1978 LPB Teardown and Rebuild

[Awl_TEQ]

Okay - I went back out to the garage and did some thunking about the air filter arrangement. I was wanting to put in a Donaldson system but where to mount it? I quite like the look of putting it on the fender outside the engine bay. Makes it look very utility or "militaryish". BUT... I want a full snorkel (In fact I will be building my own Safari knock off). The pictures below show there just isn't room for the 8" -10" dia by 16" long Donaldson - but the factory housing could (and has for others) work.

I can fab up a nice transition from the filter to turbo with a bit of tin bashing.

If I make the header "right" I can keep the down tube from scorching the firewall.

If I relocate the inlet into the filter housing I can still have the charged air go around the housing. Remember, the turbo is just hanging in approximate position in these pics.

 

[a.greenspan]

Okay - I went back out to the garage and did some thunking about the air filter arrangement. I was wanting to put in a Donaldson system but where to mount it? I quite like the look of putting it on the fender outside the engine bay. Makes it look very utility or "militaryish". BUT... I want a full snorkel (In fact I will be building my own Safari knock off). The pictures below show there just isn't room for the 8" -10" dia by 16" long Donaldson - but the factory housing could (and has for others) work.

Kevin,
the Rover V8 ( Range Rover/ Morgan plus 8 / Landrover V8 and some more british cars equipped with this engines )had a round air filter housing, looks a liitle bit nicer ( I think .... only my opinion ).
If you put it on the outside of your fender, or if you have enough space you could put it on the inside on your right fender and mount your snorkel on it.
see pic:

Cheers
Peter

 

[a.greenspan]

if you want measure this housing....
your nearest Land Rover dealer
Retailers found for Alberta

View map

Address 175 Glendeer Circle SE, Calgary, Alberta, T2H 2S8 Phone (403) 255-1994
Fax (403) 255-1946


GPS -114.03308°long, 50.9895°lat More info


Cheers
Peter

 

[Awl_TEQ]

Thanks Peter. Thats a compact unit for sure. Interesting the inlet and outlet are on opposite ends.

I am going to alter the original air cleaner from the donor BJ42 by relocating the inlet and changing the outlet. I will make every effort to make it look clean after powder coating to preserve the original look. I will try this approach first because it doesn't cost anything and I believe I can pull it off.

 

[Chamba]

Okay - I went back out to the garage and did some thunking about the air filter arrangement. I was wanting to put in a Donaldson system but where to mount it? I quite like the look of putting it on the fender outside the engine bay. Makes it look very utility or "militaryish". BUT... I want a full snorkel (In fact I will be building my own Safari knock off). The pictures below show there just isn't room for the 8" -10" dia by 16" long Donaldson - but the factory housing could (and has for others) work.

I can fab up a nice transition from the filter to turbo with a bit of tin bashing.
View attachment 377952
If I make the header "right" I can keep the down tube from scorching the firewall.
View attachment 377954
If I relocate the inlet into the filter housing I can still have the charged air go around the housing. Remember, the turbo is just hanging in approximate position in these pics.
View attachment 377953

For what it is worth, Kevin, I am not a huge fan of my Donaldson. It does open up the engine bay, which I like, but you have to drill holes in your sexy new fender (which I had to do on Patches) and it does tend to cause stress cracks over time. Also, the filter is a real pain to get at, so I tend not to inspect it very often (on the other hand, I don't really need to check it that often, as it is massive and I have a snorkel).

I agree they do look cool, but so do the factory lines of a Cruiser...

Josh

 

[a.greenspan]

Kevin,
the Rover V8 ( Range Rover/ Morgan plus 8 / Landrover V8 and some more british cars equipped with this engines )had a round air filter housing,....

Cheers
Peter

slide show plus 8 with open engine bay, you can see the air filter housing (minute 1:14 and 0:18)
The New York Times > > Interactive Feature > Morgan Plus 8


Text New York Times :
http://www.nytimes.com/2008/02/03/automobiles/collectibles/03EGO.html
Cheers
Peter

 

[Awl_TEQ]

2010 update

I've been doing less than I'd like but have made some progress...

I bought a 2.5" OD U-bend from a local speed shop...Eye-balled the angle I wanted to get the hot down pipe away from the firewall so as to not test that nomenclature...


Welded the flange from the turbo to it...


And down pipe done - for now. I have yet to add a post turbo pyro bung and likely another bend into a flex pipe.

 

[Awl_TEQ]

On to the exhaust manifold...

I hung the turbo from the ceiling and positioned it where I wanted it. I had to consider exhaust flow, inlet/ charge flow, turbo oil feed/return, water lines for the turbo (I got the water jacket type center section in an attempt to extend the operational life through supposed quicker cool down and lower temps). Also clearance from the firewall/ hood/ air cleaner/ battery/ alternator etc. etc.

Once I liked the position I took some 1/4" round bar and tacked the turbo inlet and manifold plates together to maintain their relative orientation.

Then off to the bench to hack up some 1-3/4" U-bends and build a manifold...

 

[Awl_TEQ]

I had visions of a fancy twisted up equal length runner manifold but then I realized the fact that this is a low rev(flow) diesel and not a race prepped V8 so just a simple set up will do. Plus there isn't enough room to get fancy with the radius on the U-bend I got.


I made the rectangular section at work from two halves.

You can tell by the welds that I didn't weld it I did however clean out the inside with a 6" long carbide bit for that extra 1/10th HP Pre-turbo pyro too

 

[Awl_TEQ]

A few before bolting on to the engine

 

[Awl_TEQ]

 

[Awl_TEQ]

Now for the intake plumbing - 3"

And snorkel - 3.5"

 

[Awl_TEQ]

So having decided to use my original BJ42 air cleaner assembly I'm going to alter it....


.... a little...

I want it 1" lower, 1/2" closer to the fender and rotated 20 degrees CW to fit better in the space left.

So off with the main bracket... a bit of rust and black primer


and the support... more rust


you can see I have already cut off the outlet tube from the lid and removed/ capped the inlet

 

[Awl_TEQ]

1/2" closer to the fender - to clear the charged air outlet better

1" lower - to clear the hood

20 degree CW rotation - so the three spring clips clear obstacles

 

[Awl_TEQ]

Shortened and re-attached bottom support - the air cleaner assembly still bolts to the factory holes.

Marked and cut a 3.5" + hole in the apron to give me a target to fab towards

Cut and shaped a section of 3.5" U-bend for the inlet - couldn't see what I was doing so I removed the fender and apron and worked on the bench (work smarter not harder )

 

[Awl_TEQ]

Last two for today




I will be making a snorkel at some point from aluminum powder coated black with a 3.5" inlet and outlet roughly the same shape as a Safari snorkel with a Donaldson spinner pre-filter.

more to follow in the next few days

 

[a.greenspan]

you are busy
happy new year & all the best for

Cheers
Peter

 

[Eco 45]

Great work on the turbo setup and exhaust manifold. Soon Nascar is going to be calling you to build theirs!!

 

[merbesfield]

You are amazing. Awesome fab work. You must be a very patient person bc you clearly take the time to get it right. Great reading and motivation. Keep it coming.

 

[Lucy_FJ55]

WOW! I am stunned. Incredible fab work and attention to detail. Thanks again for sharing. I'm loving the results and can't wait until you get to fire it up and drive.