Antarctic IDI Build

Discussion in '6.9L IH & 7.3L IDI Diesels' started by Thewespaul, Oct 15, 2017.

  1. Thewespaul

    Thewespaul Supporting Member Supporting Member

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    Thanks Jack! My fathers employees have been breaking things faster than I can fix, but I think 2018 is gonna be a great year for us. Hope you and your wife had a good Christmas, I still haven’t forgotten about that IP, just waiting on a new block then I can start assembling the new engine
     
  2. SirRea63l

    SirRea63l Supporting Member Supporting Member

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    No hurry here, the truck is still on the back burner. We are shoping for a 2001-2006 Yukon XL Denali for road trips. When I find one I am sure it will need some attention before I do anything else.
     
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  3. chillman88

    chillman88 Supporting Member Supporting Member

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    I will tell you I picked up a fuse box at the junkyard that might be helpful for you. I believe it was a 94ish jeep Grand Cherokee. I'm planning on using it for my headlight relays and heater relay. It would also do fuel pump fuse and relay too. It's in a box here somewhere but I think it was about 3"x12" It will fit nicely near the starter solenoid on a bricknose inner fender.
    [​IMG]
    Picture isn't mine but is the one I'm talking about.
     
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  4. Thewespaul

    Thewespaul Supporting Member Supporting Member

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    Just a small update, wired in in a manual high idle/advance switch. The truck was setup to have one but the switch seemed to be missing, figured it would be useful for cold mornings or if needing some more amps from the alt you can just flip the switch.
    387D1BD6-AEC2-4E1A-BCF1-F5C450AA46D9.jpeg D837E892-A23D-4C83-998A-63648CA7B45B.jpeg 362D94D6-4235-4AAF-A617-DB2585AF16AF.jpeg
    Still waiting on parts to finish the fuel system then turbo will be going on.
     
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  5. Thewespaul

    Thewespaul Supporting Member Supporting Member

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    Fuel system is done, got the new fittings in and fuel heater started seeping... pulled fuel filter housing apart and replaced the o ring, filled the filter with atf and it’s setting with it in the IP overnight.
    73F26A06-C347-4435-A301-3C8DB84D9C48.jpeg
    Still holding pressure in the supply side, this things gonna start great!
    B89DADE1-8DB4-4686-83F3-5469DA233D5B.jpeg
     
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  6. Thewespaul

    Thewespaul Supporting Member Supporting Member

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    Final shakedown drive before pulling it apart to install turbo. Drove 5-6 miles and everything went well, the brakes are awesome. Fuel prefilter looks like this after that little drive, glad I installed the clear cheapy
    F340D47C-065A-4A1D-AC7A-142893B0FF59.jpeg 8ED7D33C-CD10-4E3E-8234-3EF1C496714F.jpeg
     
  7. Thewespaul

    Thewespaul Supporting Member Supporting Member

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    Well the ambulance is gonna sit for a bit while I work on Matt’s other truck, the Ambo got a bath for Matt to check out the progress. Cleaned up pretty well, I’m definitely going to have to build an ambulance like this one of these days.
    8E6897D6-993F-4596-9B3A-AD9C1C9653AA.jpeg A19261FE-5B55-4C05-8763-9E4AD79DB311.jpeg 2B76B8DB-0E54-4AC9-B0A7-33AC265AE2CA.jpeg
     
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  8. Hydro-idi

    Hydro-idi Full Access Member

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    Nice lookin rig!
    Can’t believe all the crap that’s in that fuel filter
     
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  9. Thewespaul

    Thewespaul Supporting Member Supporting Member

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    Yeah it’s bad... no wonder its had so many issues when trying to make it reliable
     
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  10. Thewespaul

    Thewespaul Supporting Member Supporting Member

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    Progress. I’ll go into everything I did today in another post

     
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  11. Hydro-idi

    Hydro-idi Full Access Member

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    ;Sweet. Sounds nice & strong! Looks like it’s coming together really well.
     
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  12. Jason1377

    Jason1377 Supporting Member Supporting Member

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    Awesome progress sir will be a treat to see the final result
     
  13. Thewespaul

    Thewespaul Supporting Member Supporting Member

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    Thanks guys, so here’s some pics and explanation to make up for the last post. I was on a roll and didn’t want to take my hands out of my gloves to take some pics. Wasn’t cold by northerner standards but about as cold as it gets here Sunday


    This installation is sponsored by the air chisel and BFH.
    688079B9-1AC3-4D71-B849-057BB3967DD8.jpeg
    Had to completely bend over the firewall lip and remove it in some places, the trans tunnel double wall got completely removed. Clearanced the appropriate areas with the BFH but still no dice. Dropped trans cross member and lowered the trans down still needed more room, pulled the front passenger side cab mount loose and lifted that side of the cab to fit the up pipe in.

    Pulled the trans dipstick to do this, and if you can pulling only the top half of the dipstick keeps you from covering your work area in atf.

    Had to remove a bit of the fat firewall insulation to clear the turbine, replaced it with some space foam insulation that doesn’t take up as much space. The adhesive didn’t work well in our temperature, gonna go in with some upholstery adhesive and make sure it stays put.
    3D8633C1-FF16-42D0-8944-66EDC339BB7D.jpeg

    Next obstacle was the wiring harness for all the ambulance accessories, it ran behind the engine and was held to the firewall with a couple self tappers. Pulled it loose and had to move some things around but routed it in front of the intake and away from the turbo hot side, really the only way without cutting everything and adding a couple feet to the harness. 40951DF7-894D-407C-BE03-1EFEE52CF80A.jpeg

    It’s a mess down there. Gonna be cleaning some of this up once some of the more crucial work is done.
    09869146-7FDC-4B04-9160-E2B2B1862C11.jpeg
    Crossover installed, gonna use a wireless thermometer to see what temp the fuel pump is getting to. May need to make a heat shield but would rather not bury the fp and keep the serviceability but we’ll see. BF8E85D2-7E88-4C90-9D89-C302BA937A67.jpeg
    Currently the oil drain is leaking, got a new gasket for it. Gonna be pulling the turbo to reclock the compressor housing so it lines up with the intake box, currently not even close.
     
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  14. Thewespaul

    Thewespaul Supporting Member Supporting Member

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    Before moving the ambulance harness
    5C199218-76B6-4262-A629-2BF67A4BC933.jpeg
    Afterwards. Held in by a harness clamp self tapped to throttle bracket.
    A5B3B173-AE61-4D5D-BC35-38D30179DB92.jpeg
    Old exhaust removed. There’s a couple places where it was pinched from getting crushed under the frame and ambulance box, probably not helping performance.
    86FD3204-8DA4-4582-BE86-7F989160ECDC.jpeg
    Trans double wall removed 9EBF2868-23EC-4B38-B385-6CC7D43B2F9F.jpeg
     
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  15. no mufflers

    no mufflers Supporting Member Supporting Member

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    looks good. with the hypermax kit almost the whole fire wall lip has to be cut or bent over. not as bad with the banks but its a pain to get the up pipe in.
     

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