Let's swap a motor and do some other stuff to a 60....

[c2dfj45]

While we had it all apart I figured we'd put a rebuilt steering box in. We've been using Red Head for a while now....great company to do business with and this one was on the shelf(2 different versions for the 60....ours was the offset version).

 

[c2dfj45]

Bent up our fuel lines for the left side of the frame.....tank made it's way back in and a fuel filter is in the engine compartment. everything needs some fine tuning....we'll work the nickel copper lines a little to clean them up....clean up the bracket for the fuel filter...hook the fuel filter up obviously.....and then mount it all once I get done painting the frame.

 

[fl4031003]

Does the fuel tank intake system have some sort of flapper to prevent back spray?

 

[c2dfj45]

Does the fuel tank intake system have some sort of flapper to prevent back spray?

Yeah...there's a restrictor in the factory filler neck. Maybe for back spray? Maybe so you can't put diesel in a gasser? Emissions? Never really thought about it...I just know I can't fill that truck up with it in there

 

[TheNeek]

Yeah...there's a restrictor in the factory filler neck. Maybe for back spray? Maybe so you can't put diesel in a gasser? Emissions? Never really thought about it...I just know I can't fill that truck up with it in there

I learned this the hard way. Finished my diesel swap, super proud, go to the station, try to put the nozzle in..... ugh.
Loving this build, and your shop. Thanks for letting us follow along.

 

[c2dfj45]

I learned this the hard way. Finished my diesel swap, super proud, go to the station, try to put the nozzle in..... ugh.
Loving this build, and your shop. Thanks for letting us follow along.

If I hadn't poured thru @davegonz 's thread a million times, I would have for sure forgotten the restrictor and been in the same position as you on that first fill up My 79 builds all have diesel fillers so it never would have crossed my mind.

The shop can be a wild place....today would have been super confusing to most people. This is what was going on one side of the shop today....

While this was happening on the other side.

And this was going on outside at some point. Even I was a little confused

 

[c2dfj45]

Dog had to do some last minute inspections......got the clearance to cut the motor mounts from her.

Adios 2F mounts.

 

[c2dfj45]

I bought some mounts from @orangefj45. These mounts are STOUT and they saved us a ton of time. We build a lot of parts from scratch....always fun and satisfying but when we can buy something as good as these, it's a treat.

In order to locate them, we left the H41 in the truck and mounted up the new H55 bellhousing to it. Again, lots of info on this on @davegonz build.

New bellhousing courtesy of ra.parts....these guys are amazing and have great prices. Can't get all the stuff from them but what they can get is very well priced.

Somehow this dog does not care what is going on with engines. Just treats and walks.

 

[c2dfj45]

Everything kind of lined itself up pretty well....got a couple of bolts in the bellhousing....took some quick measurements from from fan to radiator.....everything seems just about as good as it gets. We didn't put too much weight on the mounts...just enough to get them to settle where everything was happy.


We're using 70 series mounts. I'll have to get some part numbers up once we do a final install.

We've been using a lot of weld thru primer on areas where there will be metal to metal that gets sealed up....this red stuff is some of the best we've used. Found it in a thread on Mud. Will have to get a pic. Great stuff.

Tacked in

Motor looks like it belongs here

 

[c2dfj45]

Burned in and cleaned up.....next I need to get some paint on this frame.

 

[c2dfj45]

Put a few more bolts in the bellhousing and pulled the motor and trans out as one. Figured that was a little easier.

Industrial looking combo for sure

Good bye 4 speed. You've done well.

Last week for this 1HZ looking like this

 

[c2dfj45]

Last week was a busy one on the truck, quite a bit got done which should set us up pretty nicely for this week.

Had a couple intercoolers come in.....I think I'm settling on this one. Not huge but better than nothing. This should require a very small amount of trimming of the grill. The larger one(nearly 2' long) would have required a ton of cutting.

 

[c2dfj45]

In between jobs on the other side of the shop, we had a small window for my lead guy to start going thru the wiring. Our goal on this truck is to have a mega clean engine compartment with a minimal of things in it.....wiring will get routed thru the fenders.....we'll pull out stuff we don't need and hide any part of the harness that is visible. Beauty of these diesels is how little they need to make them run. Like magic.

Since it's hidden, we left a lot of the OEM plugs and connectors....basically just pulled out what we needed....alternator on this side along with a sensor I think. We'll route some of the other wires(coil trigger for sure) over to the other side behind the grille. I try to stay out of his way on when this stuff is being done....it's tedious work but compared to when he builds full harnesses, this is child's play.

All cleaned up and loomed...

 

[c2dfj45]

Ran out of time to finish but the passenger side wiring was started to be picked over and cleaned up.....more on this side I believe with some temp and pressure sensors along with our fuel cut to the injection pump. I usually run aux gauges so there will be a few here....water temp for sure along with boost. Not sure if the EGT will cross over the back of the motor to this side or not.

 

[c2dfj45]

Running a stainlesstrays.com battery tray.....going to sit an Odyssey 1500 in there. Really nice piece and a great deal.

I'm keeping the battery tray on the passenger side.....thought about swapping it over to the driver side but I'll keep it here for now I think.

 

[c2dfj45]

We spend far too long on our motors.....it's become a bit of an obsession to make them better than new. This was a low mile one so we won't go in to it.....maybe have a look at the bearings but other than that, just replace everything we can.

Stripped and ready to get masked for paint after another cleaning. This one is super clean compared to some of the ones we've done.

 

[c2dfj45]

Last year we built a vapor blast cabinet for restoration/refinishing work.......mainly to do aluminum and some of the lighter blasting work we tend to do. It is my favorite piece of equipment I think. It's job satisfaction rating is 100 out of 100 I can spend hours running parts in it. Amazing setup

This is pretty clean aluminum so the cabinet made quick work of it. On some of the more oxidized or discolored aluminum, we'll run it thru the sand blaster with 120 aluminum oxide to cut thru the bad....then vapor blast it.

Before....

After

 

[c2dfj45]

The transfer case was pretty disgusting on this truck.....had a tough time cleaning it with our heated power washer. Had to break out the Easy Off.....that melted the grime right off.

We tore the case down and got it into the blast cabinets....these needed dry blasting first before vapor. The vapor blasting provides such a smooth and polished surface....very sensitive to pressures too so I'm still learning what works best. This was pretty good. Could have spent more time in the dry blast cabinet first I think but this is fine for a transfer case. They are also drying in these pics....so they look a little splotchy and dark.

 

[c2dfj45]

Where we really nerd out is on the hardware. I bought a Caswell Copy Cad 3 gallon system last year so we could do small batches in house. I was always unhappy with painting old hardware....never really a perfect finish that lasted. Thought I'd give this a try. It's labor intensive as the hardware has to go thru cleaning, blasting, polishing, cleaning, plating but it's well worth it. We do it in batches....goes pretty quickly. Mindless work but enjoyable. I like it as we can control what we are doing....very organized. Not dropping it all in a bucket and giving it to the plater to have to sort out later. Plus, if we miss something, we can do small pieces easily. We are using yellow and blue chromates over our zinc. Besides vapor blasting, this is one of my favorite things to do.

Ultrasonic cleaner to get all the dirt and grease off. These are amazing for smaller parts and hardware like this. We keep them in containers with various degreasers...that way we're not constantly draining fluid from the machine. Plus we can change cleaners easily. Pine Sol has been one of our favorites.

Everything is bagged and tagged as it comes off

Blasted

We run them all thru a wire brush on a bench grinder....this is the part that takes up so much time but they need to be very smooth....we wire them up with copper wire, dip them in acetone.

Then they get dipped into the various chemicals. Pretty basic setup but it works amazingly well.

 

[c2dfj45]

The final result of all that work after about 25 minutes in a zinc bath with a dip in the chromates.....maybe better than new

We hang them to dry overnight usually....then back into their bags so we know where they go.

They are by no means perfect but they're very good. Some kit a little