It has been a while since a update. I had to wait for some key components to come in prior to continuing the engine build.
I measured the tolerance levels on the engines head with feeler gauges and discovered it was warped. This is something you cannot see with the naked eye, but can effect compression. I had to ordered a new head and new valve springs (I checked the tension on the springs and they were bad as well). After assembling the head, it was installed on the block and I did a valve spring adjustment prior to putting the valve cover on. I installed allot of various parts on the engine such as a new water pump, intake manifold, turbo manifold, new starter, new fan clutch, new alternator, and the oil pan, etc. The old alternator was bad and I ended up having to make custom brackets to fit the new 80 amp alternator. The mount where the alternator brackets to on the engine was to short (see in attached comparison photo). I also had to fabricate a tension bracket that I bolted to the shock absorber bracket, to adjust the belt tension on the pulley assembly.
I included some pictures of the above process. The engine is nearing completion and I have several key finishing touches before it is ready and I can move on to the rest of the build:
- I need to finish the installation process for the turbo (This includes: Installing the EGT and PSI boost gauges for the turbo, adjust turbo boost after the intercooler is installed which is probably around 12-13 PSI, hook up a custom piping bracket to the front of the turbine on the turbo to the external Donaldson air filter box which brings in cooler external ambient air temperatures from the snorkel, hooking up the intake and return oil lines on the turbo, and a few other miscellaneous things.)
- I need to install the PWR water to air intercooler for the turbo (This includes: Installing the barrel air exchange unit from the intake manifold to the turbo, mounting the inline filler where the coolant goes into, mounting the electric water pump that pumps the coolant, and mounting the radiator/fan that cools the coolant which will probably be mounted about the valve cover somewhere.
- Mount and installed the coolant system for the engine (This includes: Installing the radiator, piping, fan, coolant reservoir, and fan shroud).
- Install the new heat exchange unit on the firewall that I had to replace.
- The alternator after fabricating a custom bracket is physically installed, but now I need to complete the electrical installation of the wires form the unit.
- The starter is physically installed, but I need to complete the electrical installation of the wires to the unit.
- Install the battery tray and Red Top Optima battery (Later I will fabricate a dual battery tray for the Red Top and a Yellow Top Optima in a dual battery configuration).
- Installed the nozzle leakage pipe with washers (I had to order replacements) on top of the fuel injectors.
- Install the heater pipe
I am sure there are allot of miscellaneous things I am missing, but this is more of a macro snapshot of where I am at on the build.
Currently I am headed to Virginia this weekend to stay with a good friend of mine while I attend hyperbaric treatment for my TBI (Traumatic Brain Injury) and continue the build. I will start by taking the body off the frame and continue working on the engine. I currently have another wounded veteran friend of mind that got medically retired last year with me who is planning to start the overland Journey on the Pan-American Highway tentative May 2015. This vehicle has been a great outlet for me to help with my anxiety and when I cannot sleep. I will continue on this build and working towards the journey. I will continue to update as I progress.
I also want to thank my family for starting a Gofundme page to help facilitate this journey for us on this journey:
http://www.gofundme.com/cqc76o.
.
