Project Big Red

[laserjock]

Afternoons work. Got the power steering and hydroboost plumbed in.

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The hydroboost, master and pump were bought used so I flushed them all a bit before connecting up the steering box which is a new redhead. All new hoses. I added a wix magnetic filter in the return from the hrydroboost. Not optimal but better than nothing. There's no room for it underneath from the cooler do-dad. I may replace that cooler. If I do I'll add another filter or move this one. Wanted to plumb it into the radiator but someone here tried that and it didn't work for some reason.

I ran the pump by hand to fill everything. It's certainly not bled by any stretch but it won't start dry. Up next I think will be starting to fit the intercooler. Maybe I'll get started on that tonight.

 

[laserjock]

Didn't get as far as I wanted but I did get the IC set in there.

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I also hung the radiator to make sure things would fit. I went and pulled the rubber isolators out of my old radiators. I don't think this one is even going to set on the pins. Seems like it's a little narrower.

Photobucket is giving me the finger on that pic so I'll put it up later.

Here ya go.

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The precision mock up positioner (aka 2x6) seems to have it at just the right height. I may have to trim the grill. We shall see. Need to figure out how to mount it. I'd like to make the mounts out of aluminum so I don't have to worry about them rusting.

That's where I finished up the day.

 

[laserjock]

So today was mainly about the intercooler. It's the IC0022 from CXRacing that seems fairly popular. First had to mount the hood catch. I cut the center support down so I could mount the hood latch. Quickly figured out I had to cut down the hood catch lever.

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Okay now to figure out the top mounts. With the IC mocked in place, I saw I could use a speed nut hole on the left side. Figured what the heck and duplicated it on the right side. M8 body bolts.

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Okay now some L brackets to hang the thing.

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Okay. Looking good. Now to clearance the core support for the boots and pipe to go through. Easy enough right? Seen lots of pictures. Ugh. I hate cutting into fresh paint.

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Intercooler fits good. Room around the boots. You real observant folks will say, hey, isn't the lip on the radiator in the way of the pipe going through? The answer is yes. Now the dilemma, do I clearance the radiator flange or do I try to clearance the core support more and try to clear the radiator. I have two hang ups with clearancing the radiator. 1. It may cause problems with the fan shroud mount point. 2 if I ever have to mess with the radiator, I'll have to pull all that piping and possibly clearance the new radiator if for some reason I'm doing a roadside repair God forbid.

What say the masses?

In other news, I connected up the clutch and installed the slave cylinder. Filled it but did not bleed it yet.

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Hard to see but I got the steel hard line rather than the plastic. The one for the F-superduty crosses to a steel line from Dorman just FYI.

That's about it. I think I know how I'm going to do the lower IC support. I may remake the upper brackets in aluminum so they don't rust. They are nothing special. I think a duplicate set could be used on the lower mount as well. We shall see.

 

[Dailydriver]

My 2 cents. Cut out the core support. You thought way ahead about the radiator which I may not have done. Cut it out as far as you need to. Weld a strip of metal following the curve to reinforce the hole in the core support. OH MAN! Welding now is not really what you want to do in there.

Option B. You could cut 2 plates of steel, put one on each side of the support where the hole is and bolt them together sandwiching the core support in between them. I don't know if your willing to look at that astectically but it wouldn't bother me personally given its concealed location.

 

[laserjock]

So here is my dilemma really. I'm having a hard time deciding what to do with the batteries. The core support is really heavy as is. Then you add two group 31 batteries to it and then you cut out more of the meat. It seems like a recipe for problems. I wish there was a good way to relocate the batteries but I have not come up with a solution I'm happy with yet. I wanted to put them both on the passenger side but that is just concentrating the weight more in one spot. Not super keen on that idea either the more I contemplate it. Granted I'm not going to pound this thing off road but I already welded the cracks up in this core support once because it was beaten up.

More contemplation needed.

 

[79jasper]

I would move them.
In the bed, you would lose a little space up front. But if you have a tool box you plan to put in....
Passenger frame is a fair spot. Would sorta equalize the weight of the front tank, if you have one.

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[laserjock]

Okay. Got the new evap core.

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Looks pretty much like the original and bonus it came with an orifice and orings.

Got the dryer too. It looks like the original.

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Fits good too. Little tweak to the tubes to get things to mate.

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I made some aluminum brackets for the IC. Need to trim the top ones down and cut and mount the bottom ones.

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Ran a piece of Al angle across the bottom. Couple angle brackets to hold it off the AC condenser a little.

I think I have come to a decision on the batteries. More on that later.

 

[IDIoit]

incase you wanted to mount both batteries on the frame,
I would highly advise these, as I have mentioned.
http://www.ebay.com/itm/PER-660-661...Panel-Mount-/261346618826?hash=item3cd978edca

 

[laserjock]

Well tonight I got the IC all mounted.

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And with the IC removed.

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I'll trim things up and round the corners a little and things should be good. Still lots of trimming to do to fit the pipes. But I've decided I'm going to mount the batteries on the frame rail so that minimizes my concern about the extra weight and lost structure. Besides it will open up a lot of room. I'm trying to decide what to do about the inner fenders. Mine are not in the greatest condition. I can get replacements for about $130 shipped. I suspect they are for a gasser but I'm not sure if there is really a difference. I suspect there is a difference but I'm going rogue enough it may not matter. I could build a set but I'm not sure I have the ambition for it. I'm shifting heavily into get it done mode.

 

[Dailydriver]

Nice

 

[79jasper]

Really dude?
There's a section for that crap...
Put it in the classifieds/marketplace.

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[Dailydriver]

.

 

[catbird7]

You may have already explored this direction however have you considered the new "light weight" batteries? I'm not familiar with their capabilities and maybe they simply cannot offer enough CCA's to start a diesel??? Just a thought........

BTW, red paint looks AWESOME! You're like the "swiss army knife" of do-it-yourselfers!

 

[IDIoit]

considered the new "light weight" batteries? ........

I wouldn't waste the time exploring this until they have proven themselves.
if he uses the E series battery trays, they hold a group 31 just fine.
easy enough to put on a jack and install.

 

[laserjock]

A pair of these just shipped.

http://i996.photobucket.com/albums/af85/51dueller/001-1.jpg


I may mount them both together or separate. Not sure exactly what I'm going to do yet but I have a start.

[emoji6]