PIIIIIIIIIICS!Well its been nearly 2 years since beginning this thread, I got locked out and somehow couldn't log back in with my devices at the time.
Ive got a bit to catch up on. The short of it is that The engine is fitted, goes hard, and we're currently 8 months in to our big around Australia trip with no major problems yet.
The bare metal thing did not last as predicted by Cleg, So I painted it up in the factory 416 Dune Beige. The vehicles original and my favorite 40 series colour.
As it turns out, the clutch (Clutch Industries 4Terrain from a HJ61 Turbo) is no where near strong enough to handle the torque that the engine is putting out. this is currently the weak point of the driveline, but while we are travelling fully loaded at about a 3.5T GVM it serves as gearbox/diff overload protection. It still transmits plenty of torque regardless. We can overtake 52m long road trains on the outback highways with ease.
I ended up designing a 3D model of the bellhousing I needed to fit the H55 Box and engine together. I got this made in China and delivered. (5 day turnaround! crazy hey!) It was machined out of a billet of 6061 Aluminium. Shouldn't break! I also designed the clutch throwout fork and got that machined out of 4340 chrome-moly. the quality, speed and price was unbeatable. I'll be using this process for future projects for sure!
I used 2X Donaldson filters each rated to 250CFM at 6"water of vacuum. they have cyclonic dust seperators in the intake which gives them a reasonable dust capacity. I worked out I needed 500CFM airflow at full tilt, but in hindsight the clutch cant handle the torque at that airflow anyway, so realistically I could have used a smaller turbo, less ducting, one air filter and achieved the current power that I have (which I'm very happy with!). All good lessons!
my camper ended up weighing much more than I expected (as usual) and for weight reduction/simplicity I haven't made it removeable (yet).
I'll get some photos up as soon as my technology permits.
I welded up a monster of a fuel tank out of two old tanks that needed repairs, managed to get 275L out of it. This combined with the factory tank gives me 360L useable in total. Also a massive overkill! It has been useful in the far remote north, but realistically for the complication/risk/weight I'd be better off just buying the fuel at the exorbitant prices up there. you just don't need the 2480km range!
Fuel economy has been worse than expected, but I guess the vehicle weighs 600kg more than expected, so thats not helping! It's worked out to about 14.5L/100km (thats about 16.2 US MPG for you crazy non metric types!) I was hoping for more like 12ishL/100km. (20ish
Pics ............. p-r-e-t-t-y p-l-e-a-s-e........
^^what he said.....^^
Ditto on the pics... Excited to see the progress of your build!!
That bellhousing is a work of art too.. But how to you get at the slave-pushrod and fork-return-spring?
I bet the twin 45 degree Donaldsons make people ask what size donk you've got under the bonnet.
Thanks again for posting the pics..