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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #350 on: November 18, 2015, 09:45:00 PM »
From what I've read the higher you go the more difficult it can be to start in the cold among other things.  Have you seen the 12 valve beginners thread on cummins forum?   I mean no insult by suggesting it.  It's chock full of everything you need to know about our engines.  Fuel supply issues timing etc.  After reading that several times through I've decided I'm going to 16 or 16.5 when I time mine.  Seems to strike the best balance.  Although I have to get it in the truck and running before I mess with the pump or timing.  I did put my 4k governor springs in today though. 

If you don't mind I can paste the link.  It's bookmarked on my phone it's that good.


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Re: SquareD Part 7 Start it up!
« Reply #352 on: November 19, 2015, 10:57:19 AM »
I have seen that before. Wealth of good info there.
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #353 on: November 19, 2015, 11:00:52 AM »
Would you know it...already had it saved under my Cummins tab.
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #354 on: November 19, 2015, 09:46:22 PM »
Got some more done

I'm prepping to have the engine running properly, so moving lines around is the order of the day

I was having a problem filling the fuel tank. I'd fill it for awhile, then it would burp like a pint of fuel out of the filler!

Examining it, I noticed the vent hose had a dip in it, or low spot which was collecting fuel, blocking off the vent altogether, and the fill line did as well.

So everything had to be cut a bit shorter and moved so as to provide a positive slope from filler to tank
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #355 on: November 19, 2015, 09:47:07 PM »
I moved the filler pipe up about an inch or so
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #356 on: November 19, 2015, 09:48:46 PM »
And then I shortened and "T-ed" into the main tank vent line with the vent line from the aux tank.

I will also vent the entire system to atmosphere in the next step of the tank fitting operation
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #357 on: November 19, 2015, 09:50:33 PM »
At this point, I ran out of fittings to plump in the fuel return and aux tank transfer line, so I went on to the wiring. I ran the wires and connected everything. The pump switches on and the wire is run for the fuel quantity gage
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #358 on: November 19, 2015, 09:52:24 PM »
The filler neck for the aux tank is a machined piece of pipe that fits into the cap threaded adapter. The two parts have to be permanently affixed to each other prior to assembly
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #359 on: November 19, 2015, 09:53:40 PM »
I decided to sweat the two pieces together with some tin/lead solder just like it was a copper joint. It worked out great!
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #360 on: November 19, 2015, 09:54:46 PM »
I like how that cap works!
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #361 on: November 19, 2015, 09:56:08 PM »
With the help of one of the pre-rangers, I bolted in the magnetic catch and got the lid working. I then affixed it's decals
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #362 on: November 19, 2015, 10:01:09 PM »
The fuel filler pipe looks better

I'll install a couple pipe nipples here and attach up the fuel injector return line and the aux fuel transfer line
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #363 on: November 19, 2015, 10:01:55 PM »
Yea, I don't like the black painted screws either!

The #10 X 24 screws are in the mail somewhere and will replace that WTB (Way-too-big) hardware that is currently messing with my head

I installed some wire loom protector here and there and did some things inside the cab, but of course did not take pics, so I know...It didn't happen!

But the truck is looking and functioning ever more like a truck with every new day
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #364 on: November 24, 2015, 09:31:14 PM »
I pulled the filler pipe from the fuel tank to drill it for two bulkhead NPT fittings. One if for fuel return from the engine injector harness, and the other is the transfer line from the aux tank.

I thought it would be a good idea to run the line from the engine injector bypass to the tank, because that fuel will have been warmed by that hot motor. That hot fuel will also warm the 30 odd gallons in the tank on those really cold days when the chicken grease in there has turned into a solid.
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #365 on: November 24, 2015, 09:32:59 PM »
I built that pipe up with some O-rings on both the inside and the outside, then additionally applied a bead of RTV to the inside of the fitting
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #366 on: November 24, 2015, 09:34:38 PM »
The pipe was reinstalled and the new lines hooked up
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Re: SquareD Part 7 Start it up!
« Reply #367 on: November 24, 2015, 09:35:36 PM »
Then I sorted out the new hoses and tied them down
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #368 on: November 24, 2015, 09:38:49 PM »
At this point the fuel system is vented to the main fuel filler neck only. That is insufficient in my view, so Here goes another vent line that will "T" into the existing vent and have it's own atmosphere port

To do this I will be using plastic hard line and push-to-connect fittings and a cool brass "Maze" vent fitting
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #369 on: November 24, 2015, 09:40:19 PM »
The vent found a home near the top of the topper just behind that sturdy antenna mount
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #370 on: November 24, 2015, 09:41:44 PM »
The "T" fitting was inserted in the vent line after a corresponding sized piece was removed
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Re: SquareD Part 7 Start it up!
« Reply #371 on: November 24, 2015, 09:43:00 PM »
And that was connected to the bulkhead fitting. Now I feel the fuel storage system is adequately vented.
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #372 on: November 24, 2015, 09:44:13 PM »
Next, I started to create the filler pipe that will connect the port with the tank inlet
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #373 on: November 24, 2015, 09:46:33 PM »
The inlet to the tank is a smaller size than the 2.5" filler port neck, so I'll be starting with a larger diameter radiator hose, then sectioning it to get the right shape, then finishing the tank end with a smaller diameter hose, and gluing the two pieces together to form a new hose
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #374 on: November 24, 2015, 09:48:36 PM »
With the magic of a mostly used up tube of rubber cement, I permanized the two parts into a happily married piece. (Hmmm, bad analogy...most marriages these days break up...)
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Offline husker77c

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Re: SquareD Part 7 Start it up!
« Reply #375 on: November 25, 2015, 07:45:56 AM »
After plumbing my engine I really admire all the work you've put into your fuel system. 


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Offline stlaser

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Re: SquareD Part 7 Start it up!
« Reply #376 on: November 25, 2015, 11:21:30 AM »
The ol Dodge is looking pretty clean. Nice work.
Living in the remote north hoping Ken doesn’t bring H up here any time soon…..

Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #377 on: November 25, 2015, 10:49:36 PM »
The timing tool is on the property and Wayne, the diesel mech is coming over Monday to time it up.

I hope this clears things up (literally!)
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Offline TexasRedNeck

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Re: SquareD Part 7 Start it up!
« Reply #378 on: November 26, 2015, 07:19:12 AM »
! Looking forward to the outcome!


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Offline Nate

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Re: SquareD Part 7 Start it up!
« Reply #379 on: November 26, 2015, 10:15:51 AM »
popcorn
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Offline Higher Caliber

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Re: SquareD Part 7 Start it up!
« Reply #380 on: November 27, 2015, 09:32:18 AM »
It's a bit busy in here, but not to worry, the inside gets carpet glued up in the bare fiberglass

Carpet???? or some of this material???
http://americanblastsystems.com/blast-and-bullet-resistant-curtains/
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #381 on: November 27, 2015, 01:39:33 PM »
^^^ Now that is interesting

Used to roll with that Kevlar blanket stuff in the aircraft

Odd that they stretched it out in the back to protect you guy's butts, but didn't put any under the pilots seat!
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Offline Higher Caliber

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Re: SquareD Part 7 Start it up!
« Reply #382 on: November 28, 2015, 07:31:48 AM »
grunt perks! collective bargaining- We got Kevlar seat cushions in the helo and the 42A's got to keep their up-armored Humvees that never left the wire... Of course we still stole them. I remember there being a note on the door from the navy chief requesting that we maintain branch integrity when we pick the vehicles we were going to steal.
« Last Edit: November 28, 2015, 07:37:21 AM by Higher Caliber »
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Offline Atkinsmatt

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Re: SquareD Part 7 Start it up!
« Reply #383 on: November 28, 2015, 09:42:39 AM »
Sometimes you had an armored seat. We had no more than a helmet and chest anchor.
Matt
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Offline BobbyB

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Re: SquareD Part 7 Start it up!
« Reply #384 on: November 28, 2015, 10:32:28 AM »
I don't remember kevlar blankets in the back of the birds I flew in. I remember canvas webbing seats, or no seats with metal flooring.
So, Bobby...being the calculating trained warrior NCO that you are.  Take the appropriate action, Execute!
your standard grunt level CQB is just putting rounds and rounds on scary stuff till it stops scaring you!

Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #385 on: November 28, 2015, 11:24:24 AM »
I don't remember kevlar blankets in the back of the birds I flew in. I remember canvas webbing seats, or no seats with metal flooring.
Oops...Maybe I wasn't supposed to mention that...
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Offline wilsonphil

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Re: SquareD Part 7 Start it up!
« Reply #386 on: November 28, 2015, 01:13:14 PM »
Of course we still stole them. I remember there being a note on the door from the navy chief requesting that we maintain branch integrity when we pick the vehicles we were going to steal.

This brings back some memories!

Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #387 on: November 30, 2015, 07:10:44 PM »
Well Wayne and I have been working on SquareD all day. He is doing the timing trouble shooting, with me helping, and I am doing all sorts of things while not turning the motor over in this timing marathon job.

I started the day with finishing off the fuel system and getting that leak free. Wayne started with pulling the engine down enough to get room to work on the necessary stuff
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Re: SquareD Part 7 Start it up!
« Reply #388 on: November 30, 2015, 07:21:45 PM »
This job is not for the feint of heart. The pump must be separated from it's gear inside the timing cover, and an access plug pulled from the back of the cover as well as the #1 delivery valve
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #389 on: November 30, 2015, 07:26:02 PM »
The timing took set is required to do this job. Without it, I do not see how an accurate timing setting can be attained.
Pictured is that timing tool set...
With one notable exception

A barring tool

Without it, I will never attempt this job again
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Offline TexasRedNeck

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Re: SquareD Part 7 Start it up!
« Reply #390 on: November 30, 2015, 07:26:48 PM »
MOAR!
Kids today don't know how easy they have it. When I was young, I had to walk 9 feet through shag carpet to change the TV channel.

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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #391 on: November 30, 2015, 07:28:33 PM »
We did not have the barring tool, which is a clever little tool.

It is used to rotate the 6BT engine.

You pull a rubber plug out of the block adapter and push that tool in until it engages the flywheel teeth, then turn it with a 1/2" ratchet

You will be spinning the motor around a few times
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Re: SquareD Part 7 Start it up!
« Reply #392 on: November 30, 2015, 07:30:16 PM »
As you can see the valve cover-cover and injection lines must be removed. You also have to remove the cold side upper pipe all to allow access to the parts you will be spinning
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Re: SquareD Part 7 Start it up!
« Reply #393 on: November 30, 2015, 07:31:29 PM »
You gain access to the pump gear through the front cover by simply removing the oil filler neck
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Re: SquareD Part 7 Start it up!
« Reply #394 on: November 30, 2015, 07:32:40 PM »
This is where the fin starts...finding top dead center
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Re: SquareD Part 7 Start it up!
« Reply #395 on: November 30, 2015, 07:34:46 PM »
While Wayne fussed with that, I installed the block heater
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Re: SquareD Part 7 Start it up!
« Reply #396 on: November 30, 2015, 07:39:46 PM »
Then the aux fuel filler neck pipe
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Offline cudakidd53

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Re: SquareD Part 7 Start it up!
« Reply #397 on: November 30, 2015, 07:47:12 PM »
Hey Don-

Wouldn't the aux filler neck be less prone to leaks if you flipped it?  Then the upper half would go into the lower half instead of the current flow path hitting the inside edge of the lower half......just a musing from the popcorn crowd.  :)
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Re: SquareD Part 7 Start it up!
« Reply #398 on: November 30, 2015, 07:48:08 PM »
He got a bit closer, identifying the timing as having been set at 13 degrees. Now that's good and that's bad.

Remember this truck is pumping out raw fuel from the exhaust so something is amiss. Since the timing could be a culprit, verifying correct timing concerns me for what might be going on here.

This dial indicator screwed into the #1 fuel delivery valve is how one sets timing. The pump is set to a very specific number. In the case of this engine I settled on 16.5 degrees BTDC as my timing number. Factory was 12.5, and this pump had been set at 13 degrees. Up to a point, the more timing (Larger number) the more fuel the motor can digest and hence, make more power.  So we had to turn the engine over very slowly until we got .258" on the dial indicator.

Next while holding the motor steady, you have to break the injection pump collet loose from the timing gear. Then with no contact between the two, set the motor back to TDC.

Yes this is very tedious.
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Offline Flyin6

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Re: SquareD Part 7 Start it up!
« Reply #399 on: November 30, 2015, 07:49:41 PM »
Hey Don-

Wouldn't the aux filler neck be less prone to leaks if you flipped it?  Then the upper half would go into the lower half instead of the current flow path hitting the inside edge of the lower half......just a musing from the popcorn crowd.  :)
No Mike, a consensus of me and I consulting us confirms proper OPP (optimum part placement)
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