Builds Big Red Toy

[The Phoenician]

now the cross member,

He's going to weld some brackets for the crossmember and leave enough room so that when I get more funds, I'll have a skid plate protecting all the goods.

 

[cody c]

Another fast update.

Mounted the transfer case, The TC vacuum was hitting the frame, so Edwin had to straighten up the engine for it to fit. He also ordered a few things for the TC and made a crossmember strong enough to handle the oncoming apocalypse.

Here are some pics.


View attachment 738915

waiting on parts, hopefully tomorrow

View attachment 738916

you cant really tell with this picture, but the vacuum pump clears the frame though it's still very close.

View attachment 738917

I've had some problems with my setup (same AA adapter) leaking trans oil through to the split case, if its not too late make sure you gasket goop the sh!t out of everything between the two.

've actually had the case apart a couple times, and I may have a different split case then you, but there was a bolt hole that runs through the flange of the adapter which the split case bolts up to, that was allowing trans oil to leak out the back.

Looks good though, your cross member mount should isolate vibration and sound better then what Ive built.

 

[The Phoenician]

I've had some problems with my setup (same AA adapter) leaking trans oil through to the split case, if its not too late make sure you gasket goop the sh!t out of everything between the two.

've actually had the case apart a couple times, and I may have a different split case then you, but there was a bolt hole that runs through the flange of the adapter which the split case bolts up to, that was allowing trans oil to leak out the back.

Looks good though, your cross member mount should isolate vibration and sound better then what Ive built.

Cody,

Thanks for the heads up. Did you end up getting it resolved and what did it finally take to make it work? I remember putting down a lot of silicone type stuff between the transmission and the adapter. Will make sure to also do that between the adapter and the t case.
Finally, are you happy with the adapter, I mean does it hold up to some mild abuse?

Thanks again.

 

[The Phoenician]

Here's today's update.

Use 7/16" angle iron to use as brackets with grade 8 bolts. Here it is mocked up, not yet welded.

I got to take this moment to thank Edwin and his crew. Since I've come back from Iraq, they made this rig their priority and have been great about letting me hang around all day. I'm usually in the way and I'm asking dumb questions, but they are great about answering me and letting me just be in the way. Anyway here are the pics.

 

[The Phoenician]

Here it is welded and no longer being supported by a jack.

 

[GLTHFJ60]

Sweet That's the kind of angle my motor mounts are made of!

 

[The Phoenician]

Took the little man to see Big Red per his request. He asked me if he can have it when I go to heaven. I told him I was driving it there so he needs to get his own. Said fine but his will be bigger.
Anyway the AC/alternator bracket arrived and it looks like it will hit the PS motor mount. We decided to get back to it later after we look at how others fixed it. The rig can run without AC for now. I want it ready for April 12.

little man giving us his expert advice


Alternator/ac bracket



where it would be hitting the motor mount

 

[The Phoenician]

here are some random pics as well.

This one is of the clutch fork and pivot ball that gave us such a hard time a few weeks back. Ended up using the Toyota clutch fork and it seems to work perfectly. Fingers crossed.



This is a random picture of the engine bay. I must admit I like the green color on the engine a lot



This is Edwin and the cross-member he fabbed. It looks good and it's sturdy.

 

[GLTHFJ60]

Dude, my bad. I completely forgot that you were using the front mount brackets. I'm using mid-mount brackets, so my bracket fits there perfectly.

I'm not sure if any of the PS mount AC brackets that don't use the front motor mount bolt holes. There are guys that mount AC brackets to the DS top head bolts, then run a v-belt accessory drive. Tons of possibilities for a custom mount setup though.

 

[The Phoenician]

Johnny,
No worries. I was originally thinking of having the AC on the DS like you mentioned, but then the fuel shut off solenoid would be in the way. There's ways around it, it's not a show stopper. I just want this thing on the road soon.

 

[davegonz]

Mine is up top on the passenger side, but you'd need to make the bracket. It also uses a Sanden compressor that is a little slimmer than stock. Edwin can get the hoses redone easily at a hose shop he knows about in town.

 

[The Phoenician]

Small update...
Ordered a fan, fan cooling clutch, a shifter and an oil line for the vacuum pump, they should all be here by Thursday morning. We plan on turning it on Thursday afternoon. It will be the first time the engine turns on in the engine bay.

As far as work for the day, Edwin did the fuel lines, the shifter and took measurements for the inter-cooler. Afterwards I went to the local club meet and joined them. Met some great guys and looking forward to outdoor events with everyone. And now the pics

Shawn and Edwin deciding which is the best way to do this


Edwin drilling a 3 in hole in the body



Now it goes faster because it's that much lighter.

View attachment 740794


Tomorrow should be the transfer case and finishing up the inter-cooler.

 

[The Phoenician]

a couple more pics.




Obviously this is before he drilled the hole

 

[cody c]

Cody,

Thanks for the heads up. Did you end up getting it resolved and what did it finally take to make it work? I remember putting down a lot of silicone type stuff between the transmission and the adapter. Will make sure to also do that between the adapter and the t case.
Finally, are you happy with the adapter, I mean does it hold up to some mild abuse?

Thanks again.

There was a threaded hole on the face of the adapter for a bolt through the back half of the split case, the split case I had didn't have a hole through it for the bolt to go through. At some point it started allowing the expensive NV4500 oil through the bearing (I broke the AA bearing somehow, actually split it in two where it is machined on the outside for the snap ring), anyways, the thing was leaking and I couldnt for the life of me find out where. Turned out to be a hole without a bolt on the adapter.

On the good side, you can access that hole with silicone without separating it, or maybe your splitcase had that bolt hole through it so there shouldn't be any need.

Am I happy with the adapter... I'm not sure, I've had a few more leaks then Id like and have pulled it apart a couple times to re seal it. It could just be my workmanship, and it worked without error for a year or two before I had any problems, and I have been kinda hard on it. I've broke a birf and a couple diffs since the 5 speed, as well I broke a clutch disc somehow...

I'd just reccomend sealing the bugger really well, and letting the gasket cure for a day or two before adding oils, as well, use locktite on each and every bolt.

Lately its been pushing oil from the trans into the t-case again. Im really not sure why or how, its got a double sealed bearing between them and a sh!t load of gasket maker goop. Ive actually started topping up the trans with regular gear oil instead of the $35 a litre synthetic stuff your supposed to use from the dealer for the carbon fiber synchros.

YMMV.

BTW, the intercooler instal looks pretty good!

 

[Realultpwr]

Thank you for your service Phoenician! I have followed this thread, but didn't have any pertinent information to give. Just threw a rod bearing in my 2f would love to go diesel but funds do not allow and since I already bought a 3fe that will go in instead! Great build and go out and have fun with that thing you deserve it!

 

[The Phoenician]

Thank you for your service Phoenician! I have followed this thread, but didn't have any pertinent information to give. Just threw a rod bearing in my 2f would love to go diesel but funds do not allow and since I already bought a 3fe that will go in instead! Great build and go out and have fun with that thing you deserve it!

Thank you SIR. I understand about funds being low. This build has taken me about 2 years to save for. If you think about it, it's cheaper than a new car because its a rig that costs less than $18k when it's all said and done, but that is built the way you want to do whatever you want. Sorry to hear about the rod bearing, but the 3fe is a great engine. Thanks for following.

 

[The Phoenician]

updates,

Got the t case and drive shafts installed, all in the stock locations, no lengthening or shortening needed. The fuel lines work and the inter cooler has a bracket to hold it in place. We finally got the engine running, fires right up, not as much vibration or noise as I expected. Anyway here are some pictures of the inter-cooler

At first I didn't see it



I like how it looks and fits



side view with the brackets. It has angle iron holding it from the bottom as well,

 

[The Phoenician]

Here are the videos of the engine firing up for the first time in the bay. Technically right now Big Red can move under his own power, but we haven't added any oil in the transmission. The only worry I have right now and I'm praying to God that it's nothing is the transmission not shifting into 5th gear. It goes smoothly into all other gears but resists the 5th. I know this is a common problem and has a solution. I'm hoping once we add gear oil and get it moving it will sort itself out.

https://www.youtube.com/watch?v=d4qTEWXKLrQ

https://www.youtube.com/watch?v=3RNn-8YxR4w

Hope you enjoy.

 

[GLTHFJ60]

Man o man, I remember that feeling. You must be on cloud nine right now. Congrats!

It's all smooth sailing from here!!!

 

[davegonz]

Congrats Mike. Looking good.

Also, here's a guy selling a high mount AC bracket.
http://www.4btswaps.com/forum/showthread.php?26708-High-AC-mount