Brown Truck Under the Knife Project - Engine

[6 Nebraska IDIs]

SWS,
This is why.

You must be registered for see images attach

Early this year I had a kid pull out right in front of me on my way to school and to avoid rear ending his ******** I down shifted and when I started the truck after school that day, I got that nice surprise.
Thinking it was bent valves I didn't mess with the truck all spring and just let it sit. After Calvin and a few others convinced me that it was a blown head gasket I pulled the motor and tore into it.

 

[hesutton]

What I did was bought the pillar pod for the 92-97 trucks, cut it down to where it would fit well over the 83 pillar ......

I did the same with my A-pillar pod. Just had to cut the top and bottom off. No one is (or likely ever to) makes a pillar pod for the '83-'86 interior.

Heath.

 

[seawalkersee]

So....just the smoking? It did not sound that bad.

SWS

 

[91f2504x4]

So....just the smoking? It did not sound that bad.

SWS

Listen to the thud/missing sound from the exhaust in the video when it shows the exhaust pipe.

 

[6 Nebraska IDIs]

Yea, allot more than smoke. It was stuttering so badly that the doors would shake and you can't hear the metal on metal type sound? Seriously, it sounds like two hammer heads hitting each other. I figured I had some major carnage in there being apparently caused by my downshifting, but was very surprised to only find a blown head gasket causing all the racket.
I decided to change the bearings not because of wear but because of a single deep score in almost every bearing. Better to replace them than put them back and run lower oil pressure than I could have.

 

[david85]

I decided to change the bearings not because of wear but because of a single deep score in almost every bearing. Better to replace them than put them back and run lower oil pressure than I could have.

I don't remember you mentioning that before. Definately a good call to replace all of them in that case.

 

[6 Nebraska IDIs]

Hey guys,
Haven't posted an update here in a while, mainly because I'm STILL waiting for my heads to come back from the machine shop, a project that was supposed to be finished 2 weeks ago.
But I can post some updates and a few pics. I have officially finished wiring everything in my truck.
That includes,
Wiring in; a running light relay, an ignition switched positive relay (for all my new gauges and such), all the gauges and gauge lighting, ground and running light leads to the roof for a Lund visor, tach leads to engine compartment, and the new 4x4 indicator and reverse light harness for the ZF5 transmission.
My new gauges are all Autometer Sport Comp's with LED 194 bulbs for lighting and include a pyrometer, boost gauge, and oil temp gauge in the pillar. A set of 2 5/8" gauges from my Z28 now reside below the dash and include a mechanical oil pressure gauge, mechanical water temp gauge, and a volt meter.

THEN, today I finished it up for the most part... if I EVER see some sorry SOB drinking coffee in my truck again, I'm likely to kill them! I spent over 2 1/2 hours cleaning all the vents, crevices and nitty gritty tight ass spaces in an attempt to remove all the coffee that had made a thick coating over literally EVERYTHING. I'm pleased and proud to say that I have as close to a new truck in terms of clean interiors as anyone could possibly achieve.
Here's the pics from the last few days.

You must be registered for see images attach

You must be registered for see images attach

You must be registered for see images attach

You must be registered for see images attach

That missing radio knob has driven me nuts since I've owned the truck, cant believe it just cost me $25 for a new set from Pioneer.

 

[reklund]

Is that a cassette player? Time for a single DIN conversion and a nice CD/MP3 player!

I'm kidding- it looks great! I wouldn't want to go cutting up a pristine factory dash like that either. If you ever get the bug there are several companies that make shaft-style radios with modern AUX/iPod inputs that'll bolt right in

Did you paint everything, or match the pillar pod color so close it all matches? It looks GREAT!

Ryan

 

[FordGuy100]

Dang that kicks my interior's **** like no tommorow. Colors match!!! And the wood looks brown not purple!!! Looks good man

 

[6 Nebraska IDIs]

Lol Ryan. I really like that radio even though its a cassette player, but I have a cassette tape that I can plug my Ipod into and it sounds just fine. I would actually like to upgrade my speakers next year.

Thanks for the compliments. I molded a pillar pod section from a 90's pillar pod into the 83 pillar, wish it had come out a little nicer, but oh well. I color matched some SEM interior dye as close as I could possibly achieve, its not perfect but its close. I'm not very happy with how easily that dye just rubs off. Everyone has always told me its the best interior dye out there, but I just can't get the stuff to stick no matter what I do.

 

[trackspeeder]

Nice job on the interior. I had the same issues with the dye not adhearing well to the plastic on my 85. Try some Bull dog adhesion promoter. You can find it at Wallymart. This stuff works great. No more issues with the dye.

 

[6 Nebraska IDIs]

Got me an intercooler today, or charged air cooler if you want to get technical.
After some research I discovered that the OEM 98.5-02 Dodge Cummins intercooler will fit perfectly around my "odd wide radiator". Found a guy parting out a truck on one of the Cummins forums and contacted him last night.

You must be registered for see images attach

Pulled from an 02 Dodge Cummins 3500 with less than 100k on it. I bought it as a stock oem cooler but it's thicker and has longer outlets than any stock unit I've ever seen. I purchased it with the parallel flow AC condenser as well as the intercooler piping and couplers, except from the pic the guy just sent me it looks like he cut the frickin couplers on the cooler. ***? I guess I'll see if he sends me some replacements.
This intercooler is frickin HUGE, to top it off its a short route design so it uses allot less fabrication of the lines.
Price for everything; intercooler, ac condenser, mounting hardware, intercooler piping, couplers and clamps... $250 to my door! YEEEAAH BABY!

 

[seawalkersee]

Dude...Score!!!

SWS

 

[6 Nebraska IDIs]

Ring grooves cleaned and I'm 3/8 done with cleaning the carbon off the pistons. I really want this motor back together this weekend, but my moms asking if we'd all go visit family this weekend. So I'm not sure if it will happen.

 

[6 Nebraska IDIs]

Got my pistons cleaned up today, ring grooves weren't too bad. Two pistons must have had stuck oil rings because there was quite a bit of carbon build up in them, but other than that not bad. The cut and sharpened ring worked great for cleaning them.
After I cleaned the ring grooves I scrubbed all the carbon off the rest of the piston with a stainless steel gun cleaning brush and a liberal amount of Chem Dip. The Berrymans brand Chem Dip I used didn't have the nasty smell that most carb dips have and it works GREAT! I tried using gasoline and diesel but it just didn't break up the carbon like that chem dip did. If you use this method to clean your pistons WEAR SAFETY GOGGLES, GLOVES, CLOTHING, AND A FACE MASK! This stuff BURNS if you get it on your skin!

You must be registered for see images attach

You must be registered for see images attach

You must be registered for see images attach

So did I get them clean enough?
Also, did the 6.9's use Mahle pistons? Because these are Mahle pistons. I thought only the turbo motors got Mahle pistons.