But just barely...
http://orca.bcnewsgroup.com/gallery-pho ... tartup.mov
I still have a list of things to do as long as my arm, but tonight was a small milestone in the process of getting the truck back up and running again. Time to take the rest of the night off.
Dave
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DaveB
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bclandrover
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DaveB
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Hi Don,
Well, I did drive it up and down the block today a couple of times, but here's my to-do list as of today:
End of Phase 1:
- new master cylinder
- knock out and replace front frame bushings with neoprene
- reinstall front wings
- wire front lights
- reinstall bumper & winch
- rewire rear lights
- finish battery box in rear
- re & re transmission and install new synchro springs
- repair broken transmission mount
- fabricate hand brake linkage to make room for the exhaust
- install exhaust system
Phase 2
- bracket for intercooler
- remove egr manifold setup and install simplified intake pipe, thus allowing room for intercooler hoses
- plumb intercooler
Ripping up and down the road today, I was pretty impressed with the power and got it up to about 14 pounds boost in second gear. Should be fun to get used to...
Dave
Well, I did drive it up and down the block today a couple of times, but here's my to-do list as of today:
End of Phase 1:
- new master cylinder
- knock out and replace front frame bushings with neoprene
- reinstall front wings
- wire front lights
- reinstall bumper & winch
- rewire rear lights
- finish battery box in rear
- re & re transmission and install new synchro springs
- repair broken transmission mount
- fabricate hand brake linkage to make room for the exhaust
- install exhaust system
Phase 2
- bracket for intercooler
- remove egr manifold setup and install simplified intake pipe, thus allowing room for intercooler hoses
- plumb intercooler
Ripping up and down the road today, I was pretty impressed with the power and got it up to about 14 pounds boost in second gear. Should be fun to get used to...
Dave
Last edited by DaveB on Mon Jul 10, 2006 9:43 pm, edited 1 time in total.
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bclandrover
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DaveB
- Defender of the World
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- Joined: Mon Feb 09, 2004 7:45 pm
- Location: Vernon, BC
It may seem a long list, but compared to my original phase 1 list it's now pretty short. I didn't include the actual re & re of the diesel engine in this list, just the things that have had to be done since the initial install. Even though there's lots to do yet, I'm feeling pretty good, compared to what had to be done. The items with this symbol: √ are completed -- it shows as a check mark in my browser, but may be a different symbol on yours.
Clutch
√ bleed
√ resolve clutch linkage issue
- lengthen actuator at m/c
Cooling system
√ mount expansion bottle
√ properly mount heater (may require heater disassembly and resealing)
√ link small hose on front lower rad hose to expasion bottle
√ shorten lower rad hose to clear fan belts (may not be needed)
√ top up system
√ buy matched rad caps
Oiling system
√ repair leaks in front mounted oil cooler
Fuel system
√ properly mount fuel filter unit on left wing
√ install accelerator cable
√ inspect lines for rubbing and add protection where required
Electrical system
√properly wire in glow plug curcuit
- finish battery box cover
√ remove extra curcuits from new wiring harness
√ install new fuse box
√ install new wiring harness
√ wire up all engine components
- wire up front lighting
- wire up rear lighting, and other rear components
√ wire up dash and ignition
√ fix routing of hot cable to starter
√ hook up all curcuits and test
√ Add additional curcuit for manual fan override
√ wire in new guages
√ finish guage and switch panel
Old repairs
- lubricate rear u-joint or replace
- replace front spring bushings with neoprene
- remove transmission and replace spring clip on synchro
- replace transmission mounts
- lower rear transmission crossmember 1 inch
√ repair steering tie rod ends
√ reroute brake line to the rear brakes.
- replace brake master cylinder & bleed
Air Intake
√ build outlet for airbox to turbo intake
√ build bracket for airbox and mount it
- build intercooler bracket
- plumb intercooler
- fabricate snorkel & install
Exhaust
- reroute hand brake linkage on right hand side to make room for exhaust
- take to muffler shop to install 2 1/4" exhaust inside the frame
Body
- reinstall front bumper and hook up winch
- reinstall floor
- reinstall wings and hood
- add sound deadening to interior
- add new drivers door lock
- reinstall doors
- install hard top with open sides
- measure and mark curtains and take for sewing $150
√ reinstall fuel carrier on rear tailgate
Dave
Clutch
√ bleed
√ resolve clutch linkage issue
- lengthen actuator at m/c
Cooling system
√ mount expansion bottle
√ properly mount heater (may require heater disassembly and resealing)
√ link small hose on front lower rad hose to expasion bottle
√ shorten lower rad hose to clear fan belts (may not be needed)
√ top up system
√ buy matched rad caps
Oiling system
√ repair leaks in front mounted oil cooler
Fuel system
√ properly mount fuel filter unit on left wing
√ install accelerator cable
√ inspect lines for rubbing and add protection where required
Electrical system
√properly wire in glow plug curcuit
- finish battery box cover
√ remove extra curcuits from new wiring harness
√ install new fuse box
√ install new wiring harness
√ wire up all engine components
- wire up front lighting
- wire up rear lighting, and other rear components
√ wire up dash and ignition
√ fix routing of hot cable to starter
√ hook up all curcuits and test
√ Add additional curcuit for manual fan override
√ wire in new guages
√ finish guage and switch panel
Old repairs
- lubricate rear u-joint or replace
- replace front spring bushings with neoprene
- remove transmission and replace spring clip on synchro
- replace transmission mounts
- lower rear transmission crossmember 1 inch
√ repair steering tie rod ends
√ reroute brake line to the rear brakes.
- replace brake master cylinder & bleed
Air Intake
√ build outlet for airbox to turbo intake
√ build bracket for airbox and mount it
- build intercooler bracket
- plumb intercooler
- fabricate snorkel & install
Exhaust
- reroute hand brake linkage on right hand side to make room for exhaust
- take to muffler shop to install 2 1/4" exhaust inside the frame
Body
- reinstall front bumper and hook up winch
- reinstall floor
- reinstall wings and hood
- add sound deadening to interior
- add new drivers door lock
- reinstall doors
- install hard top with open sides
- measure and mark curtains and take for sewing $150
√ reinstall fuel carrier on rear tailgate
Dave
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John
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DaveB
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- Joined: Mon Feb 09, 2004 7:45 pm
- Location: Vernon, BC
Inside the frame rails, as opposed to underneath the various crossmembers. There is room on the right side, inside the frame rail if I do a bit of change to the park brake linkage, specifically the vertical rod on the right side.
i've seen too many custom exhausts lately that are hanging too low and just waiting to get hit. I've got the opportunity to keep the entire system up in between the frame rails and thats where I hope the exhaust installer will agree...
Dave
i've seen too many custom exhausts lately that are hanging too low and just waiting to get hit. I've got the opportunity to keep the entire system up in between the frame rails and thats where I hope the exhaust installer will agree...
Dave
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DaveB
- Defender of the World
- Posts: 1749
- Joined: Mon Feb 09, 2004 7:45 pm
- Location: Vernon, BC
New check marks tonight:
√ lengthen clutch actuator at m/c
√ install new brake master cylinder
√ bleed brakes
Test run: ripping up and down the local farm road a few times. woo hoo!!
√ hammer out front frame bushings on one side.
Tomorrow night I'll try and finish the bushings, and wire the rear lights. I can then insure it and actually drive it on the road. Then a week or two of all the little bits...
Hmmm, maybe I should just leave the exhaust like this. Sure can hear that turbo wind up.
D
√ lengthen clutch actuator at m/c
√ install new brake master cylinder
√ bleed brakes
Test run: ripping up and down the local farm road a few times. woo hoo!!
√ hammer out front frame bushings on one side.
Tomorrow night I'll try and finish the bushings, and wire the rear lights. I can then insure it and actually drive it on the road. Then a week or two of all the little bits...
Hmmm, maybe I should just leave the exhaust like this. Sure can hear that turbo wind up.
D
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DaveB
- Defender of the World
- Posts: 1749
- Joined: Mon Feb 09, 2004 7:45 pm
- Location: Vernon, BC
√ replace front spring bushings with neoprene
Both sides now done. For the first time I used a sawzall to cut through the old bushing sleeves. This turned a 30 minute cut and cuss job into about 15 seconds with the question coming up... oops, did I cut too far?
Actually I tested first on an old hunk of metal. The sawzall with a 9 inch extra heavy duty Search and Rescue quality blade is an amazing piece of equipment and ate through the steel sleeve like a hot knife through butter. This one is Andrews. gotta get me one of these!
Now out to wire the rear lights, then insurance in the morning. Still not ready to go cruising in the bush, but at least I'll be able to say its back on the road.
Dave
Both sides now done. For the first time I used a sawzall to cut through the old bushing sleeves. This turned a 30 minute cut and cuss job into about 15 seconds with the question coming up... oops, did I cut too far?
Actually I tested first on an old hunk of metal. The sawzall with a 9 inch extra heavy duty Search and Rescue quality blade is an amazing piece of equipment and ate through the steel sleeve like a hot knife through butter. This one is Andrews. gotta get me one of these!
Now out to wire the rear lights, then insurance in the morning. Still not ready to go cruising in the bush, but at least I'll be able to say its back on the road.
Dave