Build Dirty Koala Build - Cummins Common Rail + NV4500 + HF2AV Swap

[nuncaperdido]

Big day today! Cummins build 2.0 has begun.

I have been waiting all summer for the weather to get out of the 100’s so this job wouldn’t be a miserable affair. Forecast for today was a high of 85...perfect.

@bryson came over at 11am to start turning some wrench with me. Goal was to get as far as possible today, we ended up getting more done than I thought we would.

Pulled the front bumper, winch, lights, grill, core support, condenser, radiator, intercooler and lower valance.

Got and the plumbing and electrical disconnected, shifters removed, driveshafts off, hood off, 2 crossmembers pulled, motor mounts out of the way and slid the big donk, trans and xfer case out of the engine bay as one unit.

We separated the trans from the engine and got the motor mounted onto my purpose built engine stand ready for surgery.

We then cleaned up all the tools and figured well it’s still daylight, so also pulled the rear Slee bumper off. She is almost ready for the next phase of build 2.0.

It is soo much nicer working on cruisers with a friend than by yourself, it’s fun, keeps the motivation going, and you make so much more progress in a short period of time. Thanks again for spending the day getting greasy @bryson!

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I like your engine stand. Way better weight distribution than hanging it all the way out there. What surgery are you doing to it? Looking fwd to the continuing saga.

 

[Dirty Koala]

I like your engine stand. Way better weight distribution than hanging it all the way out there. What surgery are you doing to it? Looking fwd to the continuing saga.

Yes I love it, I had this stand built by a friend last winter as I knew I was going to need a heavy duty rotating stand and I didn’t want to pay $4k for one...going rate for stands rated for the big diesels.

Surgery = a full engine rebuild along with some more go-fast parts.

 

[OGBeno]

Damn dude! Always a work in progress.

Looking forward to the next phase, Morgan.

 

[Mr Cimarron]

Nice! I wish the weather would break here as I haven’t worked on anything the last few months. Still have a month to go I think.
Did you find a Donaldson type air cleaner to fit?

 

[Dirty Koala]

Damn dude! Always a work in progress.

Looking forward to the next phase, Morgan.

Indeed, and this will give me the “opportunity” to fix the things I half arsed the first time around.

 

[Dirty Koala]

Nice! I wish the weather would break here as I haven’t worked on anything the last few months. Still have a month to go I think.
Did you find a Donaldson type air cleaner to fit?

The weather only just broke this week. Had to get this done before it gets too cold to want to work outside

I haven’t got the Donaldson yet, but I certainly will be getting one. Most likely the same one you’re running.

 

[Box Rocket]

that 1/4 Japanese dude is pretty useful. That's nice progress.

 

[Dirty Koala]

that 1/4 Japanese dude is pretty useful. That's nice progress.

Yes he is! Was a power day for sure!

 

[Dirty Koala]

Now that that drivetrain is out and everything has been stripped, it’s time to move onto the next phase of build 2.0. Yesterday I had the now much lighter (~3000lbs) carcass hauled down to Tenacity Overland for some love.

 

[boots4]

Looks like you gained a couple inches of lift too with all that weight removed. It's exciting to see your 2.0 progress.

 

[Dirty Koala]

Looks like you gained a couple inches of lift too with all that weight removed. It's exciting to see your 2.0 progress.

It’s totally BroDozer height right now. I am 5’11” and the rear window sill is at neck height. It’s also sitting so high that the track bar is pulling the chassis way out to the left.

 

[Dirty Koala]

I guess you could say things are getting serious.

Just picked up the new OEM glass all around...minus rear windshield which was in good shape still. Last driver front glass in the country is in that pile.

 

[Dirty Koala]

The prep continues. Found a small spot of rot in the bottom of the passenger rear quarter panel that needs new steel. Tailgate needed some work to straighten out also.

 

[Dirty Koala]

Went down to the shop to checkout the progress, it’s coming right along. The jams are all done in the new Kevlar Bedliner. The upper black trim has been also been painted. I am really happy with how this is coming together.

The hood has been made into Swiss cheese also...this is going to flow a good amount of air!

 

[Dirty Koala]

All the doors and hood are mounted back on in prep for the exterior spray...getting close.

I really liked the hood louvers I added to my Turbo LX, so I got another pair but made out of steel that have been added to this hood along with a big honking hood scoop that @Box Rocket put me onto out of Oz. Took a while to clear customs, but I am pretty thrilled with how it’s coming together.

 

[Mr Cimarron]

Are you welding that scoop into the hood? Look good

 

[Dirty Koala]

Are you welding that scoop into the hood? Look good

The scoop is made of fiberglass, and it is bolted and bonded to the hood. The entire thing will then get coated in the Kevlar liner.

 

[Dirty Koala]

The exterior got lined yesterday and then top coated this morning. Once it’s cured for a few days the reassembly will begin. Getting excited.

 

[Mr Cimarron]

Looking great. What is the coating again? How does the price compare to a normal paint job? I’m thinking of doing the 75 in some sort of bed liner. There is no way I can get the body straight enough to pay for real paint. Plus it will be used and abused.

 

[Wrencher93]

The exterior got lined yesterday and then top coated this morning. Once it’s cured for a few days the reassembly will begin. Getting excited.

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That looks awesome. I'm not sure if I can bear to line the whole body when I get the paint done but this makes it very tempting!