My 3 linked daily driver build thread

Joined
Apr 4, 2013
Messages
2,288
Location
Springfield, OR
Visit site
Tried my hand at Aluminum DC TIG for my turbo drain fittings....ran out of shielding gas with no luck so far. I did, however, manage to rebuild the transmission today. Just the main bearings, cleaning, inspection replaced the input and input pilot bearing with a jeep AX15 input. Added the Marlin Crawler hardened thrust washer and billet bearing retainer; hopefully the transmission lives a long and glorious life behind the diesel. Onto the pictures for the day.

IMG_4969.JPG


IMG_4971.JPG


IMG_4972.JPG


IMG_4973.JPG


IMG_4974.JPG
 
Last edited:
Joined
Apr 4, 2013
Messages
2,288
Location
Springfield, OR
Visit site
Still waiting on my flywheel, waiting game is getting really old. It is to my benefit in a sense I suppose. My source for aluminum tig welding fell through a few weeks back and I had to come up with alternatives to several different aspects of the project. The turbo drain fittings were all supposed to be aluminum and the compressor outlet for the HX40 was supposed to get cut down and welded on at a 90* angle since for some reason the cast 90* elbow is more like a 80*. Also the charge pipe from the HX that feeds the K14 was supposed to be aluminum. The solutions I came up with: cut new turbo drain flanges out of some 3/8 mild steel I had laying around, order new -12AN weld on fittings in the stainless variety, order the ridiculously expensive v-band clamp and o-ring for the turbo elbow and buy a 45/180 3" stainless mandrel bend to replace the aluminum charge pipe. Waiting on the mandrel bend at the moment.

IMG_5008.JPG


IMG_5009.JPG


IMG_5011.JPG


IMG_5012.JPG


IMG_5016.JPG
 
Last edited:
Joined
Apr 4, 2013
Messages
2,288
Location
Springfield, OR
Visit site
A few more pictures because we all love pictures. I also modified the stock vacuum operated internal wastegat by cutting the assembly off of the bracket it was attached to and drilling the bracket to fit the billet adjustable wastegate from KINUGAWA the fit is like it was meant to be.

IMG_5020.JPG


IMG_5022.JPG


IMG_5024.JPG


IMG_5026.JPG


IMG_5027.JPG
 
Last edited:
Joined
Apr 4, 2013
Messages
2,288
Location
Springfield, OR
Visit site
Not a whole lot of forward progress the last couple of days, was supposed to have the nerves in my lower back burned down again but the VA gave me a cortisone injection instead because they scheduled me for the local clinic that doesn't have the tools to do RFA, so I've been a bit sore. I managed to get the transfer case assembled to the transmission, just need to torque the input and drive flange nuts. The HZJ79 transfer case adapter housing, adapter shaft and shift linkage all work perfectly with the fj62 manual shift converted split case. I also drilled removed and drilled out the transmission and transfer case breathers and tapped them for 1/8npt for hose barb fittings. I removed the exhaust manifold and welded the old EGR port shut and have been working on grinding down any weld that protrudes into the exhaust and wastegate ports. Lastly, I removed the turbo drain fittings and blended them in for better drainage flow and made an intake manifold inlet adapter that needs welded still. I didn't get many pictures. Today I will hopefully receive some more packages in the mail. Header wrap and ties, turbo plumbing hose from Fragola. Also waiting on a new oil cap and gasket since I noticed a crack in the original, and lastly I have a couple turbo blankets coming for the turbine housings. The wrap and the blankets are my attempt at keeping direct heat off of the Turbo-smart wastegate and oil feed/drain hoses, they should look decent ok I hope.

IMG_5034.JPG


IMG_5035.JPG


IMG_5036.JPG


IMG_5037.JPG


IMG_5033.JPG
 
Last edited:
Joined
Apr 4, 2013
Messages
2,288
Location
Springfield, OR
Visit site
For some reason I'm unable to edit my previous posts at the moment...which is going to suck a big floppy donkey dk if I can't edit them. Anyway, since I'm still waiting on the machinist for my flywheel and Marlin Crawler whose motto seems to be "we should have your part next Wednesday, it should ship on Thursday" I rebuilt the turbo, and painted the parts I got back from the metal cleaners. Installed new seals, gaskets, idler pulley and damper, alternator,power steering pump, water pump and thermostat and vacuum pump. Also, I built my hx40 hybrid with 12cm^2 wastegate-less exhaust housing. Here are a couple teaser pics since the majority of pics are on my phone. if I regain editing abilities I will edit this post to reflect.

IMG_4881.JPG


IMG_4885.JPG


IMG_4886.JPG


IMG_4887.JPG


IMG_4888.JPG


EDIT: People liked the post and it wouldn't make much sense for me to delete the content now, so now the pictures are double posted.
 
Last edited:
Joined
Feb 3, 2004
Messages
1,823
Location
Lincoln, CA
Website
nexusmetalwerx.com
Looking great man!

The interest in the 606 will be high for CA owners... if they don't know they will learn that CA doesn't allow 6bt swaps to be registered in CA technical... (there are some rumored ways around this)

However the 606 is appealing because it was offered in a "like vehicle", something nessassary for a CA approved swap since the 80 series is on the books as a station wagon and not a 3/4 ton truck.

You could open the market!

-A
 
Joined
Apr 4, 2013
Messages
2,288
Location
Springfield, OR
Visit site
Looking great man!

The interest in the 606 will be high for CA owners... if they don't know they will learn that CA doesn't allow 6bt swaps to be registered in CA technical... (there are some rumored ways around this)

However the 606 is appealing because it was offered in a "like vehicle", something nessassary for a CA approved swap since the 80 series is on the books as a station wagon and not a 3/4 ton truck.

You could open the market!

-A
@AMMO I was saying this very thing when I first posted that I was working on this swap. Seems like @Tugarin may have come across a better solution though with his OM648 swap. I would have gone the OM648 route myself but the stand alone tech wasn't out there, and I kind of don't like the electronic dependency of the OM648. They are, however, far superior in fuel economy and power in stock trim. I may do another project with an OM648 in the future...distant future. I have to get this one and 2 others done and save some money lol. I hope to have my flywheel next week but I won't hold
My breathe, the machinist doing the work said he could have it done by June 14 which was the ATL date I gave him for delivery, he didn't even get the material until the day before and I'm not sure he's even started it. Anyway, I'm just doing what I can in the mean time, which isn't much at the moment. I'm rebuilding and converting the 38mm split case this weekend and doing some minor Fab work for the turbo setup today, I need to figure out the drain line setup still. Anyway, hopefully I can bring this swap to fruition soon and hopefully have something worthwhile to offer the community.
 
Joined
Apr 4, 2013
Messages
2,288
Location
Springfield, OR
Visit site
Holinbolt....German for dipstick tube adapter. So the dipstick tube for the om648 (oil pan I'm using) is no longer available. The om606 tube is 29/64 OD, the inner hole for the om648 tube is 0.515". A 14mm shoulder bolt is roughly 0.505" at the shoulder. So I'm center drilling the bolt to 29/64 and cutting the head and threads off to make a bushing for the OM606 dispstick tube to go into and I will tig a mounting flange and the tube to the bushing to make a functional dipstick tube.

IMG_4895.JPG
 
Last edited:
Joined
Feb 3, 2004
Messages
1,823
Location
Lincoln, CA
Website
nexusmetalwerx.com
@AMMO I was saying this very thing when I first posted that I was working on this swap. Seems like @Tugarin may have come across a better solution though with his OM648 swap. I would have gone the OM648 route myself but the stand alone tech wasn't out there, and I kind of don't like the electronic dependency of the OM648. They are, however, far superior in fuel economy and power in stock trim. I may do another project with an OM648 in the future...distant future. I have to get this one and 2 others done and save some money lol. I hope to have my flywheel next week but I won't hold
My breathe, the machinist doing the work said he could have it done by June 14 which was the ATL date I gave him for delivery, he didn't even get the material until the day before and I'm not sure he's even started it. Anyway, I'm just doing what I can in the mean time, which isn't much at the moment. I'm rebuilding and converting the 38mm split case this weekend and doing some minor Fab work for the turbo setup today, I need to figure out the drain line setup still. Anyway, hopefully I can bring this swap to fruition soon and hopefully have something worthwhile to offer the community.

Dang doing 2 more after yours... hummnnn.... PM inbound.
 
Joined
Apr 4, 2013
Messages
2,288
Location
Springfield, OR
Visit site
I added some pictures of what's been done so far (page 7) as I wait patiently for my machinist to either return me emails or call me with a finished flywheel. I will work on the transmission tomorrow and if I have any time I will hopefully weld up some turbo drain fittings.
 
Joined
Apr 4, 2013
Messages
2,288
Location
Springfield, OR
Visit site
Got some goodies in the mail and via FedEx and UPS. Header wrap, turbo blankets and my oil feed and return lines. Have to remove a broken manifold stud from the head and I will reinstall the manifold with turbos and hook up the drains and feed lines. I added an EGT bung to the turbo adapter coming off the manifold too.

IMG_5038.JPG


IMG_5040.JPG


IMG_5042.JPG


IMG_5043.JPG


IMG_5041.JPG
 
Last edited:

Users who are viewing this thread

Top Bottom