New Guy, '97 12 valve, Many, Many Adventures To Go!
- Thread starter GJStringert
- Start date
GJStringert
Observer
Thank you all for the kind comments! I'm so pleased with how the rig is turning out. My friends and I had such a great time putting the whole thing back together, "R&R"ing the engine was a blast, and nowhere near as bad as I thought it would be. Fortunately one of the guys helping me makes fulltime job out of buying and reselling 2nd gen 12 valves. He knew everything about pulling that engine down to what size socket handles which bolts. Interestingly you can pretty much strip one of these trucks with only 10-15mm sockets. That's all we used about 90% of the time!
I'm still buttoning up odds and ends but the truck is back together and running very well. I'm not monitoring mileage numbers or anything until after the first oil change and "break in".
Some of you may recall, back at the very first page of this thread, when I installed a pretty cheezy fuse block for my aftermarket stuff. Well, after over a year of kicking around the idea of it, I'm finally a member of the Blue Sea club.
I also got crafty with that window inkjet paper I use to make my service stickers and made up some simple labels for the new fuse block. Now I don't have to remember which are the roof lights just by the fuse they use hahaha!
I'm still buttoning up odds and ends but the truck is back together and running very well. I'm not monitoring mileage numbers or anything until after the first oil change and "break in".
Some of you may recall, back at the very first page of this thread, when I installed a pretty cheezy fuse block for my aftermarket stuff. Well, after over a year of kicking around the idea of it, I'm finally a member of the Blue Sea club.
I also got crafty with that window inkjet paper I use to make my service stickers and made up some simple labels for the new fuse block. Now I don't have to remember which are the roof lights just by the fuse they use hahaha!
Wh1t3nukle
I gotz dis
yo bud, great progress!
Question regarding mount of the blue sea, as I have one too but have balked on mounting. Looks like you attached to cover of the fuse/relay box?
Show and tell? My thought was actually the same, use some sticky adhesive for velcro...
Question regarding mount of the blue sea, as I have one too but have balked on mounting. Looks like you attached to cover of the fuse/relay box?
Show and tell? My thought was actually the same, use some sticky adhesive for velcro...
08Silverado
Adventurer
Great job with the build! I'm enjoying watching all the things you've done to an ancestor of my rig!
GJStringert
Observer
Hey gang! So I haven't been on in a LONG time, as you can tell. Sorry about that! I graduated in May and just recently finished moving for my new job so I haven't had much time to do anything.
I dare say the truck is nearing completion. Really I spent more time this summer camping and offroading with it than I did working on it. The truck took the girlfriend and the dog and me on several overnighters this summer and they were all pretty enjoyable! No problems to report except that I still REALLY need lockers. Otherwise the old truck's been treating us pretty well!
I do have a few updates, no real pictures at this point, but updates no less!
1) Sad to say the camper project has been officially repurposed. Where it was, it would have taken SO much time and a good bit more money to properly finish it the way I wanted to, and especially with this move and the new job, it was kind of hilighted that I didn't have as much use for the camper as I was hoping. So, by "repurpose", I'm switching directions with it and building more of a "skid" that will rest on my bed with provisions for a water system and a roof top tent. Think of it like one of the M101 trailers that they build in the trailer forum, that will rest on my flatbed. Kind of a similar idea to that. Once things settle down I'm hoping to get going on that. This way I'll have room to haul out elk and deer on my hunting trips too. Wouldn't have had that space with the camper.
2) It's looking pretty certain that I'll be having an Atlas II built for the truck. My NP241 has a crack around the tailhousing and I can't keep fluid in it to save my life. Update to come on that, but I'm hoping to have the Atlas transfer case by January. Just have to nurse my 241 along through elk season this year and we'll be good to go!
I gotta get going but I'll do my best to get back on the forum now that things are settling down.
Take care everybody and I'll tune back in soon!
Graham
I dare say the truck is nearing completion. Really I spent more time this summer camping and offroading with it than I did working on it. The truck took the girlfriend and the dog and me on several overnighters this summer and they were all pretty enjoyable! No problems to report except that I still REALLY need lockers. Otherwise the old truck's been treating us pretty well!
I do have a few updates, no real pictures at this point, but updates no less!
1) Sad to say the camper project has been officially repurposed. Where it was, it would have taken SO much time and a good bit more money to properly finish it the way I wanted to, and especially with this move and the new job, it was kind of hilighted that I didn't have as much use for the camper as I was hoping. So, by "repurpose", I'm switching directions with it and building more of a "skid" that will rest on my bed with provisions for a water system and a roof top tent. Think of it like one of the M101 trailers that they build in the trailer forum, that will rest on my flatbed. Kind of a similar idea to that. Once things settle down I'm hoping to get going on that. This way I'll have room to haul out elk and deer on my hunting trips too. Wouldn't have had that space with the camper.
2) It's looking pretty certain that I'll be having an Atlas II built for the truck. My NP241 has a crack around the tailhousing and I can't keep fluid in it to save my life. Update to come on that, but I'm hoping to have the Atlas transfer case by January. Just have to nurse my 241 along through elk season this year and we'll be good to go!
I gotta get going but I'll do my best to get back on the forum now that things are settling down.
Take care everybody and I'll tune back in soon!
Graham
GJStringert
Observer
A Few Little Updates...
I managed to grab a few pictures from my phone while I'm at work, so here's what I have:
Kaity bought me a set of Rigids Dually floods for our anneversary this year, WAY better than the Autozone junk I had up there.
And speaking of LEDs, I had some cheepy LED strips left over from another project that I decided to hang behind the grill. This is a "just for fun" mod, but it looks pretty cool!
Otherwise here's a few from our annual anneversary camping trip!
And we didn't want the dog to get too cold:
Switching gears, here's a few more you might enjoy. I'm helping my uncle with a 1984 CJ 7 project he just started. He picked it up with a blown 4.2 (previous owner hydrolocked and broke #1). I helped him get the tub off and drivetrain out last week, so this is out little side project together.
So that's about what I have for now. I'll do my best to be a little more vigilant about getting on, hate to leave you guys hanging with a thread gone cold. Everybody take it easy now!
Graham
I managed to grab a few pictures from my phone while I'm at work, so here's what I have:
Kaity bought me a set of Rigids Dually floods for our anneversary this year, WAY better than the Autozone junk I had up there.
And speaking of LEDs, I had some cheepy LED strips left over from another project that I decided to hang behind the grill. This is a "just for fun" mod, but it looks pretty cool!
Otherwise here's a few from our annual anneversary camping trip!
And we didn't want the dog to get too cold:
Switching gears, here's a few more you might enjoy. I'm helping my uncle with a 1984 CJ 7 project he just started. He picked it up with a blown 4.2 (previous owner hydrolocked and broke #1). I helped him get the tub off and drivetrain out last week, so this is out little side project together.
So that's about what I have for now. I'll do my best to be a little more vigilant about getting on, hate to leave you guys hanging with a thread gone cold. Everybody take it easy now!
Graham
GJStringert
Observer
Hey friends!
It's been an extremely busy past several months. I've been pretty jammed up moving around for work and getting the girlfriend settled into her new job and apartment. Had to put a lot of projects on hold for a while. But stuff is still pressing on!
I'll try to do this in order from where I left off back in November. My transfer case was giving me serious fits, the front seal was just puking fluid everywhere and the rear extension housing had a crack in it. My guess is that could be from an out of balance driveshaft or something. Anyway, that all didn't end up being an issue since I completely detonated my transfer case back in January. I was towing a small trailer through some really fluffy slippery snow at my dad's cabin and kept getting stuck, finally got fed up and dumped the clutch in 3rd/low range at around 2500 rpm. The front driveshaft was a complete loss (blew the double cardan apart), and the shift linkage, shift fork and planetary for low range were, in the shop's words "extremely damaged". So, pulled the case and had it rebuilt and resealed again, and re-clocked it to 20* down using a really nice "infinitely clockable" ring from Northwest Fab up in Canada (nice folks up there). I just barely clearanced the cross member enough for this when I threw the skyjacker ring in for the first go around so that saved me some fab work.
http://i1330.photobucket.com/albums/w577/GJStringert/0129161016_resized_zpsnvsvgzms.jpg
So this is how my front driveshaft sits in relation to the radius arms. In my opinion, this is still pretty steep for the torque this thing puts down, but the only way to combat this would be to have the transfer case further back and have a high pinion front end, I'd think. I guess that'll be the plan for the future?
http://i1330.photobucket.com/albums/w577/GJStringert/0201161558_resized_zpsenthg7gx.jpg
OK what else... I swapped in some 3rd gen flippy mirrors, and I REALLY like them. Worthwhile little mod...
http://i1330.photobucket.com/albums/w577/GJStringert/0505161709_resized_zpsw0ul4ghd.jpg
Now onto something a bit more involved. I ended up pulling off my big crossbox on top of the bed. No matter what I did to it with weather stripping, caulk, or any combination of the two, I could not keep water out of it. All of my tools were rusting badly. I was pretty happy I was able to sell it to a local guy with a similar flatbed. I hate scrapping usable stuff but I was tired of having oily hands from all the wd-40 I had on my tools to keep them from rusting. Switched to some 4'x1.5'x16" boxes from Northern Tool and have been very happy with them.
http://i1330.photobucket.com/albums/w577/GJStringert/0711161803_resized_zpstaqnfzv7.jpg
And if you're interested, tare weight on my truck is 8,400 lbs (been running a lot of stuff to scrap lately). That's a heavy monster!
Ok, now to the really good stuff. So, if you remember from the first iteration of this rebuild (when I pulled the engine), I have an Aurora 3000 turbo, marine pistons, and Cummins marine 370 HP injectors with a minor timing bump and a #10 fuel plate. The truck has been running very well when it's unloaded, but lately, especially with the summer heat, my EGTs have been reaching 1300* pretty easily. That, and I'm after a bit more power. I have a good friend that had an Aurora 5000 for sale (71.5 mm T4 from ATS diesel), so I bought that off him to do a compound turbo setup, with my Aurora 3000 as the small charger. Currently, the truck is at PRT Diesel in Peckham having piping built and a bit bigger injectors installed. The end goal there is 600 HP with EGTs never over 1200* again. Obviously if I get stupid with it or I'm loaded REALLY heavy it'll climb, but I think this should be pretty driveable. I hope...
http://i1330.photobucket.com/albums/w577/GJStringert/0809161111_zpshzfamnc6.jpg
And that brings us up to date. Kaity and I have made it out to several overnight camping trips this summer up in the Pike National Forest:
http://i1330.photobucket.com/albums/w577/GJStringert/0715162048_resized 1_zpsefbsip9y.jpg
http://i1330.photobucket.com/albums/w577/GJStringert/0715162032_HDR_resized_zpsgyspdgu5.jpg
And I also found out that a Drake Off Road mud tire shift knob for a Jeep TJ fits the nv4500 perfectly!
http://i1330.photobucket.com/albums/w577/GJStringert/0708161815_resized_zpsezyssomr.jpg
So hopefully I'll be able to keep the big rig together once I get it back here in a few weeks. I know the engine, transmission and transfer case should hold the power as long as I don't get too aggressive taking off from a stop or anything. The only thing I'm really worried about is rear axle wrap since I don't have traction/ladder bars back there. But I'm also only running a 2" block with an 8-leaf spring pack so I kind of feel like it should be alright. Guess there's only one way to find out!
Take care folks and I'll tune back in once I get the compound turbocharged old 12 valve back on the road!
Graham
It's been an extremely busy past several months. I've been pretty jammed up moving around for work and getting the girlfriend settled into her new job and apartment. Had to put a lot of projects on hold for a while. But stuff is still pressing on!
I'll try to do this in order from where I left off back in November. My transfer case was giving me serious fits, the front seal was just puking fluid everywhere and the rear extension housing had a crack in it. My guess is that could be from an out of balance driveshaft or something. Anyway, that all didn't end up being an issue since I completely detonated my transfer case back in January. I was towing a small trailer through some really fluffy slippery snow at my dad's cabin and kept getting stuck, finally got fed up and dumped the clutch in 3rd/low range at around 2500 rpm. The front driveshaft was a complete loss (blew the double cardan apart), and the shift linkage, shift fork and planetary for low range were, in the shop's words "extremely damaged". So, pulled the case and had it rebuilt and resealed again, and re-clocked it to 20* down using a really nice "infinitely clockable" ring from Northwest Fab up in Canada (nice folks up there). I just barely clearanced the cross member enough for this when I threw the skyjacker ring in for the first go around so that saved me some fab work.
http://i1330.photobucket.com/albums/w577/GJStringert/0129161016_resized_zpsnvsvgzms.jpg
So this is how my front driveshaft sits in relation to the radius arms. In my opinion, this is still pretty steep for the torque this thing puts down, but the only way to combat this would be to have the transfer case further back and have a high pinion front end, I'd think. I guess that'll be the plan for the future?
http://i1330.photobucket.com/albums/w577/GJStringert/0201161558_resized_zpsenthg7gx.jpg
OK what else... I swapped in some 3rd gen flippy mirrors, and I REALLY like them. Worthwhile little mod...
http://i1330.photobucket.com/albums/w577/GJStringert/0505161709_resized_zpsw0ul4ghd.jpg
Now onto something a bit more involved. I ended up pulling off my big crossbox on top of the bed. No matter what I did to it with weather stripping, caulk, or any combination of the two, I could not keep water out of it. All of my tools were rusting badly. I was pretty happy I was able to sell it to a local guy with a similar flatbed. I hate scrapping usable stuff but I was tired of having oily hands from all the wd-40 I had on my tools to keep them from rusting. Switched to some 4'x1.5'x16" boxes from Northern Tool and have been very happy with them.
http://i1330.photobucket.com/albums/w577/GJStringert/0711161803_resized_zpstaqnfzv7.jpg
And if you're interested, tare weight on my truck is 8,400 lbs (been running a lot of stuff to scrap lately). That's a heavy monster!
Ok, now to the really good stuff. So, if you remember from the first iteration of this rebuild (when I pulled the engine), I have an Aurora 3000 turbo, marine pistons, and Cummins marine 370 HP injectors with a minor timing bump and a #10 fuel plate. The truck has been running very well when it's unloaded, but lately, especially with the summer heat, my EGTs have been reaching 1300* pretty easily. That, and I'm after a bit more power. I have a good friend that had an Aurora 5000 for sale (71.5 mm T4 from ATS diesel), so I bought that off him to do a compound turbo setup, with my Aurora 3000 as the small charger. Currently, the truck is at PRT Diesel in Peckham having piping built and a bit bigger injectors installed. The end goal there is 600 HP with EGTs never over 1200* again. Obviously if I get stupid with it or I'm loaded REALLY heavy it'll climb, but I think this should be pretty driveable. I hope...
http://i1330.photobucket.com/albums/w577/GJStringert/0809161111_zpshzfamnc6.jpg
And that brings us up to date. Kaity and I have made it out to several overnight camping trips this summer up in the Pike National Forest:
http://i1330.photobucket.com/albums/w577/GJStringert/0715162048_resized 1_zpsefbsip9y.jpg
http://i1330.photobucket.com/albums/w577/GJStringert/0715162032_HDR_resized_zpsgyspdgu5.jpg
And I also found out that a Drake Off Road mud tire shift knob for a Jeep TJ fits the nv4500 perfectly!
http://i1330.photobucket.com/albums/w577/GJStringert/0708161815_resized_zpsezyssomr.jpg
So hopefully I'll be able to keep the big rig together once I get it back here in a few weeks. I know the engine, transmission and transfer case should hold the power as long as I don't get too aggressive taking off from a stop or anything. The only thing I'm really worried about is rear axle wrap since I don't have traction/ladder bars back there. But I'm also only running a 2" block with an 8-leaf spring pack so I kind of feel like it should be alright. Guess there's only one way to find out!
Take care folks and I'll tune back in once I get the compound turbocharged old 12 valve back on the road!
Graham
Snorkeld_Zuk
Adventurer
Nice. I love these trucks, just read through the whole thread, looking forward to seeing this compound turbo setup. Did you ever get a dyno run in of the previous setup?
GJStringert
Observer
Thanks. Nope I've never had a chance to get it on a dyno. The guy that rebuilt the engine swears it should make around 450 HP, which sounds pretty realistic. It's actually tuned pretty conservatively, I love old school mechanical diesels but I hate the coal rolling craze so I try to keep it kind of mild. Once I get it dialed in with the new compounds I should really find a dyno event and see what it'll do.
GJStringert
Observer
Got Boost??
Hey folks!
I'm very excited to say the old 12 valve is now compound turbo charged, and oh my lordy, this thing runs HARD.
I've had the truck for about 2 months now, after the install, and I'll be honest, I had some issues at first. Chief issue was that the factory intercooler wanted nothing to do with the massive CFM the 2 turbos were pushing, and I blew several lines out of the driver side end tank. Installed a Mishimoto (kind of expensive, but a VERY nice piece), and some BD Diesel spring loaded clamps and boots, and we're relatively insured for a good amount of boost. I also ended up blowing the gasket between the intake horn and grid heater, and the gasket under the intake plenum on the head. Not a huge issue, pretty cheap, but that intake plenum one is a pain because you have to remove fuel lines to get to it, and re-bleed the lines afterwards. I pulled my hair out over this for weeks on end, trying to track down boost leaks. Ended up being pretty difficult because it's a stick shift and I can't load it up at a standstill (like brake-boosting an automatic), so I ended up just replacing gaskets and clamps here and there until I finally got it all sealed up. Re-torqued the head studs just to be safe, and only one took about a half turn to get into spec, so I should be all good in the head gasket department.
And some numbers:
At an unloaded 80 mph cruise, I'm at around 16 PSI and 800* EGTs. Unloaded, in 5th, from about a 50 mph roll to 80, I can get about 55 PSI out of the compounds, and I have yet to get the pyro above 1200*, loaded or not. That Aurora 5000 is an absolute animal. What's weird too is that the truck doesn't really drive like a diesel anymore. It feels like it has a much wider powerband, it almost drives like a gasser now, except that it has immediate torque off idle.
The only other thing I feel like I'm going to need is a lift pump of some sort, like an Air Dog or FASS. I'd like to try and keep it all mechanical, but as it is, my p-pump is completely maxed (AFC full forward, #10 plate full forward), and the turbos still outrun the fueling. It doesn't smoke at all, not even a haze, when the turbos are lit. But that's a modification for the future.
Otherwise, I recently installed 10 RGB rock lights from Infinite Offroad. Kind of a "hey, look at me" mod, purely to attract attention, but MAN are they cool! I have 2 under the hood shining down behind the grill (which are actually very handy for working under the hood at night), one in each front wheel well, 1 under the cab on each side, and 2 under the flatbed on each side. Kinda ricer, but they're super high quality and put a smile on my face!
Friends I hope you all had a great Thanksgiving, and if I don't check in before Christmas, have a Merry Christmas! I'll leave you with a heavily edited poser shot!
Take Care!
Graham
Hey folks!
I'm very excited to say the old 12 valve is now compound turbo charged, and oh my lordy, this thing runs HARD.
I've had the truck for about 2 months now, after the install, and I'll be honest, I had some issues at first. Chief issue was that the factory intercooler wanted nothing to do with the massive CFM the 2 turbos were pushing, and I blew several lines out of the driver side end tank. Installed a Mishimoto (kind of expensive, but a VERY nice piece), and some BD Diesel spring loaded clamps and boots, and we're relatively insured for a good amount of boost. I also ended up blowing the gasket between the intake horn and grid heater, and the gasket under the intake plenum on the head. Not a huge issue, pretty cheap, but that intake plenum one is a pain because you have to remove fuel lines to get to it, and re-bleed the lines afterwards. I pulled my hair out over this for weeks on end, trying to track down boost leaks. Ended up being pretty difficult because it's a stick shift and I can't load it up at a standstill (like brake-boosting an automatic), so I ended up just replacing gaskets and clamps here and there until I finally got it all sealed up. Re-torqued the head studs just to be safe, and only one took about a half turn to get into spec, so I should be all good in the head gasket department.
And some numbers:
At an unloaded 80 mph cruise, I'm at around 16 PSI and 800* EGTs. Unloaded, in 5th, from about a 50 mph roll to 80, I can get about 55 PSI out of the compounds, and I have yet to get the pyro above 1200*, loaded or not. That Aurora 5000 is an absolute animal. What's weird too is that the truck doesn't really drive like a diesel anymore. It feels like it has a much wider powerband, it almost drives like a gasser now, except that it has immediate torque off idle.
The only other thing I feel like I'm going to need is a lift pump of some sort, like an Air Dog or FASS. I'd like to try and keep it all mechanical, but as it is, my p-pump is completely maxed (AFC full forward, #10 plate full forward), and the turbos still outrun the fueling. It doesn't smoke at all, not even a haze, when the turbos are lit. But that's a modification for the future.
Otherwise, I recently installed 10 RGB rock lights from Infinite Offroad. Kind of a "hey, look at me" mod, purely to attract attention, but MAN are they cool! I have 2 under the hood shining down behind the grill (which are actually very handy for working under the hood at night), one in each front wheel well, 1 under the cab on each side, and 2 under the flatbed on each side. Kinda ricer, but they're super high quality and put a smile on my face!
Friends I hope you all had a great Thanksgiving, and if I don't check in before Christmas, have a Merry Christmas! I'll leave you with a heavily edited poser shot!
Take Care!
Graham