Just a few photos from the progress over the last few weeks - this is a repost of Benzworld.
We had a visit from Charlie Aarons and his big blue Unicat - whilst not as big as Ron's GXV, it's still a big truck. Charlie was having a little problem getting it registered due to the overhang. In Australia, the max overhang is 60% of wheelbase. Charlie's was a bit longer, luckily he could take off the tool boxes and the spare wheel holder to bring it back to legal limits - he can put it on once the truck has been measured - and run the risk of getting a fine, but at least it would be registered.
Anyway, back to my truck. Progress has been slow, mainly because I have to do more planning than work - re-designing the air system and where to put all the different components.
I've also been sizing a new turbo for the truck - a GT2860R. I've spoken to a few experts, and after a lot of email exchanges with then and maps from the Honeywell people who put this turbo forward. It's right in the "sweet spot" of the turbo, it should come on boost from just above idle, and run to the 2600rpm limit. It is quite a small turbo compared to the original KKK turbo, but it actually flows a lot more. The charts say it is good for over 300hp, so my target 180hp should be no problem. I have to get a T2-T3 adaptor, and make a new flange to connect the exhaust brake.
The twin aluminium secondary air tanks fit right up at the back - one tank is the "wet tank" which is the tank designed to trap the water and oil from the compressor. The second air tank is the purge tank - when the system is up to pressure, it purges the filter to make it last longer. Fabricating bracket sure takes a long time - cutting the steel, bending up connecting pieces and ensuring everything fits, the hoses can be fitted without major angles, all whist allowing for the flex of the body and utilising the exisitng bolts all along the chassis.
The brackets for the main air tanks are a "work of art" - they also support the filter/dryer and the four way valve. Each bracket takes quite a while to design, fabricate and paint up. They took a long time - and quite a few attempts to ensure the tanks, the drain valves and all the fittings on the tank, the 4 way valve and the air dryer all fitted, then to check that all the air lines can be fitted etc - and finally, they have to be able to flex with the chassis - so the air tanks don't at as struts - all that for two brackets.
I've finished painting the underside of the truck, and that's the last of the Unimog Orange paint gone.
Finally I've made a number of brackets to hold the airlines in place securely - and when the tube clamps for the brake line are in place - the last of the major mechanical bits on the body will be completely. Before I run the plastic air lines, I will finish the welding of the various "sub floor" box frames and then start on the aluminium sheeting for the floor.
All going well I will be able to take the rear box off for hopefully the final time to finish the underside. Once the floor is finished, it will be time to start painting the underside - first with an etch primer, then a sealer / undercoat then finally a decent top coat. Then I'm going to look at some form of heavy duty liner underneath - something like this.
U-Pol
