BJ42 going in half - project (1 Viewer)

[-MaTTi-]

New OEM fender sliced:

... to get it 2" wider:

I got new dark brown belts assembled by local seat belt renewer company:

Friend of mine sold these almost perfect jump seats to me. The problem was I had two right side seats. I don’t know if they were installed in the factory because the mountings were so equally rusted.

This is the spare tire carrier’s handle with new bronze/teflon bushing:

And with copper washer shims it’s very solid:

I made the pin from stainless steel bolt, I had to grind the flange down:

My tarpaulin shed got new steel door frames and plywood doors, because the zippers didn’t work anymore.

This is how it looked at October 2021:

 

[tucker74]

Great picture dump, thanks for sharing!

Tucker

 

[60 40]

Wow just read through this whole thing, learned some stuff.

Wish I had thought to cut and mill the joint in the steering shaft like you did and might copy your home made shock mount too.

Looking good keep at it!

 

[-MaTTi-]

Great picture dump, thanks for sharing!

Tucker

Thanks. I will write something between later.

Edit: done

 

[macdaddy59]

Fantastic work and progress. Keep it up and keep the pics coming.

 

[firefighterjed]

Impressive work!

 

[-MaTTi-]

Some updating, this is happened 2 years ago. The front fender modifications. First some patching for the steering box opening:

And room for the HJ61 steering box:

Then I bought a turbo (Holset HE221W) and started to make an exhaust manifold for it, it was surprisingly easy to do:

 

[-MaTTi-]

And there it sits ”backwards” along with the OEM heat shild:

And the OEM air cleaner fits also without any modifications:

The oil drain plug (AN12) is welded to the oil pan:

And the pressure line is also installed with AN4-fittings. I also made that support bar between the engine block and the compressor housing:

I changed the injection pump’s diaphragm for sure:

 

[-MaTTi-]

Along with the Mercedes W123 240D spring:

But this made the engine too sensitive, hard to keep steady throttle. So, I changed it back to the OEM.

Then back to the front fenders:

I taped the front channels and first poured them full of epoxy:

Then sprayed the insides of them with tinted Troton Rangers (similar as Raptor bed liner):

 

[-MaTTi-]

I still don’t know which blinkers I want to install:

Then back to the exhaust manifold. I brushed it with that graphite stuff:

It was good stuff:

The the heat shied and an exhaust gas temp sensor installed:

 

[-MaTTi-]

Then this chinese bleed valve (0.1 to 1 bar) to the injection pump hose:

And the wastegate actuator with a softer spring (6-20 PSI). I had to clock the compressor housing:

And some insulation on the stainless 2.5” downpipe:

Some support bracket between the downpipe and compressor:

 

[60 40]

Looking good!

I really feel you should go with the square turn signal considering your vehicles later build date and color.

 

[-MaTTi-]

Then I thought I’ll need an intercooler, water intercooler. First the 24V pump (not so easy to find):

The barrel (8x4”) and the reservoir from Aliexpress (chinese stuff):

Then, because of the very limited space, I choosed that 44-row oil cooler for radiator for the intercooler:

After that I’m just tried to get my new garage ready to move in. Hope it happens soon…

 

[Richco]

And back to the tub. It’s now cut in half.

Rust/rest in peace, bye. I don’t miss you.

The front part is also taken off and carried to my other smaller garage room.

Not much room to do, but maybe just enough.

I bolted peaces of plywood to the windshield hinges points the prevent the tub touching ground.

Quite good, but there is some need to repair.

And the same spot from the other side.

Right rocker panel’s support is got some hit.

Something is bubbling, I have to cut out this.

Looks ok.

IAlso have to do lots of work mine is also rotten like your vehicle