I like your sense of adventure of driving it back but ... you're going to have insurance and title issues --- and going through Mexico could be dodgy. Much easier to just through it in a conex container. Good luck.
Builds My Costa Rican BJ40 search begins
- Thread starter Mr Cimarron
- Start date
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- Thread starter
- #322
Ahh yeah. May want to read a bit more into my thread as I have had it imported awhile back. I agree with your statement as that is the way method I went with.
- Thread starter
- #323
Got a little more work done yesterday and this morning on the brakes and new alt bracket.
First off I extended the rod from the booster to peddle. I shorting the booster shaft down and used a coupler which I center drilled to join the added shaft together. it also gives me a place to put a wrench for adjustment.
I should have taken more photos when I was at a friend's shop machining the alt bracket. I'll take some more later today of the pieces we made. I was excited to help machine parts that I forgot to take progress photos.
First off I extended the rod from the booster to peddle. I shorting the booster shaft down and used a coupler which I center drilled to join the added shaft together. it also gives me a place to put a wrench for adjustment.
I should have taken more photos when I was at a friend's shop machining the alt bracket. I'll take some more later today of the pieces we made. I was excited to help machine parts that I forgot to take progress photos.
- Thread starter
- #324
I got the alternator bracket 90% done. After a few test fits it was welded up today at work.
This is how it looked compared to the stock bracket after we tacked it together.
And what it looks like now after final welding. I still need to grind a bit more clearance on the right side to make more space for the coolant pipe. Once that's done I can clean it up, paint, install and be one step closer to power brakes.
This is how it looked compared to the stock bracket after we tacked it together.
And what it looks like now after final welding. I still need to grind a bit more clearance on the right side to make more space for the coolant pipe. Once that's done I can clean it up, paint, install and be one step closer to power brakes.
- Thread starter
- #325
I did the finally mock up yesterday and painted the bracket. I also started figuring out the alternator wiring along with cleaning up some suspect Costa Rican wiring on the passenger harness. I got to use my new label maker that can print on shrink tubing. Next up getting a new pulley and oil lines for the alternator.
- Thread starter
- #326
Progress progress progress
I feel like I am almost back to having it driving. I got the oil lines made at a local hydraulic shop this morning. They are way overkill but they will work. I didn't get them crimped because I wanted to test fit and mark how they should be oriented so I will get them finished tomorrow. The one thing the shop didn't have was a M10x1.25 banjo bolt. I spent most of the day trying to find one around town with no luck. On the way home I pulled in to the Kawasaki dealer next to my house and sure enough they had one in stock. I should have known to check a Japanese place first.
I also got my case tractor pulley in which surprisingly fits perfectly. I thought I would need a spacer so no complaints. Maybe when I tighten the nut it will need one. Only thing holding me back now is brake lines. I am having no luck making double flare ends with my kit. I guess I just don't have the touch so I ordered a handful of random premade lengths just in case I give up this weekend.
The Case tractor pulley is a 78mm and the original one was 82mm I believe so only a tad smaller.
10Mx1.25 banjo bolt for the oil feed. Return line banjo bolt is a M14x1.50 I think.
I feel like I am almost back to having it driving. I got the oil lines made at a local hydraulic shop this morning. They are way overkill but they will work. I didn't get them crimped because I wanted to test fit and mark how they should be oriented so I will get them finished tomorrow. The one thing the shop didn't have was a M10x1.25 banjo bolt. I spent most of the day trying to find one around town with no luck. On the way home I pulled in to the Kawasaki dealer next to my house and sure enough they had one in stock. I should have known to check a Japanese place first.
I also got my case tractor pulley in which surprisingly fits perfectly. I thought I would need a spacer so no complaints. Maybe when I tighten the nut it will need one. Only thing holding me back now is brake lines. I am having no luck making double flare ends with my kit. I guess I just don't have the touch so I ordered a handful of random premade lengths just in case I give up this weekend.
The Case tractor pulley is a 78mm and the original one was 82mm I believe so only a tad smaller.
10Mx1.25 banjo bolt for the oil feed. Return line banjo bolt is a M14x1.50 I think.
- Thread starter
- #327
It's been crappy weather this weekend with constant rain. I was hoping to get everything squared away for a test drive but I only got as far as getting the alternator/vacuum pump finalized yesterday. It's all bolted and wired in. Started it up and it all works. I have vacuum and 14.2v at the battery! I'm pretty sure it was the coldest start the engine has seen in its life as well. I think it was 42 yesterday morning when I started it up. It took a few times to get it to stay on but once I got the fuel going it idled up real nice like. I also hadn't started it in over two months.
I also added another project to the short term list. I noticed the clutch MC was leaking inside the cab. Obviously it had been doing it before I got it judging by the paint. As I followed everything down to the trans to see what else might need to be ordered I saw another Costa Rican fix. I ordered a new Aisin MC and slave cylinder from Rock Auto.
I also added another project to the short term list. I noticed the clutch MC was leaking inside the cab. Obviously it had been doing it before I got it judging by the paint. As I followed everything down to the trans to see what else might need to be ordered I saw another Costa Rican fix. I ordered a new Aisin MC and slave cylinder from Rock Auto.
78fj40mg
TLCA #23510
Where did you source the new alternator/vacuum pump?
Very nice
Very nice
ERNRAM
SILVER Star
Same question on the down facing oil filter .
Is the system 12v or 24V?
Is the system 12v or 24V?
- Thread starter
- #330
I got it on eBay for $99 brand new. I believe I searched "NPR alternator".Where did you source the new alternator/vacuum pump?
Very nice
I'm curious as well. Looks like you didn't have to modify the bracket to make the new alternator fit? I'm currently searching for an alternator now myself.Where did you source the new alternator/vacuum pump?
Very nice
- Thread starter
- #332
It's a 12v. Mine came with the downward oil filter. I don't know what models came with the downward/upward filter housing. It's seems lately the 3b guys have been looking for the downward versions for turbo additions.
- Thread starter
- #333
I made a custom bracket but it wasn't to hard. Pictured are a few posted up. The stock bracket could have been modified to work but I didn't want to hack up a perfectly good one. Never know when I may need it again. I really wanted a stock alternator/vacuum pump but wasn't willing to pay the going rate for one.
78fj40mg
TLCA #23510
- Thread starter
- #335
You will also need the pigtail that pops ups on that search. I also forgot to mention that I didn't remove the external regulator even though the NPR is internally regulated. I reused the ground wire, ignition wire, and B post wire from the harness. I ran the S wire from the new alt straight to the battery.
- Thread starter
- #336
I was finally able to finish the brake mods, mostly. I bench bled the MC and installed. Then as gravity did its job I replaced my DIY lines that leaked with the ones I bought. I was hoping for at least one line to not leak but I wasn't so lucky. It was very frustrating as I went through a whole quart of brake fluid changing out lines and keeping the reservoir full. Now only thing left is to bleed the system but I'm home alone till this evening so it will have to wait. I also need to secure my junctions on the frame.
I also replaced the leaking clutch MC. It was easy. As I went to replace the slave I noticed it has the return spring arm built into it and my replacement doesn't. I decided to wait to do some research to see if the return spring is needed or if I can hook it somewhere else. I could bleed the clutch solo since I can reach the clutch with my right arm and move the bleed screw with my left but I'll wait.
Brake lines ready for bending. I got them from Low Range Offroad. $4-$7 a piece. After ordering I found out Napa has them as well for a few bucks more.
To make the loops I would find random round things around the garage. Much easier than using bending tool. The best thing I used was an old D battery MagLite. No photo but it worked great because I was able to clamp it in a vise.
I also replaced the leaking clutch MC. It was easy. As I went to replace the slave I noticed it has the return spring arm built into it and my replacement doesn't. I decided to wait to do some research to see if the return spring is needed or if I can hook it somewhere else. I could bleed the clutch solo since I can reach the clutch with my right arm and move the bleed screw with my left but I'll wait.
Brake lines ready for bending. I got them from Low Range Offroad. $4-$7 a piece. After ordering I found out Napa has them as well for a few bucks more.
To make the loops I would find random round things around the garage. Much easier than using bending tool. The best thing I used was an old D battery MagLite. No photo but it worked great because I was able to clamp it in a vise.
Awesome work Cimarron. Great progress amigo.
Good idea on using the maglight. I did like you, used various round objects. The handiest I found was a large deep socket (must have been at least for 1 1/2 bolt, maybe bigger), with a long extension on it, which made it easy to hang onto. After the coil was bent I would then put the 90* on each end of the coil.
Good looking job there.
Don
- Thread starter
- #339
Were you capable of making your own lines unlike me?
