MG Metalworks Van Build

[Pengyou]

What an awesome vehicle! I have read though the posts...maybe I missed this part. When you started, was the van already 4x4? If you put 4x4 in this and also toss in a Cummins, is it mandatory to do either/both a body or suspension lift? I am thinking of following in your footsteps, but I would like to keep the van as close to the original height as possible. I want 4x4 so that I have better traction in poor weather and on forest service roads, when I go camping. I am not looking for "true 4 wheeling", or to put a tire any larger than I have to on the van. BTW, which transmission did you decide on?

When choosing a new diesel, had you ever considered the Isuzu inline 6? It is a little more than 3" shorter than the Cummins engine.

 

[mgmetalworks]

What an awesome vehicle! I have read though the posts...maybe I missed this part. When you started, was the van already 4x4? If you put 4x4 in this and also toss in a Cummins, is it mandatory to do either/both a body or suspension lift? I am thinking of following in your footsteps, but I would like to keep the van as close to the original height as possible. I want 4x4 so that I have better traction in poor weather and on forest service roads, when I go camping. I am not looking for "true 4 wheeling", or to put a tire any larger than I have to on the van. BTW, which transmission did you decide on?

When choosing a new diesel, had you ever considered the Isuzu inline 6? It is a little more than 3" shorter than the Cummins engine.

Yes, the van was already 4x4 when I got it.

The 6.7L Cummins I'm putting in the van will fit without any major issues (Keep in mind that my definition of "no big deal" might be different than others...). There is one spot where the turbo is going to be tight against the body and a spot on floor where the trans might be really close but I already have a plan to take care of that while that body is off the frame.

I chose to go with an Allison 1000 6-speed for the transmission. Same trans as a Duramax truck except I have a different bellhousing on mine that makes the whole assembly shorter than a GM trans.

When choosing a diesel for a conversion, I think the most important thing to consider is (assuming you know you have room in the engine compartment): "how much information is available for the drivetrain you're using"? I found tons of info for the Cummins and on top of that there is a vast aftermarket for tuning and hard parts. It was an easy choice against other options.

 

[mgmetalworks]

As I've mentioned before, I picked up a couple CANbus Triple devices (https://www.canb.us/) for various parts of this project and so far they're working as planned. When they work... They are a little finicky to start up and get going but once they do start up and work, you can do quite a bit with them. Recently, the developer released a message filtering application which helps narrow down what is going on when you make specific actions (like button pushes or stepping on the brakes or gas pedal). One thing I need for integration of the Ford CAN with the Cummins and Allison is throttle position. I got the app running today and started cycling the gas pedal. What the software does is display messages by ID instead of sequentially. You can look through the list at what is changing and find things fast. So pushing down on the pedal, you could clearly see the data values changing as I pushed through the full sweep of the pedal. I can now isolate that one message identifier and view it all by itself with a click of button (sweet....). Two things I need to know are the message ID, which I now know, and the range of values. Later today I'll isolate that message ID and note how each value changes as I increase throttle position. Once I have swept the whole range, I'll be able to write a conversion equation for the values that the Cummins apps pedal outputs.

 

[mk216v]

4FF is my BFF! :drool::sombrero:

 

[mgmetalworks]

Here it is... one NV273F transfer case ready to mate up to an Allison trans. The input shaft had to be swapped out for the 29 spline part out of the Dodge NV273D. Same bearing, same seal, just a longer snout and the correct spline for the Allison output shaft. Pretty easy to swap out actually.



I'm getting closer every day... :sombrero:

Changing gears now to go collect CAN data on a '14 Ram/Cummins. My days have been quite a mix of activities leading up to this engine swap. It's been interesting to say the least.

 

[fmboss429]

Here it is... one NV273F transfer case ready to mate up to an Allison trans. The input shaft had to be swapped out for the 29 spline part out of the Dodge NV273D. Same bearing, same seal, just a longer snout and the correct spline for the Allison output shaft. Pretty easy to swap out actually.


I'm getting closer every day... :sombrero:

Changing gears now to go collect CAN data on a '14 Ram/Cummins. My days have been quite a mix of activities leading up to this engine swap. It's been interesting to say the least.

Sounds like you are about to really start knocking out some big things! As always, Thanks for the update

 

[mgmetalworks]

More shiny machined parts done today!!!





These are "tone wheels" for the Allison's Output Speed Sensor. Turns out, the cost of a one-off was only a few bucks less than making 5 so I now have extras (just like all of the other parts I've machined).

The Allison's tail-housing will be machined to accept the sensor and then we're ready to reassemble the trans.

The observant follower of this build may recall my earlier plans to put this sensor in the t-case housing however, because of the shape of the output shaft, it simply wasn't as cost effective as this solution. Don't judge me for changing my mind...I was young and naive back then.

In other exciting news, I picked up a junk van to rob it of some body parts. I'll have pictures soon of the full firewall, floor, doghouse and front end sitting atop my frame. This will make it easier to get all of the fabrication done prior to pulling my van apart.

 

[bknudtsen]

Flimsy... lol!

 

[jjohnny350]

Nice work, I love following along with all the updates. Keep them coming and as usual, very nice work. You are slowly swaying me to wait and see how rad this thing is going to turn out, I am going to do a diesel for my next van and having a cummins in there would be amazing. Again, very nice work.

 

[mgmetalworks]

Fun times with awesome tools!!

I'm not at all happy with the quality of this purchased cast bellhousing adapter part...


So I took it into a metrology lab and poked around with one of these 3D measurement arms...


To get the dimensions I needed for the hole patterns to design this....


I love technology!!! Sure beats using a tape measure and a set of calipers!

While these are being machined, I have some time to dismantle and cut up my extra van body and get it mounted over the Cummins.

 

[Jasper Jones]

So awesome! I love seeing all the technology you are using for this.

 

[fmboss429]

As always, I am blown away!

 

[mgmetalworks]

As always, I am blown away!

Haha! If you liked that, then you're really going to like the next update...

 

[mk216v]

I don't see anything happening here.

 

[dcguillory]

[QUOTE/]=While these are being machined, I have some time to dismantle and cut up my extra van body and get it mounted over the Cummins. [/QUOTE]

Say what! I thought I was following this thread closely. This is getting out of hand.

How do you stay focused? I wouldn't mind being able to turn on an "MG Caliber Focus" switch here and there.