, because it offers plenty of power and reliability to make it to any destination.”
You might also like
Introducing the Diesel Industry's First Fully Reversible Delete Kit
The Fully Reversible Delete Kit (FRDK) allows your truck to be fully emissions-compliant and then fully “deleted” at the flip of a switch.
