Project Big Blue

aggiediesel01

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where I can be sure everything is air tight and installed perfectly before it’s up against the firewall and you have to stand on your head to reach everything.

What do you do to seal the "ball joint" at the Y pipe and feed pipe on old wiggly castings? Is there a high temp putty or caulking that can be jammed in there or do you have to weld it up and grind it to fit before coating?
 

Thewespaul

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What do you do to seal the "ball joint" at the Y pipe and feed pipe on old wiggly castings? Is there a high temp putty or caulking that can be jammed in there or do you have to weld it up and grind it to fit before coating?
Copper rtv works well for old castings, welding it is a permanent solution for guys running a lot of drive pressure. This one has never been apart since the factory, I left it together when taking it apart and assembling it.
 

Thewespaul

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Copper lugs crimped on the cables and installed
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New speed nuts and hardware to replace the busted rusty battery tray hardware
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Radiator hoses installed with stainless t bolt clamps
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Getting pretty close to getting to some fab work. Just buttoning up small stuff now, heater hoses in, ac pump and alternator installed, accessory wiring harness cleaned up and installed, tensioner installed, powersteering lines hooked up and reservoir filled, crank and water pump pulley installed and torqued.

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Thewespaul

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Installed some new sillverstar ultras in the new headlight housings, the bulbs that came out were almost 20 years old, and the bulbs that came with the housing are pretty crap, so should be a pretty good upgrade.

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While I had the batteries out I went through the engine bay harnesses cleaning up the connectors and loom.

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Thewespaul

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Blasted a spare fuel filter housing (With ports blocked off and a spare fuel filter on) and deleted the fuel heater.

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Primed and painted with sensors installed and return line blocked off

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Stripped the lift pump to filter head line and installed a new olive in the top fitting. I like to leave the line nuts bare polished brass, heres my trick for painting only the line.

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Thewespaul

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Fuel filter housing and bracket installed with the painted fuel line
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And got most the intercooler kit done, just waiting on some more material to come in Monday, then it will head out to the fab shop for welding up and building jigs. I use electrical tape to wrap around the welding joints, we cut out a piece to lay the tack welds down and then pull the tape off and finish weld it.

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Laine D

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While I was in the engine bay I noticed the battery trays had started to rust, so blasted both sides and hit them with some chassis black.
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Battery cables are in good shape, but the terminal ends are pretty rough so Im going to cut and crimp copper lugs on to get rid of the fatigued clamp style terminal connectors.
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Engine going in..
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And bolted into its final place. Little bit of a fight to get the torque converter lined up with the sagging body mounts but not too bad. Looks pretty nice in there.
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man I wish I went with that color blue instead!
 
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94bluebeast

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Fuel filter housing and bracket installed with the painted fuel line
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And got most the intercooler kit done, just waiting on some more material to come in Monday, then it will head out to the fab shop for welding up and building jigs. I use electrical tape to wrap around the welding joints, we cut out a piece to lay the tack welds down and then pull the tape off and finish weld it.

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That looks great Wes, really liking the routing, nice and clean.


Sent from my iPad using Tapatalk
 

Thewespaul

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Waiting for the order of intake hats to be finished at the fab shop so I can finalize the intercooler piping, I went ahead and got the a pillar gauges wired in and installed, taking time to get it fitting tight against the a pillar for a clean install.

Clean white leds installed

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All the wiring completed, just a single power and ground coming out for all the gauge controllers and lighting, and a single loomed harness for the sensors.

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Fits tight against the dash and headliner trim, with all the hardware going into the factory holes so didnt have to add any holes in the cab.

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Thewespaul

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Not sure if I posted this in a previous update, but got the -6 IP feed line made with the inline fuel pressure gauge. I’m pretty happy with how it came out since it retains the factory vacuum warning light on the one output port on the filter head but still gives the benefits of having a proper gauge. I decided to put this line kit on the website, it’s going for $75 with all the fittings, line and gauge.
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Also made a couple small changes with the piping, and finished the 4” intake pipe, topping it off with the prefilter and mounting the washer reservoir in place on the inner fender.

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Thewespaul

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Got the oil changed to pdd’s 15-40w conventional and plumbed the oil feed line for the turbo

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Pulled the batteries off the trickle chargers and cleaned them with some acid remover. Got them installed with new terminals and with the new copper lug ends on the factory cables.

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Picked up an intake hat from the fab shop and finalized the piping for finish welding.

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Pulled the factory insulation off the hood and pressure washed the layer off grease off to reveal the pretty factory paint.

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Prepped it with acetone and laid down some more noico insulation.

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IDIBRONCO

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Just for my curiosity, what is the purpose of the under hood insulation? Does it help reduce interior noise? If so, I may have to do that to mine in another couple of months.
 

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