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- #341
Thanks, I appreciate that. I did an aluminum roof top tent rack for my ford pickup as the first aluminum welding project (its in this build thread somewhere).
Builds Red Dawn (60 converted 62 Build Thread w/ R2.8) (9 Viewers)
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- Thread starter
- #342
Finished up putting the end tanks on the intercooler core. Found 4 holes after filling it with water. Should be good until I do a real pressure test.
Put it back in the truck as a fit check. Things are tight but it works. The full width of the core is exposed to the moving air. No end tanks blocking things off from the radiator. Pretty happy with it.
So now it's time to work on mounting this whole package. Plan is to mount the radiator and intercooler together and then install onto the core support. The original radiator mounts, rubber bushings and sheet metal pieces that bolt to the core support are great. I think they are a great solution and I want to re-use that mounting concept with the new intercooler and radiator. I am going to lose the ability to unbolt the cores support mounts, going to weld those directly to the core support. The intercooler is wide with the end tanks, the mounts are being pushed out. I think that's a sacrifice that needs to be made.
To attach the radiator to these points will require new brackets that bolt to the 4 studs on each side of the radiator. Let the fabrication begin:
The keen observer will not that I had to make some nips and tucks as I went along. Constantly fitting and checking. Luckily never had to start form scratch. The .75" dimple die was perfect for the rubber bushing and I'm really pumped on the fitment thus far.
One more tab on each end tank welded to the intercooler that mounts to this new piece I made and I can start placing it all on the truck and finish up the cooling package.
Put it back in the truck as a fit check. Things are tight but it works. The full width of the core is exposed to the moving air. No end tanks blocking things off from the radiator. Pretty happy with it.
So now it's time to work on mounting this whole package. Plan is to mount the radiator and intercooler together and then install onto the core support. The original radiator mounts, rubber bushings and sheet metal pieces that bolt to the core support are great. I think they are a great solution and I want to re-use that mounting concept with the new intercooler and radiator. I am going to lose the ability to unbolt the cores support mounts, going to weld those directly to the core support. The intercooler is wide with the end tanks, the mounts are being pushed out. I think that's a sacrifice that needs to be made.
To attach the radiator to these points will require new brackets that bolt to the 4 studs on each side of the radiator. Let the fabrication begin:
The keen observer will not that I had to make some nips and tucks as I went along. Constantly fitting and checking. Luckily never had to start form scratch. The .75" dimple die was perfect for the rubber bushing and I'm really pumped on the fitment thus far.
One more tab on each end tank welded to the intercooler that mounts to this new piece I made and I can start placing it all on the truck and finish up the cooling package.
Gorgeous.
- Thread starter
- #344
Got the lower mounts done over the weekend.
Need some triangulation for the upper part. Ready to mock up in the truck and get it all welded in.
Need some triangulation for the upper part. Ready to mock up in the truck and get it all welded in.
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- #345
This weekend is a bit of a mixed bag. I'm removing the engine and transmission in preparation for replacement of the starter ring from Axis Industries. The original part is prone to failure and they are sending me a replacement free of charge. Rather than doing the swap on my back in the truck, I just disconnected everything and am going to pull the whole engine and trans out. I also got my radiator supports all finished and ready to weld onto the core support. Been tig welding aluminum too much, the steel welds look terrible.
Transfer case is down:
Plan for the radiator is to position everything in the truck (when the engine is back in. Then tack weld these brackets on, pull it all apart and finish weld it.
Transfer case is down:
Plan for the radiator is to position everything in the truck (when the engine is back in. Then tack weld these brackets on, pull it all apart and finish weld it.
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- #346
I answered the question of how long it would take me to remove the engine and transmission. Separate them. Put them back together and set them back in the frame. Two days. Kevin at Axis industries has a new starter ring for his adapter. The old ones fail. It's a bummer that I have to undo so much, but thankful I didn't get further in the project before this happened. A couple of photos to mark the occasion.
Old on the left, new on the right. It's about a tenth thicker. Might not be able to tell in the photo but the adapter spacer hub needs to be spot drilled to allow for the extra thickness. I re-blued the drill parts to try and keep rust away.
A bit of a bummer to see the truck back like this again.
Almost completely back to the where I was. We now return you back to your regularly scheduled, albeit slow, build thread.
Old on the left, new on the right. It's about a tenth thicker. Might not be able to tell in the photo but the adapter spacer hub needs to be spot drilled to allow for the extra thickness. I re-blued the drill parts to try and keep rust away.
A bit of a bummer to see the truck back like this again.
Almost completely back to the where I was. We now return you back to your regularly scheduled, albeit slow, build thread.
- Thread starter
- #347
Anyone got a good writeup post on what wiring can be ditched when doing a motor swap? Maybe an LS swap thread? I'm slowly piecing it together but it's slow going.
- Thread starter
- #348
Got the radiator mounts tack welded onto the core support. Put some temporary fenders on the the truck as well. The perforated angle gives me access while keeping the core support upright and fixed in space. Put the inner fenders on as well so I can start placing things (ECU, air box, etc). All in all, it's starting to "come together" which is exciting. Tons of fabrication left to do.
I need to drill a hole here to bolt the uprights on the intercooler to the radiator. This is the stackup of the cooling package
Inner fenders in. Still need to do the fan shroud as well before I start on any radiator hoses.
I need to drill a hole here to bolt the uprights on the intercooler to the radiator. This is the stackup of the cooling package
Inner fenders in. Still need to do the fan shroud as well before I start on any radiator hoses.
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- #350
The factory condenser still fits on the front of the core support. Figured I would reuse it since the system for mounting is already there. I have a tentative plan to mount a small 10 pusher fan to the front like D.I.Y Pusher Fan on 60 - https://forum.ih8mud.com/threads/d-i-y-pusher-fan-on-60.1073074/
It's going to be tight with lines and such, Will probably have to pop a new hole in the core support since the intercooler covers the original port.
- Thread starter
- #351
With the Spal 16" fan from Wizard Cooling, I got a shroud kit. It was some flat 5052 Aluminum sheet that is laser cut for the opening of the fan. I trimmed the top and bottom down, which got quite thin where the fan hole and metal edge almost became tangent. You'll see I clipped some square tubing to those areas to keep the whole thing from tacoing while I tried to bend it.
Tracing out the radiator outline and mounting hole locations.
Here is the issue. The radiator core is a bit recessed from the flanges that are welded on the sides. So the small gap I thought I would have top and bottom to fill with some rubber gasketing or foam sealing material ended up being a bit bigger than expected. I assume the shroud would work OK, but it definitely won't be very good with this giant gap in there. If necessary I'll cut down the sides and weld on some new flanges to bring it down. Oh well, not everything is gumdrops and kittens.
Finished up the intercooler with the integrated shroud.
Mock Up
Couple of edges to smooth no doubt, but this is pretty big for me. Should be all the big things in the way and mounted which means I can do intercooler and intake plumbing as well as all the fluids. Should be a fun couple of weeks filled with some good progress.
Tracing out the radiator outline and mounting hole locations.
Here is the issue. The radiator core is a bit recessed from the flanges that are welded on the sides. So the small gap I thought I would have top and bottom to fill with some rubber gasketing or foam sealing material ended up being a bit bigger than expected. I assume the shroud would work OK, but it definitely won't be very good with this giant gap in there. If necessary I'll cut down the sides and weld on some new flanges to bring it down. Oh well, not everything is gumdrops and kittens.
Finished up the intercooler with the integrated shroud.
Mock Up
Couple of edges to smooth no doubt, but this is pretty big for me. Should be all the big things in the way and mounted which means I can do intercooler and intake plumbing as well as all the fluids. Should be a fun couple of weeks filled with some good progress.
- Thread starter
- #352
Had a few more minutes to kill and dropped in this oil pressure sensor kit form Axis. Will use the factory pressure sender.
Need to buy a new sender.
Need to buy a new sender.
Just caught up on your build! Well done... that radiator/intercooler is a beautiful work of art. I am just putting the finishing touches on my R2.8 conversion in my '87 HJ61... she has been my daily driver for a whole 5 days now! : )
Thanks for the pics of your exhaust, and the tip on that DOC delete pipe... all great stuff as I am designing my exhaust system now... shes just dumping under the engine compartment at the moment lol.
Great work, a true inspiration. Give me a shout if you are ever up in Whatcom County.
Thanks for the pics of your exhaust, and the tip on that DOC delete pipe... all great stuff as I am designing my exhaust system now... shes just dumping under the engine compartment at the moment lol.
Great work, a true inspiration. Give me a shout if you are ever up in Whatcom County.
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- #354
Got the whole cooling package back in the truck. I have one spot I need to clearance at the bottom of the radiator, I think the added weight of everything compresses my old radiator mounts quite a bit. Tacked together one of the charge pipes and one of of the radiator pipes. Made a few orders for some tubing that I still need. Hoping to get the ATF lines done this week and start hanging some stuff off the inner fenders. This oil filter thing is gigantic.
I bought the tool that puts the bead on aluminum tubing so I can make each one completely custom.
I bought the tool that puts the bead on aluminum tubing so I can make each one completely custom.
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- #355
Using some space on the firewall to mount the trans dipstick. Probably put a few more things on this bracket as I get other systems figured out. Put the transmission breather on here as well. I'll revisit it when all those things are finished. Still need to TIG weld up some seams to make it really rigid.
Origami. Just trying to figure out the bend sequence. I still had to get creative to make this happen.
Altered the layout slightly and had to clearance for a bumped out section of the firewall.
Get some hardware and we're all set.
Origami. Just trying to figure out the bend sequence. I still had to get creative to make this happen.
Altered the layout slightly and had to clearance for a bumped out section of the firewall.
Get some hardware and we're all set.
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- #356
Got two more tubes tacked up today. Going to have a ton of aluminum finish welding to do. Should be good practice.
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- #357
I built a baffled power steering reservoir today. Pretty fun aluminum construction challenge. I think it turned out pretty good. Still need to make a bracket and mount it to the radiator somehow.
All the parts:
Basic sub assemblies:
This is the high pressure baffle coming from the steering box. Keeps the fluid from cavitating and causing bubbles or frothing.
Drinking a beer on the deck with my new reservoir:
All the parts:
Basic sub assemblies:
This is the high pressure baffle coming from the steering box. Keeps the fluid from cavitating and causing bubbles or frothing.
Drinking a beer on the deck with my new reservoir:
@LyndenCruiser79 I'm connecting the dots now. Saw your cruiser scream past me on the freeway near Ferndale. R2.8 makes sense...
Thats awesome! Yeah, the new motor is really growing on me, truth be told, acceleration up to 40ish doesnt feel terribly different then the 12HT diesel I had before but the R2.8 really shines in 5th! Almost seems limitless... kinda wished I had a 6th gear lol
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- #360
This is good to know. The 6L80e does have a .67 ratio 6th gear.
