Author Topic: SquareD Part 5: The build continues and gets more aggressive (Read 421042 times)

Sammconn · « **Reply #850 on:** February 02, 2015, 10:45:57 PM »

Not sure if you'll like the pull to run. If a knee or something were to bump it, off she goes. I've seen various shut offs over the years pull to kill.
Just my .02, but I'd be nervous in a SHTF situation of bumping it and your dead in the water.

Bob Smith · « **Reply #851 on:** February 02, 2015, 11:30:35 PM »

All the shut off I have been around were also pull to stop. One less thing sticking out of the dash in the way at the worst time.

Flyin6 · « **Reply #852 on:** February 03, 2015, 08:28:31 AM »

The ones I used in Armee trucks were also pull to stop, as is my dozer, but that is the only way I see to "Wire" it. Cable can't come in from the bottom, no room. So a pull from the top is about what I am left with.

I'll take a good long look at it to see if there is anyway to reverse things, but I doubt it...

Flyin6 · « **Reply #853 on:** February 03, 2015, 08:39:15 AM »

JR, I checked out those Kennedy Diesel pumps. Looks pretty good, especially that dual pump setup. I think I'll pick up one of those for my dual pump setup

Thanks for the tip!

cruizng · « **Reply #854 on:** February 03, 2015, 11:02:39 AM »

Don, Could you just fab a lever that would attach to the mount you already made up where the cable attaches to one side and a rod attaches to the lever and the original cable connection? My 1cts worth. 8)

BobbyB · « **Reply #855 on:** February 03, 2015, 03:41:30 PM »

Bobby went and looked at a Square D of my own. Maybe if tax time is nice and I eliminate some debt before late spring I shall own her.

Flyin6 · « **Reply #856 on:** February 03, 2015, 06:08:37 PM »

No work on the beast today, however, I did get some parts in, some things sorted out and the fuel system parts on order.

Thanks to JR, I solved the lift pump problem. He recommended Kennedy lift pumps so I checked them out. It seems they have a dual pump setup which bolts two of the single pumps together in tandem so without complicating the plumbing I got the dual pump setup I wanted more simply.

I will wire each pump independently so that I can run on pump A, Pump B, or both. Should one fail, then I would see no degradation to performance.

These pumps are centrifugal, not positive displacement. THat is both good and bad. Good because, if one if off, fuel passes around the impeller head as if it wasn't there. Bad because it will not self prime. It requires a bleeding process which required me to invest in a manual primer which I found conveniently located on a filter head

JR · « **Reply #857 on:** February 03, 2015, 07:11:36 PM »

Here is my setup.

The filter is a 5 micron with water trap with the pump right after it with a splash shield as it sits IFO the tire. Pump is wired to ignition ON.

Up top I have the adapter to run a Cat 0749 filter that is 2 micron.

I change them at factory setting now since I get way more filtering and have about tripled my filter area.

Flyin6 · « **Reply #858 on:** February 03, 2015, 08:41:55 PM »

Did you have any problems with the prime when you first installed it?

JR · « **Reply #859 on:** February 04, 2015, 02:17:46 AM »

Quote from: Flyin6 on February 03, 2015, 08:41:55 PM

Did you have any problems with the prime when you first installed it?

Never been an issue, nice and quiet too.

Flyin6 · « **Reply #860 on:** February 04, 2015, 11:50:20 AM »

Just got an inbound notification on both the Kennedy fuel pumps and the hand priming filter head...COOL!

Flyin6 · « **Reply #861 on:** February 04, 2015, 07:06:18 PM »

OK, I listened and thought about the fuel shutoff, so I changed it!

Now a simple pull should shut off the engine.

Repositioning the fuel lever arm and modifying the solenoid bracket did the trick.

First I removed it and cleaned it of all the paint

Flyin6 · « **Reply #862 on:** February 04, 2015, 07:07:49 PM »

I drilled a hole in the side for the cable to pass through, then welded in a bracket to hold the cable in place

Flyin6 · « **Reply #863 on:** February 04, 2015, 07:09:18 PM »

Next I cut away the old solenoid mounting hole and cleaned up the appearance, then painted it

Flyin6 · « **Reply #864 on:** February 04, 2015, 07:11:37 PM »

Then I connected everything using a cable end which captures the movable part of this cable assembly

Flyin6 · « **Reply #865 on:** February 04, 2015, 07:12:41 PM »

A simple short pull of the knob should make things quiet

Flyin6 · « **Reply #866 on:** February 04, 2015, 07:14:18 PM »

Next up was mounting the transmission cooler lines and hooking all of that up

First I gave them a new coat of paint

Flyin6 · « **Reply #867 on:** February 04, 2015, 07:15:33 PM »

Here the hard lines are bolted in

Flyin6 · « **Reply #868 on:** February 04, 2015, 07:18:39 PM »

I want to ensure the roof mounted cooler does not drain back into the pan, so I installed a one way check valve in the supply line. Hopefully this should keep everything fluid filled and no big voids in the cooler

I had to add a line since this valve made everything fit wrong. I'm not sure I like this setup, so it may change to a cleaner installation, but the check valve stays

Flyin6 · « **Reply #869 on:** February 04, 2015, 07:21:27 PM »

Next, back to the wiring harness

It is now complete enough to start to close up. Here is the completed harness that goes aft to the transmission and the transfer case

Flyin6 · « **Reply #870 on:** February 04, 2015, 07:24:02 PM »

I will be adding a new supplemental harness to hook all the new accessories to. That will be finished in the same manner. The blue wires are the fuel pump leads prewired in

Flyin6 · « **Reply #871 on:** February 04, 2015, 07:25:35 PM »

Tomorrow, I'll tackle that ugly harness mess and cut out a bunch of wires from it and recover it

But for now that's it for build day 214

EL TATE · « **Reply #872 on:** February 05, 2015, 11:33:43 AM »

it's getting so close it's electric. ::)

Flyin6 · « **Reply #873 on:** February 05, 2015, 12:08:45 PM »

Quote from: EL TATE on February 05, 2015, 11:33:43 AM

it's getting so close it's electric. ::)

It's just endless problem solving right now.
I need a fitting for the transmission line, so I solve that puzzle.
I need to wire it up so I solve that puzzle
and on and on until one day I can declare that the majority of the problems are solved!

cudakidd53 · « **Reply #874 on:** February 05, 2015, 03:40:34 PM »

Quote from: Flyin6 on February 05, 2015, 12:08:45 PM

Quote from: EL TATE on February 05, 2015, 11:33:43 AM
it's getting so close it's electric. ::)
It's just endless problem solving right now.
I need a fitting for the transmission line, so I solve that puzzle.
I need to wire it up so I solve that puzzle
and on and on until one day I can declare that the majority of the problems are solved!

Then you'll start it and drive over a mulch bed and get it dirty! More problems- then a KIA will get stuck and some Bunny Hugger will complain about all the Sparks and not recognize the glory of it all......problems!

Flyin6 · « **Reply #875 on:** February 05, 2015, 06:27:36 PM »

But at least I'm building it mo-stronger than the Jap and Kolean Kars

Flyin6 · « **Reply #876 on:** February 05, 2015, 06:30:20 PM »

Well, I worked about 6 hours on the truck today, but don't have any really cool pics, just run of the mill stuff.

It's just nug work now. Dig in and solve one problem after another, then repeat until the chow whistle blows.

So, the big goal for today was to get this wiring harness doctoring completed and get that cat in the bag. Here is the mess I have to start with on the driver's side:

Flyin6 · « **Reply #877 on:** February 05, 2015, 06:32:34 PM »

Seeing all that depressed me, so I took some valium and worked on the other side. It only required removal of the old sheathing junk and reinstallation of the convoluted tubing stuff

It turned out well

Flyin6 · « **Reply #878 on:** February 05, 2015, 06:33:38 PM »

I think that dog will hunt!

On to some mo-fixin'

Flyin6 · « **Reply #879 on:** February 05, 2015, 06:35:23 PM »

And now onto the bad side!

I planned to just cut the whole harness apart and start over. All that anti-lock brake junk is leaving stage left!

Look at all those useless wires!

Flyin6 · « **Reply #880 on:** February 05, 2015, 06:36:29 PM »

They didn't last long!

Flyin6 · « **Reply #881 on:** February 05, 2015, 06:37:50 PM »

After sorting through that bird's nest, I loosely taped the various legs of the harness together to organize the wires a little better

Flyin6 · « **Reply #882 on:** February 05, 2015, 06:39:04 PM »

Then for the next hour or so, covered everything with various diameters of the tubing

Flyin6 · « **Reply #883 on:** February 05, 2015, 06:40:23 PM »

Then I went after the remaining bundles on the engine and firewall

Flyin6 · « **Reply #884 on:** February 05, 2015, 06:41:35 PM »

With that done, I ran the harness under the firewall and hooked up the transmission. While I was there I installed the transfer case shifter rod

Flyin6 · « **Reply #885 on:** February 05, 2015, 06:45:47 PM »

Then I tried to move the transfer case shifter

It wouldn't budge...YIKES!

In stead of suffering through another heart attack/anxiety attack combo, I gathered my thoughts, and started to hum Kum-Bye-Ya.

After some thoughtful moments of contemplation, I remembered those new fangled detent balls and springs which I torqued down to 700 Ft. Lbs.

Yup... So's I's (eyes) gets me handy allen socket and gets-to-loosenin' them thar critters. Then just like that, everything shifted like a democrat the day after election!

I was a happy man at peace with the universe once again!

Flyin6 · « **Reply #886 on:** February 05, 2015, 06:48:08 PM »

The next project was gonna be the new throttle cable, but, hear that??? It's the chow whistle!

Flyin6 · « **Reply #887 on:** February 05, 2015, 06:49:04 PM »

So that'll have to do it for this build day 215 in the never ending Square D oil change project

Dawg25385 · « **Reply #888 on:** February 05, 2015, 07:27:53 PM »

Looking good!

cudakidd53 · « **Reply #889 on:** February 05, 2015, 08:56:15 PM »

Sure you're already leaning this way Don, but just in case: I'd fire it up without the fenders etc. on- much easier to fix any potential wire issues where you can easily access those neat little wire bundles without having to hang by your ankles over the fenders. Remember the roof rack fiasco where you cracked the concrete and forgot your zip code for an undisclosed period of time...... ::)

JR · « **Reply #890 on:** February 06, 2015, 01:25:13 AM »

Looking nice and I like the idea of "pull" to shut off. Wouldn't want to be bouncing around over a KIA or German bike and push the engine kill!!

Mount your pumps low and they should stay primed. Mine is high and now and then I get a little bleed off (filter head needs a rebuild) and have to prime it. Most of my fitting you see are stainless too. Bout the same as brass but looks better longer.

Ordered my tires and wheels today from a guy in TX. Told me they were 90+ on wear, all 5. You got to have a spare!!

Kum-Bye-Ya,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,

Flyin6 · « **Reply #891 on:** February 06, 2015, 08:12:08 AM »

Quote from: cudakidd53 on February 05, 2015, 08:56:15 PM

Sure you're already leaning this way Don, but just in case: I'd fire it up without the fenders etc. on- much easier to fix any potential wire issues where you can easily access those neat little wire bundles without having to hang by your ankles over the fenders. Remember the roof rack fiasco where you cracked the concrete and forgot your zip code for an undisclosed period of time...... ::)

I am indeed leaning that way Mikey, however a lot of stuff mounts to the fender wells. Now the big problem with that is the fender wells mostly mount to the fenders.
If I fired it up with the AC and PS pumps not connected and the wiring harness just hanging I might could get 'er done. Still have some time before all that happens though, still a lot of things to connect.

OldKooT · « **Reply #892 on:** February 06, 2015, 11:03:41 AM »

Looking good man... I left the fenders off on our Ramcharger when I first fired it up. I just installed the inner fenders, and got everything situated and lit it up.

Norm

JR · « **Reply #893 on:** February 06, 2015, 02:36:23 PM »

FIRE IT UP!!!!

Flyin6 · « **Reply #894 on:** February 06, 2015, 06:06:13 PM »

OK Boys and girls, we're getting ever closer.

The throttle cable is installed and the transmission cooling lines are all in now so I am definitely getting closer to firing that Cummins engine up for the first time.

Before I get into the build today, the post office guy delivered me my fuel system parts. First is the twin Kennedy lift pumps. Each makes something like 6PSI and will support 600HP. Two will obviously make twice the pressure, but as previously stated I will run one pump at a time with the other remaining a back up unit

Flyin6 · « **Reply #895 on:** February 06, 2015, 06:08:48 PM »

Next is this neat filter head with a manual bleeding pump. I will locate the pumps low in the chassis and this filter a bit higher. Hopefully air will naturally find it's way to this unit where I can manually pump it out and prime the system should I ever run it dry

Flyin6 · « **Reply #896 on:** February 06, 2015, 06:09:37 PM »

Time for a short break...

Flyin6 · « **Reply #897 on:** February 06, 2015, 06:11:27 PM »

OK, all better now

What were we talking about??

Oh yes, that truck, well I got right on the throttle cable install. Starting with a 36" unit from Mr. Gasket, This is going to be another custom installation

Flyin6 · « **Reply #898 on:** February 06, 2015, 06:13:08 PM »

With the stocker out of the way, this hole will be covered by the washer/cable mount I made out of 11 gage steel

Flyin6 · « **Reply #899 on:** February 06, 2015, 06:14:13 PM »

With the cable in and attached to the go fast pedal it comes up a bit short!

Author Topic: SquareD Part 5: The build continues and gets more aggressive (Read 421042 times)

OldKooT