72 FJ40 Chevota Build

[Tokamak]

Terrx,

I have a thread called https://forum.ih8mud.com/40-55-series-tech/603329-350-tbi-engine-height.html that discusses the location of the drive train and the rear mount. I removed the crossbar (by the parking brake) and initially installed the AA Rear Mount (aka, Propeller Mount). In the other thread I was warned about using that mount so I fabbed up a transmission mount that attaches to the AA NV4500 adapter.

The mount is at the same level as the bottom of the transfer case lowest point. I decided to make it the same on both sides. I plan to route the exhaust above the mount. The mount will serve as a place to bolt my future skid plate. I am going to install a tube crossmember at the rear spring mounts to hold the frame stable.

I'm getting ahead of this thread's progress but attached are pictures of the rear mounts.

 

[cult45]

Just cut and paste from the address bar of the other thread. I love your attention to detail man, rig's gonna be sweet as.

 

[Tokamak]

Thanks Cult45 that was easy.

Next I installed the power steering box mounts. Saw this setup on the DuraGoat's excellent build.

Showing pictures of the better welds. Still learning.

 

[Tokamak]

Installed the Hell Creek 4" springs and rebuilt axles on the frame.

Layed the engine assembly in the frame.

Now you can jump to a thread called https://forum.ih8mud.com/40-55-series-tech/603329-350-tbi-engine-height.html for the discussion on locating the engine.

Also there is a side line on the rear transfer case mount vs transmission mount here https://forum.ih8mud.com/40-55-series-tech/603298-aa-tc-mounting-bracket.html

I'll continue back here with my build when you done. We are pretty much caught up now.

 

[Tokamak]

All Caught Up

Now things are going to slow down cause I gotta start figuring stuff out. This is where your help comes in handy.

I've got 4 irons burning.

Steering lay out.
Fuel system
Exhaust system
Transfer case height
Cross member at rear spring mount

Picked up a tilt wheel at the PP Yard $70. Some one had already taken the harness, dimmer, and ign switch.

Found a web site that shows dimensions of Gas Tanks Fuel Tank - Auto Parts Warehouse . Spent a few days searching for a tank that would fit behind the rear axle without moving the shock mount (S10 Blazer) and wouldn't cost $500. Finally found a 15 Gal. Who would have guessed the vehicle it comes out of. Yep, a j##p. Has the new standard locking ring and fits my old GMC in-tank pump and has the FI box. Will need to shorten the down tubes. Hopefully it won't cost me $500 by the time I'm done, but you know how that goes.

Since I have 2 1/2" Ramhorn manifolds I need to reduce them down to 2" for my Y-pipe. Found a local place that made me some 2 1/2" to 2 1/4 flare adapters with loose clamping ring. Bought a 10 foot length of 2" pipe and borrowed my Son's HF bender.

Still want to work on the Xfer Case height. I raised the body 1 inch on blocks to see what's what. One thing I noticed was I get more clearance for routing the fill hose on the rear tank.

 

[millas]

Definately subscribed!

 

[Tokamak]

Millas, I'll try to to keep it interesting and useful. Thanks

Spent all day looking for exhaust help then found a local custom exhaust shop (2 miles from home) that made up some manifold reducers and had a wall full of clamps and exhaust donuts. These are 2 1/2 to 2 1/4. I'll make my Y pipe bends from 2" then get one end expanded to 2 1/4 to butt weld to the reducer.

The new fuel tank fits nicely. I may be able to use the straps from the old GMC donor. Plenty of clearance for exhaust.

 

[Tokamak]

TBI Fuel Lines

Dug out the old fuel lines from the donor truck. It has all of the parts and pieces and makes a pretty good guide and answers most of my fuel line questions.

These originally went down the drivers side. I'm planning on the pass side so they wont be a direct fit. I can at least salvage the filter mount and the tubing clips.

Has anyone used this fuel line by Poly-Armour?

AGS Company - Brochures
AGS Company - Poly Armour

They have some good videos. Price is reasonable 3/8" is $1.00/ft for 25 ft at O'Reilly. This is NOT a sales pitch and unfortunately I don't own any stock in this company.

 

[Diskord]

Wish I could give you some assist on the steering, but I can tell you I will be watching very closely as I may need to reconfigure my entire steering setup.

However, if you are looking for ideas on how to mount the column, look here. VERY clean mounting solution.

https://forum.ih8mud.com/fj45-owners-club/116839-1964-fj45-lb-rb1-project-21.html#post6762419

 

[Tokamak]

Diskord, this is perfect! I was imagining this kind of firewall mount. Thanks

 

[78fj40mg]

Great job!!

 

[terrx]

Some TBI trucks & suburbans had the fuel lines routed to the passenger side with a filter mounted on the inside frame rail. They're hard steel lines from the throttle body down the back of the block then a section of braided stainless steel hose. Link below is a thread with a bunch of photos - turned it up in a web search since I don't have any pics handy.

89 Suburban 350 TBI ICM and Coil Install - PIC HEAVY

Earls and others make fittings from the throttle body to -AN flare so that's another route. GM used steel tube in the engine compartment rather than hose for safety, but I've seen many conversions that use plain or steel braided hose all the way to the throttle body.

 

[Tokamak]

Terrx,
I'm planning on the steel lines. The pictures of the routing are a help. I don't want to invest in a good GM flare tool so I'll get the AN adapters. They only ones I've found are #6 AN for the supply an the return.

 

[Diskord]

Fuel lines,

I picked up the pre-fabbed straight lines with fittings from NAPA (I think they were a 60" and an 18", 3/8" for the fuel, and 1/4" for the vent) and then bent them both to follow the inside of the frame. I mounted them to the frame using brackets I fabbed up, and secured them to the frame using existing mounting points.

Stock fuel pump on the SBC, so it is very close to the frame on the right side, a short rubber line to the fuel pump, it worked out fairly well. I made a mount for an inline filter to the filter mounts to the engine block just above the fuel pump (front of the block)

 

[Tokamak]

This is a 1990 TBI with the fuel pump in the tank. It's got a bypass relief valve in the throttle body for constant pressure at the injectors. The pressure side is 3/8" and the return is 5/16". Plus the vents.

 

[Tokamak]

I ordered the adapters for the throttle body that convert from GM metric flare with o-ring to #6 AN from Summit yesterday.
RUS-640803 GM TBI ADAPTERS BLK
RUS-640813 GM TBI ADAPTERS BLK

The stock throttle body adapters are:
14mm x 1.25 male to 16mm x 1.5 female for the Supply
12mm x 1.25 male to 14mm x 1.5 female for the Return

The RUS adapters are the 1.25 thread directly to #6 AN.

The information here was shamelessly taken from 1987 Chevy TBI AN Fuel Lines

 

[Tokamak]

Did a little work this weekend

Started by raising the engine another inch. The front pulley now sits 1 inch above the bottom of the frame rails at the back of the shock towers. Haven't modified the the transmission mount yet.

Started cutting on the radiator mount to lower the Champion radiator and also opened the hole for the petcock.

 

[Tokamak]

Radiator Mount Mods

At least you can now see the petcock.

Also moved the radiator mount to the center of the frame and moved it forward an inch. It looks like I will be able to run either my original GM clutch fan or the Taurus electric. I think this may be a good option.

 

[Tokamak]

Steering Column Mount

While the body was on the frame figued I would try to make the steering column mounts.

The coulmn has the rods for the dimmer and ignition switch going down the left side so my clamp needed to have clearance for those. Decided to go with 2 diameters of off the shelf pipe to make the clamp.

Turned down the schedule 80 pipe into a sleeve.
Marked the column for the rod movement.
Cut the sleeve for the inner part of the clamp.
Turn and cut sleeve pieces for the outer part of the clamp.

 

[Tokamak]

Clamped and welded the sleeve offsets then machined the top and bottom flat. Welded the straps.