Builds Harumi the Rusty Rescue JDM HJ60 - Build Thread (1 Viewer)

[BrickRunner]

Fantastic write up. I know the time it takes to take pics, post them, write about them and all that. Thats why I never do it.
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For the more complex pieces (like your overhead gauge pod)....is that cut at 'work'?

Did you design and extrude the tent mounting walls?

What are you using to sand and smooth all of those welds? Especially in the corners/hard to reach areas?

What are you doing for the underside of all the welded areas? Some places you can't paint after closing them up.

Thanks!

The altimeter gauge pod was done old school with a cardboard mockup that was then traced onto metal, cutout with a nibbler, and bent with a combination of mini-brake, vice, hammer, wrenches, etc. Most of the rust repair was done similarly.

The roof steel structure I designed in Solidworks and ordered via Sendcutsend, and then tacked together.

The aluminum extrusions are pretty standard and were purchased from 8020.net

Finishing the welds was done with flapper disc on an angle grinder. The inside corners and tight spots were ground using carbide burrs in a dremel (don't use a dremel, get a die grinder).

The inside of welded areas get coated with 3M Weld Through Coating prior to welding, and if possible, Eastwood Internal Frame Coating afterwards.

 

[BrickRunner]

Ever since I got the cruiser, there had been a clunk in the steering. After Jawbone, it had gotten noticeably worse, so it was time to do something about it. The steering damper was dead, the tie rods were about done and the left wheel bearing was loose. Thankfully the knuckles seem fine.

New tie rod set and damper, and a re-torque of the wheel bearing nuts solves most of the clunk. There is still a tiny bit of play in the steering shaft U-joint.

 

[BrickRunner]

I built a new 2.5" exhaust. The downpipe has a V-flange right above the back bend so I don't have to cut anything when it's time to do my turbo setup. The Flowmaster 70 is a bit louder under load than I would like, but should quiet down with the turbo and a Helmholtz resonator.

The jury is still out on the butt dyno.

 

[BrickRunner]

Yee haw!
Butt dyno approved...
...and real dyno verified!

With the new exhaust, it went from 56.7 HP and 138.9 ft-lbs of torque to a whopping 64.1 hp and 148.8 ft-lbs of torque. We were also able to go through the full range of RPM in 4th gear this time. On the original baseline run, the truck was hitting an RPM 'wall' from the load. 13% more power and 7% more torque... not too shabby!

 

[BrickRunner]

All loaded up for the Valley Hybrids swap meet this Saturday!

 

[BrickRunner]

Thanks to Georg and other George for hosting!
@orangefj45

Lots of cool people and sweet rigs. And I left with less stuff and more cash than I came with, huzzah!

 

[BrickRunner]

Although I did spend some cash... Mmmm well spent...

 

[softdrinkviking]

Thanks to Georg and other George for hosting!
@orangefj45

Lots of cool people and sweet rigs. And I left with less stuff and more cash than I came with, huzzah!

Awesome to see all the photos! I would love to come out there for it someday, but I'm just way too far. I've done business with George, and he's great and would love to meet him person.

 

[BrickRunner]

Soon...

This is a nice piece of machining.

 

[BrickRunner]

Sorry @duncanrm , but the stock 2H just isn't enough for the American highways and the hills and altitudes I plan on driving. Toyota had valid reasons for not selling them here. The 12HT on the other hand...

It was a struggle going over the I5 Grapevine which is only 4144 ft at its highest. I've had my 4Runner over the Continental Divide at ~11158 ft. I love hills and the 2H does not, but that's what I got.

 

[duncanrm]

Sorry @duncanrm , but the stock 2H just isn't enough for the American highways and the hills and altitudes I plan on driving. Toyota had valid reasons for not selling them here. The 12HT on the other hand...

All good.. just having a larf Good luck with the hills!

 

[BrickRunner]

All good.. just having a larf Good luck with the hills!

The trip up to Modesto and back was certainly an eye opener. Elevation and ambient air temperature make a huuuuge difference in performance. Lots more coal coming out of the exhaust at 3000+ feet. Cruising in the Central Valley (~sea level) in the morning when it was about 60-70 deg F I could easily maintain 90 kph at 600 deg C EGT's. When ambient got 90 deg F and above I could barely keep it at 80 kph and constantly have to watch my EGT's to keep them at 600 deg C and to keep the coolant temp at or below half (it's normally been between 1/4 and 1/3 thus far).

Also, the roof tent adds considerable drag. If I drafted behind a semitruck, my EGT's would drop 100 degrees C and I could get back up to 90-100 kph. There are definitely some aero improvements to be done. Before I cut the roof off and made the tent box, maintaining 90-100 kph was possible while keeping EGT's below 600 deg C.

I'm glad I did my exhaust when I did, I needed every single one of those extra 8 horses!

I am curious what kind of power the Princess makes with your fancy extractors and exhaust!

 

[duncanrm]

I am curious what kind of power the Princess makes with your fancy extractors and exhaust!

I aim to find out at some point in the near future!

 

[BrickRunner]

In preparation for the turbo, I thought it would be a good idea to replace the governor diaphragm with a fresh one. I'm glad I did, one of the screws was loose, the anti-tamper screw was in the wrong hole, and the washer that goes between the split pin and the diaphragm rod was absent...
It was nowhere to be found, not even loose in the governor housing.

The diaphragm itself looked fine(?), but I replaced it anyway.

I also built a stand and got my spare engine ready for turbo mockup. An easy out that actually worked (with lots of Kroil), huzzah!

 

[BrickRunner]

My planned manifold adapter ended up sticking out a bit further than anticipated...

So I chopped and angled it back a bit, so the dump pipe will go into the exhaust and not the fender!

 

[BrickRunner]

A little more fine tuning to be done...

So purdy...

 

[softdrinkviking]

I also built a stand and got my spare engine ready for turbo mockup. An easy out that actually worked (with lots of Kroil), huzzah!

I think I got one to work once or twice. More often they just break off into the hole, leaving behind a bit of hardened steel

 

[BrickRunner]

I think I got one to work once or twice. More often they just break off into the hole, leaving behind a bit of hardened steel

It was a pleasant surprise! I think it was soaking it in Kroil for several weeks more than anything.

 

[bcsteel]

you can still get all the pieces for the two piece exhaust manifold . 2 o rings and the gaskets.

 

[BrickRunner]

Manifold, turbo adapter, valve cover and rod cover are off to get ceramic coated.

Some more yard work in the meantime. Oleander in rocky river soil is stubborn!

And today I went on a cruise up the hill to make some noise and celebrate Independence day!