- Thread starter
- #301
Sourced an awesome Aluminum Aussie Bull Bar from Death Valley Paul! I prefer this over ARB because it’s lighter and doesn’t stick out as far but is still sturdy and can take a winch.
Builds DUKE - 1993 HDJ80 / 1HD-T / 5-Speed / 3x Locked / LHD *A slow DIY build / resto*
- Thread starter bryce0225
- Start date
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- Thread starter
- #302
Wiring up lights, auxiliary 120AH lithium battery, Viair VMS 400 compressor… this is the tedious part!
Hahaha. Bryce, it’s never final mate!
Do you have a guess (in inches) how much headroom and legroom you gained with the Scheel-Mann seats? I'm 95% there but the legroom question especially has me fence sitting. Between recovering my LX seats and the Land Tank extensions, the cost is already creeping up there.
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- #305
I would guess legroom gained was at least 6in, maybe more. I needed 4 inches and the seat isn’t all of the way back for me. They also sit a little lower but maybe only a couple inches lower, nothing crazy.
Bryce are those batteries the ODP-AGM27 & 27F? Currently been looking for reliable long term batteries for my 93 HDJ80.
- Thread starter
- #307
yup! you nailed it!
- Thread starter
- #308
I need to play catch-up on some posts here! I have put in a lot of work (and even more miles) since the interior buildout was complete.
First off: We went to Baja for 2 weeks and followed the NORRA Mexican 1000. Everything in the truck was fresh and the buildout was amazing! No mechanical problems... just some new rattles and squeaks came to light after 2000 rough miles!
First off: We went to Baja for 2 weeks and followed the NORRA Mexican 1000. Everything in the truck was fresh and the buildout was amazing! No mechanical problems... just some new rattles and squeaks came to light after 2000 rough miles!
- Thread starter
- #309
Quickly made up some custom bamboo toppers for the AluBoxes in the interior. They now work better as a working / cooking surface.
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- #310
Found some fabric that matches the rest of the headliner and decided to insulate the roof of the pop-top. It would get so hot and radiate heat. I stuffed thinsulate between the ceiling and an upholstered piece of 1/4in birch. the difference is HUGE both in temp control as well as looks.
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- #311
Put some work into the DIY rear swing out with my buddy, Hunter. The rivets I used before did not hold up and I lost the table in Baja. We decided a plate with some proper bolts would do the trick, not that this is our main cooking surface.
Hunter also disassembles and rebuilt the Gobi rear ladder to work on the right side of the tailgate... it awesome to have a ladder in the back to late n night bathroom breaks from the tent.
Hunter also disassembles and rebuilt the Gobi rear ladder to work on the right side of the tailgate... it awesome to have a ladder in the back to late n night bathroom breaks from the tent.
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- #312
Made the trip North to Bend, OR and back to attend the Overland Expo with Nomad Wheels and hang with friends. Such an epic trip!
- Thread starter
- #313
Started work on a DIY intercooler! Everything was bought off of amazon besides the intake manifold adapter (Photo below), which was bought on eBay. First step was removing the front facia of the 80 and assessing:
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- #314
Using a 2.5in stainless steel (.065) tube kit which consisted of 2x straight sections, 2x 45* sections, 2x 90* sections, and 2x 180* sections: I cut up and roughly fit everything as best I could using tape and marks to hold everything together and rough it in. If I could weld, tacking would have made this so much easier.
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- #315
Once everything was cut, I had the help of a local shop tack them up so I could test fit the pipes before burning them in. Im glad we tested because the turbo side didn't quite fit, so we had to make a couple adjustments. You can see that the pip did not like up with the turbo outlet. The intake side has proven to be the easiest and lest troublesome. Took less tie to mock up and fit like a charm on the first try.
- Thread starter
- #316
Mocking up the mounting for the intercooler core: the core was also purchased on amazon and fits beautifully! I mounted it using the bolt holes that were originally used for the center support on the hood latch that ran top - to - bottom behind the grill. I used some 90* angle aluminum I had laying around and some random SS bracket I had for an antenna I no longer use.
- Thread starter
- #317
Intercooler all buttoned up (or so I thought). time to hit the road to Colorado for the week. So far, seeing about a 200*F decrease in EGTs, better throttle response, and I now have the ability to accelerate up big highway mountain passes. HUGE improvement... but not everything goes this smooth first time around......
- Thread starter
- #319
Well, the maiden voyage with the intercooler (CA to CO) turned sour within a few hours. Just outside of Barstow, I heard a *POP* and lost all boost pressure. Knowing that one of the silicon joints in the intercooler piping popped off, I decided I would limp it to a safe spot, so I drove about 15 more miles to Barstow, where I could pull off into a NAPA parking lot. When I got out, I found that the seal I most suspected had failed. Being in a rush to finish and get on the road; I had used some JB Muffler weld to extent the pipe so that the silicon had something to grab on to... of course it failed! There was also oil EVERYWHERE! the catch can was completely full... I thought maybe the turbo had blown, but there was no oil or smoke coming out of the exhaust...
Fortunate, I brought all of the OEM parts to delete the intercooler with me, so in about an hour I had everything swapped back to stock and I was back on the road.
Later that night in Kingman, AZ I stopped at an orally to get AC charge... when I came back outside, the truck would not start. Just a singular click. Stuck starter? Bad fusible link? dead battery? bad wiring from the heat? I ended up stuck there for the night, stayed at a hotel within walking distance, and hoped I wouldn't have to call a tow in the AM. What a day of travel...
Fortunate, I brought all of the OEM parts to delete the intercooler with me, so in about an hour I had everything swapped back to stock and I was back on the road.
Later that night in Kingman, AZ I stopped at an orally to get AC charge... when I came back outside, the truck would not start. Just a singular click. Stuck starter? Bad fusible link? dead battery? bad wiring from the heat? I ended up stuck there for the night, stayed at a hotel within walking distance, and hoped I wouldn't have to call a tow in the AM. What a day of travel...
- Thread starter
- #320
BACK ON THE ROAD: I got the guys at Orileys to help me give the truck a push start... once the truck was on, everything works as it should. I drove from Kingman, AZ to Salida, CO without turning the truck off (about 16b hours) what a beast. Temps and everything were fine.
THE STARTING ISSUE: fortunately after a couple days of troubleshooting, I found that the ground wire on the LH battery was a little loose. Im glad to find that it was something so simple.
THE INTERCOOLER ISSUE: I cut and cleaned a new small extension of pipe to give the silicon something to grab onto. Huge thanks to the fabricators at Bowen Customs for welding this together for me in no time in exchange for a case of beer. I also cleaned up the intercooler core mounting brackets and make them prettier.
Unfortunately, The pipe extension on the pipe wasn't enough. The silicon kept slipping during testing. I only made it 15 miles out of town before I had to go back to stock again for the journey back to CA.
THE STARTING ISSUE: fortunately after a couple days of troubleshooting, I found that the ground wire on the LH battery was a little loose. Im glad to find that it was something so simple.
THE INTERCOOLER ISSUE: I cut and cleaned a new small extension of pipe to give the silicon something to grab onto. Huge thanks to the fabricators at Bowen Customs for welding this together for me in no time in exchange for a case of beer. I also cleaned up the intercooler core mounting brackets and make them prettier.
Unfortunately, The pipe extension on the pipe wasn't enough. The silicon kept slipping during testing. I only made it 15 miles out of town before I had to go back to stock again for the journey back to CA.
