Diesel swap - 2L-T into 22R pick up

[Fantom]

Might want to incorperate some form of wheelchair lift to get your busted old ass into it though.

I'm guessing these are words of wisdom that come from personal experience

Well I got the glow plugs sorted out, I finally received the timing belt I ordered, did a mock up with the alternator which is from an NPR truck and has way more amprage. Turns out I have to adjust some pulleys and make a spacer but that's it for those.








Since this came out of a 2wd the oil pans are different. So the pan and pickup are changed out. Turns out the pickup flange was just a little bit different and needed so shaving but it's fine now.

 

[canucksafari]

How did you get the aluminum so shiny? Did you bead blast it?

 

[canucksafari]

Will you be installing these this time?

 

[Enigma]

This is exactly why I never post my build threads.

 

[Deny]

This is exactly why I never post my build threads.

Jeff has builds?

 

[Fantom]

Doubt he has builds, I know he's got a couple projects "waiting"....err....rusting...

John, no idea what you posted, can't see it.
As for the aluminum, cleaned off the oxidation with a brass wire brush on a die grinder and some polishing compound (coarse) with a buffing wheel on the die grinder. Wiped down with never dull and done.

 

[canucksafari]

John, no idea what you posted, can't see it.
As for the aluminum, cleaned off the oxidation with a brass wire brush on a die grinder and some polishing compound (coarse) with a buffing wheel on the die grinder. Wiped down with never dull and done.

Fixed the pic. Keep forgetting I can't just copy and paste from one forum to the next.

I have both of these items. Good to know if I ever end up tearing into a TD4.2 or just pull it out for a new clutch.

 

[Tin basher]

Hey mat want another 2 l ran great till about 8 o'clock tonite yes that's my willys or what's left of it

 

[Fantom]

What?! Oh man, I'm so sorry to see that! Please tell me it was insured for fire.
Wow, that really sucks. Any idea what triggered it? Are you thinking of rebuilding it? Is the drivetrain badly damaged?
...guess you don't want the manifold flange, they will be ready this week no worries.

 

[Tin basher]

Think the starter solenoid or something shorted It moved itself away from the shop and other trucks
The diesel could be fixed without a parts motor just don't think it's worth it to me now
And no ins for fire

 

[Fantom]

Ouch, that hurts! So the truck actually moved itself away from the shop as it caught fire?! Christine?

In other news, the engine has been on hold. Life is crazy busy and between the magazine, school, etc there has been no time to work on the engine. Also the damn flanges for the turbo manifold are talking a little longer then anticipated from my steel guys, but with the prices I get from them I don't mind the wait. I ordered an external wastegate for the turbo since I will be bypassing and closing off the internal one for cleaner flow. The gauges, and parts are just waiting for some free time.....which I will have after December 20th, when school finally ends for the year. Luckily Sopel is very generous and has allowed me to cruise in style in his HJ61, thanks buddy!!!

 

[Wheelingnoob]

Think the starter solenoid or something shorted It moved itself away from the shop and other trucks
The diesel could be fixed without a parts motor just don't think it's worth it to me now
And no ins for fire

Had a friends Zuki do that in the middle of the night camping at Chehallis pre slide. Scared the crap out of us, tree stopped it on its way to the Lake. Thankfully no tents where in the way.

 

[Fantom]

After what seems like an eternity, I finally have a break from school and work. Today I tore into it full speed.








Shaping the schedule 90 elbows for fit and flow.



Tacked together.



Clamped down to minimize warping during welding



Mock up to figure out how the turbo will position, tomorrow the holes for that, the external wastegate, EGT will be cut/drilled and more flanges welded.



Started modifying the turbo housing to close off the internal wastegate.

 

[Glenn-BJ74]

Looks good!

This will succeed ....

 

[hybric4x4diesel]

After what seems like an eternity, I finally have a break from school and work. Today I tore into it full speed.


View attachment 843017



View attachment 843018

Shaping the schedule 90 elbows for fit and flow.

View attachment 843019

Tacked together.

View attachment 843020

Clamped down to minimize warping during welding

View attachment 843021

Mock up to figure out how the turbo will position, tomorrow the holes for that, the external wastegate, EGT will be cut/drilled and more flanges welded.

View attachment 843022

Started modifying the turbo housing to close off the internal wastegate.


View attachment 843023

good work mat, love to see what you can do in the right direction.

 

[sailor]

Press on! Still shoulda painted it red and white btw...

 

[Fantom]

Well it's not finished yet, I still have some parts I can paint like that
Thanks guys.
Got a bit more done, mounted the turbo flange, finished off the welding and clean up on the main body. Still have to locate the massive external wastegate so it doesn't interfere with the oil filter. That, and hopefully the down pipe for the output. Still have to seal the turbo internal wastegate and modify that housing.

Mocking up the angle



Flange is bolted down so it doesn't warp...



Welded and set...



And the turbo mounted

 

[Wheelingnoob]

Looking great Mat!

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[Fantom]

Thanks, got a bit more done, almost there. I'm torn between adding on board air in the form of an AC pump (the York is a bit too big ...I checked already ) or just saying screw it and finish it off. If I do I have to fab another bracket or 2 ....which I'll likely do ....it's only time ....right?
...argh...

The elaborate -modern art display of clamping inventiveness...







Covered for welding...

 

[Wheelingnoob]

That Wastegate arrangement looks good.

Take a look at Sanden 508 or something along those lines. They are way smaller than the York and still work well. Think you can do a mod on it so it uses grease instead of needing an oiler and consulting filter. Have good OBA is worth the extra work now rather than later.