Let's try and finish the catch-up. The rest of the pics will be some misc. parts and the start of some of the little stuff.
Here is the intercooler that came from the stepvan. It was black so I sanded off the paint from the fins and painted the ends a cream color. I like the aluminum look through the grill. It almost fits between the supports, so I'll have to do some cutting and this will go first in the cooling row.
I do have a question, but let me set it up first. I plan on stacking the cooling row like this: intercooler-FJ60 AC evap (if thats the right name for it)-FJ60 radiator. I'm going to run a large tranny cooler too, so where would you put it? In the cooling row or locate it separately?
infamous rusty inner channel being yanked
other side. It's not bad but I need to box in the rear section for the shackle mount and it doesn't make sense to leave it in to rust away.
it ended up taking me 1 full day just to get these suckers out! Only have a grinder, drill, and BFH, and prybar to get those out. I was sore the next day from pounding so much. But, alas... Victory!
You can see where the water stays and the rust forms. Luckily it will be fixed by cleaning and painting and not surgery. Back to the pass. side.
The brakes worked well on the stepvan so I'm using the system. Master cylinder painted with rustbullet.
my hydroboost came with a separate resevoir. cleaned/painted.
the hydroboost unit. Since diesels don't produce enough vacuum to run a brake booster I'd have to get a vacuum pump or go to hydroboost. Yup, that was an easy decision.
brake master goes on this side
other side. it's got three ports.
measured the distance from the mounting plate to the center of the hole on the back side of this to find out how deep to mount the hydroboost unit on the firewall
and then I made this
so that it could to here. reused some more parts from the original bracketry in the stepvan
secured those studs and quickly slapped on some paint (I'll probably repaint it)
and it mounts to the back of the hydroboost unit like this.
I just cut up the bracket on it and welded the center section into a new plate. I did it that way because it has that notch in it and I didn't want to run to the store to find the perfect sized hole saw. I might not have gotten the notch in the right place meaning the tilt on the brake master might be too much. It did have some tilt on it and if it ends up being too much I'll probably just remove that notch in the circle and rotate it accordingly. The circle is a tight fit and I won't need to find something special to seal the hole on the firewall. I will reuse the cruiser gasket that was on the firewall when I took off the original unit. That should seal it up so I don't have air leaks for cabin comfort.