Builds Another LS swap? Really???

Joined
Feb 20, 2017
Messages
542
Location
Tucson, AZ
Been a while since I updated, so I'll give a go here. Work, life and other stuff has gotten in the way of spending quality time with my project, but now that the heat is here and my garage is an oven, I can finally get some time to spin wrenches. I started with determining the location of the jerry can holder I am having built by Avid Offroad. I have a 38 gallon fuel tank, so I never planned to carry extra fuel on the bumper. I wanted to keep it trim and light, but I DO want to be able to carry a water supply sufficient for a good length trip. Enter a single jerry carrier. I will mount it on the hinge side of the swing, and have it positioned so that a hand pump can be used to dispense water right into a pot in cooking efforts. I laid out the swing to include a stove table behind the spare to keep the tail gate free and the stove out from under the lift gate(because you know, random flare ups do happen).

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Joined
Feb 20, 2017
Messages
542
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Next up was to install the new brakes that I have been holding in the parts cabinet for way too long. I was amazed at just how worn out the rear brakes were. While I was in there, I overhauled the parking brakes too. I will say this....WTF Toyota? That parking brake design is a rube-goldberg. I was cussing them when it came time to reassemble it all. The calipers were good, so I just cleaned the up and gave everything a coat of paint that I could get to. The pads were on the verge of engaging the squealers.

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Joined
Feb 20, 2017
Messages
542
Location
Tucson, AZ
I have also been swapping all the suspension bushings out as I go. Huge thanks to @GeoRoss for helping me with his labor, and the use of his bushing dies. Those bushings are freaking in there and have no desire to come out. It is all my Harbor Freight 20 Ton press can manage on a few. I dont have any pics because it has been all my attention to focus on not smashing anything. I halted my progress on the bushings due to receiving a recall notice for the 6 ton jack stands I was using. I was able to get the castor plates installed, and correct the angle on my front bump stops. I had to extend them a bit more than the standard 2" due to have the LS oil pan risking losing a battle with the tie rod.

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Joined
Feb 20, 2017
Messages
542
Location
Tucson, AZ
The biggest item I have been hammering on is the install of the Ron Davis radiator I picked up just as the quarantine started. I was looking forward to seeing the operation when I went to Glendale to pick it up, but Mr. Covid denied me. This rad is beautiful, but for what they cost, they should be. Not saying its not worth it. High quality comes at a premium price. This one is rated up to 600hp, so lets hope that I finally have the cooling woes nailed after this.

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Joined
Feb 20, 2017
Messages
542
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Tucson, AZ
I am a believer that mistakes are an opportunity to begin again, but more intelligently. My first attempt at a shroud, I used a Summit Racing shroud kit. I TIG welded the entire thing, and two things happened. 1. My clearance between the fan and the surround was way too generous. 2. My limited TIG experience lead me to putting way too much heat into the aluminum and the shroud warped. According to Ron Davis himself, you want 3/8" clearance between fan and surround. I had almost an inch. When it is that generous, you get a phenomenon called inversion. That is when the air pulled by the fan swirls off the tip of the blades and heads righ back in front. Instead of pulling air through, you just swirl it around the tips of the blades. The L96 fan is a 20" 7 blade fan. It has PLENTY of capacity to move enough air, I just had a crap shroud. Beginning again, but smarter.

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Joined
Feb 20, 2017
Messages
542
Location
Tucson, AZ
Round 2: This time, I cut some blocks of wood so that I could wrap strips of 16ga aluminum around the fan to get the 3/8" gap. I used a metal cutting blade on my table saw to get the width right, and cut long strips. Then after hemming and hawing around for way too long on the purchase, I broke down and bought a 3-in-1 shear/brake/roller. I researched it for way too long and discovered that it doesn't matter whether it says, Harbor Freight, Eastwood, JET, Grizzly, etc., they all come out of the same Chinese factory. I bought the Central Machinery one from Harbor Freight with a 20% off coupon, and ran some test pieces. I will say that my only regret is not buying this when I started this whole project. It works great. Most of the reviews and failure stories I read all came back to this NOT being a pro machine. It is simply a hobbyist rig. Of course it is! Having worked in heavy fabrication/manufacturing, good machine tools costs real money, but everything can work when used within its limitations. The third pic shows the 2 halves of the surround. I rolled the curve, sheared the length, and broke the tabs that will allow the top half of the surround to be removed. That way, I can remove the fan without having to remove the whole shroud, batteries, and headlights. Think of it as a Bush-Proofing measure. I also picked up a porta band saw and a Swag Offroad table. The right tool makes all the difference.

I'll post up more pics of the progress as it goes. Hopefully, I can finish it this weekend.

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Joined
Feb 20, 2017
Messages
542
Location
Tucson, AZ
Another post just because I need to keep it going. I was able to scoop up a Rhino Rack and 270 awning off another CSCer. I am very thankful for the great deal. I also ordered a pair of the shovel holders. After using a full size shovel while out with @D_Web, I realized it was another item I wanted to have with me on trail. I cannot wait to get back out and use this thing again. It is a passion project to build my ultimate 80 series, and I love working on it, but I need some trail time soon. I also have many more goodies in the part cabinet waiting to be installed.

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Funner

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Joined
Jun 29, 2011
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Phoenix, AZ
 
Do you still have enough clearance to get out of the garage? I am guessing you have maybe an inch with the door rolled up.
 
Joined
Feb 20, 2017
Messages
542
Location
Tucson, AZ
Do you still have enough clearance to get out of the garage? I am guessing you have maybe an inch with the door rolled up.
Brian, that was a big concern of mine, and the reason I removed the Surco rack that I am trying to sell. It clears by about 1.5 inches or 30mm. The 80 lives in the garage, and I really wanted the rack/awning on there, so I was relieved to see it fit.
 
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