Builds Another LS swap? Really???

[ARJMN]

Why yes...I do have some updates. With the cooling package wrapped up, I moved on the last major fab project, the oil pan. I had a stark moment of common sense and asked the question, "why do I have issues when using the same parts I have seen other builds use?" This led me to putting the chassis on jack stands, removing the shocks and springs, and then cycling the axle. The tie rod does indeed swing up into the oil pan, but the epiphany came when I started auditing the bits. I realized there were no bump stop spacers installed. I did not install my lift, a PO did, and I never thought to check it. I have OME 3" lift J springs and can more than spare a bit of travel to protect the oil pan and the shocks. I glued up some wood blocks to simulate bump stop extensions, and jacked up the axle. I was able to lift the chassis off the jack stands and still have .75" of oil pan clearance. I called Slee and ordered 2 sets of 2" bump stop extensions. I will take one set and part them off at 1". I plan to stack the 1" on the 2" and have a 3" spacer, which gives me a comfortable margin. It is pretty easy to develop a 2G load on bottoming, and in extreme moments, a 3G load is possible if you really work at it, and 3" of bump stop spacer gives me a warm and fuzzy. Moving on.

 

[ARJMN]

I'll post up some pics when I get the spacers installed. Other efforts went in to the building of a Certi-Flat weld table. I wanted a small fab table to aid in projects, but small enough to roll to the side out of the way. It is a 2x3 with 2" on center holes for Bessie clamps. Instead of spending $27-$50 a piece for store bought clamps, I got some $3 bar clamps at Harbor Freight, cut the end off, and welded 5/8" nubs on the ends. They work great and I wish I had done it months ago.

 

[Saddletramp]

Good stuff. Keep up to great work.

 

[Saddletramp]

Any news? Summer heat is almost here, Will this be on the road soon?

 

[ARJMN]

Sure thing Steve. Progress has been slow as of late, but it does march on. Between work, travel, and bit of illness, I have not put in many hours in the garage. I got the radiator hoses installed using the Ford Explorer/Chevy 1500 combo. I had to fab a tiny bracket to secure the steam line on the throttle body. The front end is all sorted now with the springs, shocks, and 3" bump stops in place. I think I may have to modify the RH side as it may contact the spring when crossed up. I picked up the last fuel fitting I needed today at Don's Hot Rod, and the last oil fitting is in route for a Friday delivery. That leaves me buttoning it up and filling fluids this weekend. I have put off installing the harness out of fear of damaging it. With luck, I will be priming and turning the key next weekend at the latest.

 

[ARJMN]

A few pics of the bump stops and oil pan clearance.

 

[ARJMN]

One bite at a time. That's how I have managed to chomp my way through this so far. I am seeing fewer and fewer items on my build list. The latest completions was the closing of the cooling system with a new heater valve, and new 5/8 and 3/4 hoses. I filled it with fresh coolant and distilled water. After the cold crank and prime of the engine, I'll top it all off. Oil capacity is around 7 qts and coolant is over 2 gallons. I had to fab two brackets to capture and route the heater hoses, but it turned out well. The engine bay is getting full, but amazingly, it is all going to fit.

 

[ARJMN]

A Hanging Chad that has been out there was the front sway bar installation. I got a disconnect kit from @LandCruiserPhil a while back and finally installed it. Very nice. Thanks Phil.

 

[ARJMN]

I also got the last -10AN fitting I needed to close the oil system. I needed a 110 degree fitting to get the ideal routing, and of course I couldn't find one in town, but Amazon had me covered 2 days later. The heater hoses, oil cooler lines, tranny cooler lines all have clean, secure routing that have no fouls or rubs.

 

[ARJMN]

Next up was to tackle the throttle pedal installation. I took the stock pedal assembly and laid it out on the fab table on top of some card board to get all the datums marked. Then I laid up the new pedal and made templates to close the gaps. A quick transfer, cut, dress, and tack had the bracket ready for a test fit. I tweaked it a bit on the angle and was able to match the stock position and I think it will be a weiner.

 

[ARJMN]

Here's the finished product. I am pretty happy.

 

[ARJMN]

While I was in there, I decided to replace the steering shaft seal due to it no longer being a seal, more of a peep hole to the engine bay.

Next major step is to finally sort out the wiring. I have been putting this off for so long because #1 I did not want to risk damaging the harness, and #2....I hate wiring. @D_Web is helping me out with this stage, and I owe him a huge thanks and an all you can eat bacon buffet. Stay tuned, I am getting close. I don't think I am going to beat the heat, and every time I give a date I end up owing someone beer. It is very close and will be done when it is done.

 

[Saddletramp]

Great update. I can tell you from experience, the little things at the end can eclipse the entire time spent on all the previous work. Just keep plugging away at it.

 

[ARJMN]

Great update. I can tell you from experience, the little things at the end can eclipse the entire time spent on all the previous work. Just keep plugging away at it.

I am seeing that first hand Steve. After the major leaps were done, it felt like the project was moving at a snails pace even though the hours put in were steady. The last 10% takes 90% of the effort, or so it goes.

We had a productive day today and Ben is a whizz at wiring schematics What would take me days of head scratching took him a few hours. We got the original harness de-pinned and pared down to only what we need. What hangs on the mirror is all that is needed from the Toyota harness. Next question is how I am going to get all the harness plugs through that grommet.

 

[ARJMN]

@Stepmurr, to give you credit for the idea, I'll share with you what $26 in scrap steel and 2 hours gets you......a press brake. I got real tired of bending brackets by the score and hammer method, so I fabbed up a press brake. It works great and it less headache than the old way. Thanks.

 

[ARJMN]

Now on to the latest progress. @D_Web has been a huge help in figuring out the wiring. He is a flat whizz with schematics, and is sharp as hell. Happy to have him on the job. We got the factory 80 harness de-loomed and de-pinned in order to remove all the circuits we wont need. From there we used the cheat sheet from Speartech to match up the LS harness to the proper Toyota leads and reloomed it all as one and ran it through the firewall using the factorry grommet. The leads were clipped, crimped, and assembled at the connections using DT connectors for a clean, weather tight joint. We are about 90% done with wiring at this point. I had to sort a fuel leak that held us up then, which I'll go over in the next post.

 

[ARJMN]

When we got the fuel pump wired and powered on, we were able to prime the fuel system and purge all the air. After letting it sit under pressure for a bit, I noticed a fuel leak at the end of the rigid line from the tank. This got a few choice words as it was what I was afraid of. After 20 years connected, the fittings had nearly seized together, and it took breaker bars on wrenches to get it apart. I kinked the line in the process, and that is exactly where it leaked. After looking around for a used one to scavenge, I figured it was better to go buy a new one. A trip to the dealer and $70 later, I had one of only 4 remaining in the US Toyota Parts Network. When I go the original tank and fuel line removed, I couldn't argue with the price. It is one solid tube from front to back. My logic on the tank was that since I had the original out and I had a 38 gallon Manafre tank to go in eventually, there was no point in putting the stock on back in. This turned out to be a giant can of worms, and the fit up troubles will be the subject of another post. I am still working through it and preparing a write up for the NEW owners of Manafre Offroad. I did make use of the chance to replace all the important bits on the fuel sending unit.

 

[Jgunner]

When we got the fuel pump wired and powered on, we were able to prime the fuel system and purge all the air. After letting it sit under pressure for a bit, I noticed a fuel leak at the end of the rigid line from the tank. This got a few choice words as it was what I was afraid of. After 20 years connected, the fittings had nearly seized together, and it took breaker bars on wrenches to get it apart. I kinked the line in the process, and that is exactly where it leaked. After looking around for a used one to scavenge, I figured it was better to go buy a new one. A trip to the dealer and $70 later, I had one of only 4 remaining in the US Toyota Parts Network. When I go the original tank and fuel line removed, I couldn't argue with the price. It is one solid tube from front to back. My logic on the tank was that since I had the original out and I had a 38 gallon Manafre tank to go in eventually, there was no point in putting the stock on back in. This turned out to be a giant can of worms, and the fit up troubles will be the subject of another post. I am still working through it and preparing a write up for the NEW owners of Manafre Offroad. I did make use of the chance to replace all the important bits on the fuel sending unit.

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Badass tank! Whats THAT cost! I cringe. Interested in seeing this project work out, i would love to see it in person and hear you point out the problem areas and what to look out for or do different.

 

[ARJMN]

Badass tank! Whats THAT cost! I cringe. Interested in seeing this project work out, i would love to see it in person and hear you point out the problem areas and what to look out for or do different.

@Jgunner, it is a Manafre 3880, I am working through it all currently. There are many issues with it that I am documenting as I go in order to give the new owners feedback. I can say that if I had paid the MSRP, I would be furious with the fitment, but I picked this one up from a guy here is Tucson that bought it for his LX450 just before he lost the head gasket and cooked the engine. He held on to it and posted it several times, lowering the price each time. Some time went by and he posted it for $600, so I jumped and bought it. I originally planned to run it and avoid Jerry cans, but I just ordered a rear bumper that could be configured to carry jerrys for less than the cost of the tank. So, if I hadnt got it for such a deal, I would never have gotten one. I am giving my feedback to the new owners of Manafre before I post it here, so look for it in the future.

 

[ARJMN]

Although there were many hours of garage time this weekend, the bulk of them were on the tank and I'll share all that later. I did get the bracket for the LS ECM completed and the harness close to its final state. The LS ECM nests nicely in place of the factory cruise control module and routes right under the relocated washer tank. It is coming to together nicely. The critical path is the tank, so I'll be working to finish it this week. I also got the front end put back together, and it feels so good to see it really coming back together.