Builds Meet Ivy, 1976 FJ40 w/VW TDI (3 Viewers)

[fjdiesel]

@Godfather90 that is awesome info. Thanks!

 

[alkarich]

Very impressive work!

 

[fjdiesel]

Very impressive work!

Thank you sir!

 

[fjdiesel]

Well, gonna jump down the rabbit hole a little more this week... I need to get the tune on my engine "fine tuned" but I wanted to get a couple things done before that. I have put 980 miles on so far. And here are the bugs I am gonna address this week.

1. Install heavier flywheel. Centerforce 42# compared to stock, 22# I think??
2. Install new black box housing, with temp sensor, so I will be ready to install a pump and cooler.
3. Adjust clutch linkage.
4. Finish/fix exhaust. I did the front half in mandrel bends and got lazy for the last half and had the exhaust shop do it and had them put in a muffler. I hate the muffler sound and terrible drone... So I will finish with mandrel bends and install a Flowmaster DBX. And if need be a resonator.
5. Install new positive battery cable. I had Interstate batteries make me one with another lead to go to the winch solenoid.
6. While the fuel tank is out, I need to run a couple wires behind it for speakers, dome lights, and marker lights.
7. Install a Speedhut EGT gauge, the previous Chinese one I am not happy with. I like Speedhut is USA made. Give them some stimulus money.
8. And, I think last but not least, I am gonna do some machining on a new intake manifold and install that.(this might be next week...)

This is kinda my list to make sure I don't miss anything while it is tore apart.... I have a good memory, it's just short...

Got the seat out, tank out, and the tunnel out this morning. And we all love pics!!

And my pile of parts... Didn't take long to add up...

 

[fjdiesel]

You can tell the difference in the flywheels for sure!!!

 

[fjdiesel]

Got the flywheel in and the new case on the blackbox done. My son slid under to check my work.

 

[fjdiesel]

These are some really nice battery cables that Interstate Batteries in Superior WI. makes!! And they are really fair on pricing.

 

[fjdiesel]

Test drove to work. Really like the heavier flywheel. I am surprised at how much it smooths it out in the low torque/rpms. An upgrade well worth the money. I forgot my laser temp gun.. I was gonna shoot the underdrive, trans, and t-case.

This pic makes it look like I work at a prison. lol.

 

[fjdiesel]

I had a leak on the blackbox... So it had to come out. On the new case the set screws to release the halves aren't sealed. So you need to put plenty of thread sealant on them.. Lesson learned.

 

[fjdiesel]

On a happier note, I finished my exhaust this am. Sounds way better! My welds aren't the prettiest, but they don't leak... I haven't quite got the hang of stainless in the spool gun. I suppose I should really get a tig welder... Of course, I won't know if the drone is gone until I get the blackbox back in so I can test drive. Hopefully this weekend.

 

[fjdiesel]

Got the blackbox put together and no leaks!!! Took it for a test drive, the exhaust sounds awesome!! Very happy with how it came out.

And my wife and kids got me this for father's day!!

And I had to play with it right away!! Gonna need some practice....

 

[toddm]

@fjdiesel , I just finished reading your build thread- very nice! will you be putting the ALH on a dyno after you have the tune adjusted? Just curious how much of the power you will be getting to the wheels! I have played around with tuning my Jetta's. My wife has a 06 with the BRM, I have a 05 with the BEW and I used to have a 03 ALH. I put some 1019DLC nozzles in the ALH and barely got the black smoke tuned out of it before the 05 came along for too good of a deal! It had half the miles of the ALH only 200K! The ALH I sold to my dad, and it is still running along with well over 400K miles! I didn't know anything at all about VW diesels when I did my swap. If I did another one I'd probably go that route. The tuning is so much easier and most everything has been figured out!

 

[fjdiesel]

@toddm I do plan on putting it on a dyno when I am done. I agree. It would be interesting to see what gets to the rear wheels. We road dynoed it the other day to do data logs. I had one of the high school kids from work run the laptop while I drove. First he about pissed his pants because I kicked it down on the dirt road. Then during the logs we were doing 90 mph in 3rd. He couldn't wait to get back to work to tell everyone... I think I am running a little rich. I believe they are going to dial the fuel down just a little bit. We should see on Monday.

Just for fun I would like to build one of these motors. Maybe a BHW with an ALH head?? Colt stage 2 cam? Who knows, after I get the 40 dialed in and I'm looking for a winter project that's when I will play with my extra motor on the shop floor.

 

[imyahucklbrry]

Really nice setup you’ve put together.....

 

[toddm]

@toddm I do plan on putting it on a dyno when I am done. I agree. It would be interesting to see what gets to the rear wheels. We road dynoed it the other day to do data logs. I had one of the high school kids from work run the laptop while I drove. First he about pissed his pants because I kicked it down on the dirt road. Then during the logs we were doing 90 mph in 3rd. He couldn't wait to get back to work to tell everyone... I think I am running a little rich. I believe they are going to dial the fuel down just a little bit. We should see on Monday.

Just for fun I would like to build one of these motors. Maybe a BHW with an ALH head?? Colt stage 2 cam? Who knows, after I get the 40 dialed in and I'm looking for a winter project that's when I will play with my extra motor on the shop floor.

I put a colt stage 2 in my wife's car. Unfortunately I was never able to compare it to stock because I bought it with a bad cam. Looking at my dyno runs from 2014 it looks like I left it at 138whp/230tq. I was not sure how far I could push the stock clutch and it's my wife's daily.

 

[fjdiesel]

Really nice setup you’ve put together.....

Thank you sir. Still working the bugs out, but very happy overall.

 

[fjdiesel]

I put a colt stage 2 in my wife's car. Unfortunately I was never able to compare it to stock because I bought it with a bad cam. Looking at my dyno runs from 2014 it looks like I left it at 138whp/230tq. I was not sure how far I could push the stock clutch and it's my wife's daily.

Lol, My beautiful bride gets nervous when I experiment with her daily.

 

[fjdiesel]

Haven't had time to work on wrapping up loose ends lately.... We moved, building a shop and a house... but I have been able to drive it some! Got almost 1500 miles on it this spring/summer.

 

[southern jeeper]

Any idea how long your transmission set up is? Do you think it would be too long for a stock length 40?

 

[daniel.watters]

Any idea on mpg?