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Author Topic: SquareD Part 5: The build continues and gets more aggressive  (Read 267132 times)

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SquareD Part 5: The build continues and gets more aggressive
« on: October 21, 2014, 08:27:39 PM »
Anyone ready to get back into building this cool truck?
Been a long sabbatical with the knee surgery and L O N G recovery time, which is still not complete BTW!

OK the medium term objective is to get the engine reinstalled.
To do that I am cleaning up all areas of the vehicle that relate in preparation. My hope is to rebuild the transmission next week, but first get a bunch of stuff that is laying around, cluttering up my shop, back on the truck.

So that's what I have been doing, that and messing with the door panels which I just had to pull to make something custom.

Might as well start there.

OK, the plan was to pull the plastic interior door panels and replace with a flat fiberglass/wood panel that serves as a mount for a carbine, magazines, flashlight and other immediate need emergency stuff

First I pulled the door panel
« Last Edit: November 22, 2014, 06:39:38 PM by Flyin6 »
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #1 on: October 21, 2014, 08:30:38 PM »
Since it will now support perhaps 20-25 pounds of stuff, securing it with those factory clips was problematic. Imagine the wind slamming the door open then the door panel with your weapon goes crashing to the ground!

So I'll fasten it with an equal number of small 1/4" bolts

The holes were enlarged and Nutserts were installed in the factory locations
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #2 on: October 21, 2014, 08:31:31 PM »
Like this:
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #3 on: October 21, 2014, 08:34:25 PM »
The rest of this project will be coming back in a couple days, but this was when I decided to get all this junk I was accumulating bolted back onto the truck

Remember that cool H20/alcohol tank that Dan made for me?

Well there it is getting fitted and prepped:
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #4 on: October 21, 2014, 08:36:52 PM »
After acid primer, the thing was sanded and received a coat of acrylic enamel Lycoming gray along with the transmission to engine adapter plate.
« Last Edit: October 21, 2014, 08:54:17 PM by Flyin6 »
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #5 on: October 21, 2014, 08:39:23 PM »
The paint turned out OK...I had some runs, but that is expected since I was trying to blow it into spaces between the mount bars and the floor.

BTW that tank is made from 1/4" wall aluminum with 1/2" think legs and mounts. Frankly I wanted it to serve as an emergency jacking point!
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #6 on: October 21, 2014, 08:41:04 PM »
With the quick flash of some wrenches it was permanized into it's new home.

Look how well it fits between and fills up those frame rails!

Dan did a great job building that tank!
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #7 on: October 21, 2014, 08:44:06 PM »
Now this motor is a no kiddin' 600-700 HP mill. Looking at the factory fuel system I have never been impressed.
It uses tiny lines barely 5/16" in diameter which I knew had to go. So go they will. I'm starting at the injection pump and changing it from a single inlet to a dual inlet with 1/2" lines
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #8 on: October 21, 2014, 08:45:03 PM »
Here is the new dual inlet line kit from Cummins Performance Parts, CPP.
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #9 on: October 21, 2014, 08:46:36 PM »
Here is one of the fittings installed. The other fitting goes into a port in the front that had a hex plug
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #10 on: October 21, 2014, 08:47:27 PM »
And here is the supply line installed
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #11 on: October 21, 2014, 08:49:19 PM »
You will notice the shutoff solenoid missing. I decided to use an aircraft cable to convert it to a manual shutoff so it will not be reinstalled.

I threw the motor mounts back on as well just to get them off the shelf
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #12 on: October 21, 2014, 08:51:22 PM »
I purchased a new Cummins oil line used to lubricate the vacuum pump and drive assembly, but I think it's the wrong part since mine starts out at the blocs with a straight fitting and this one has two 90's
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #13 on: October 21, 2014, 08:52:54 PM »
For awhile the build is going to be jumping all over as I get a lot of loose ends tied up and more stuff out of boxes and onto this truck.

We'll call it a day, here, the end of Build Day 176...
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #14 on: October 21, 2014, 09:01:08 PM »
Wow, like seeing an old friend, New material on Square D!  Thanks for sharing and glad you're back to building.........was scared ya were getting good at being a DOT!
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #15 on: October 21, 2014, 09:03:39 PM »
Never happen!
I want to get that truck built...Thing is, I keep coming up with ideas for what I want to add or see it able to do...It is always evolving

But first it needs to finally move under it's own steam once again
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #16 on: October 21, 2014, 09:39:42 PM »
That is one good lookin' engine. Been so long, I forgot what it looked like!

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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #17 on: October 22, 2014, 02:17:35 PM »
Ought to be a good running one as well...good valve job, Marine pistons coated with some high tech stuff, good everything. I have it set at only 12.5 degrees timing so there is a 100HP bump just by advancing the timing a bit...it should run well...
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #18 on: October 22, 2014, 03:16:38 PM »
Nice to see this back up in progress again! And of course you recovering from the knee operation, that's just awesome.

This is the first build of yours i started following, then went back and caught up start to finish on the duramax... awesome stuff!
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #19 on: October 22, 2014, 07:29:32 PM »
That's sort of how it is going to play out here

We are back into SquareD

At some point I will reenergize C-Max...After what those tie rods and ball joints did to me, worn out to the point of almost falling apart in a wee bit over 20K, I am not going to keep the stock suspension. That Dana 60 will be mated to that truck at some point.
Sort of toying with the idea of painting it OD green as well...
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #20 on: October 22, 2014, 07:35:55 PM »
Got a little bit more done today along with appointments, changing oil in the wife's Caddy, grocery shoppin, visiting Duane to complain about stuff and a few other things like that.

The theme remains the same: Get all these parts back on the truck!

So today, I tackled some linkage, some lines and a proportioning valve. But first I picked up a really brightly colored shop vac to replace the old craftsman one the red dog has been chewing on for a year or two.
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #21 on: October 22, 2014, 07:36:46 PM »
Here's the ancient old valve before I tore into it:
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #22 on: October 22, 2014, 07:38:42 PM »
I pulled the old lines off of it, then wire-brushed it for awhile until it was as shiny as the mornin' dew!

I picked up a case of the brake cleaner to use on that tired old transmission
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #23 on: October 22, 2014, 07:39:58 PM »
Theh I pulled everything out of it that would unbolt
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #24 on: October 22, 2014, 07:42:17 PM »
I cleaned it, inspected it, put in new "O" rings and reassembled it
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #25 on: October 22, 2014, 07:43:56 PM »
Then the acid etch and the top coat of paint
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #26 on: October 22, 2014, 07:45:23 PM »
Next up were the last two transmission cooler lines that are mounted to the block. Here's one as it was removed, and one which was de-rusted!
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #27 on: October 22, 2014, 07:46:34 PM »
Of course they got the treatment, rust removed, then rust converter, then paint
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #28 on: October 22, 2014, 07:48:16 PM »
I did the linkage as well since all of that nestles inside the frame which is hard to get to when that mo-hawg 6BT is crowdin' up the space
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #29 on: October 22, 2014, 07:55:29 PM »
All of that will find itself back onto the frame tomorrow

The brown truck also delivered me the trucks portable survival radio, a Voyager which has a hand crank, a NiCad battery, 3 AA batteries and a solar cell. It operates on AM/FM SW/LW and the NOAA weather channels
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #30 on: October 23, 2014, 10:25:56 PM »
Got a few things done today, but not enough for a decent post, so I'll add more workie tomorrow.


I was bending brake lines and destroyed two 1/4" lines, then I discovered I needed some darned metric junk to fit the gen 2 master cyl

So I threw in the drop cloth and called it a day
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #31 on: October 27, 2014, 08:11:01 PM »
OK, I'm tracking to get this transmission rebuild going this week.

In prep for that I am tying up a bunch of loose ends, basically getting a bunch of parts off the shelves and onto the truck.

The big short term goal is to get the engine and transmission set back into the chassis pretty quick. That frees up floor space and work room and sets the stage to get the front clip headed home.

So first I found the correct fan belt and threw that on that purdy motor

Having the factory manual is very handy indeed!

Now there is proper spacing between the fan belt and the tensioner pulley
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #32 on: October 27, 2014, 08:13:43 PM »
Next up was remounting those coolant hard lines I painted the other day. Since this block came off a stick truck, I had to pull the plug that has been there since the Clinton era and install a nipple. It was stubborn but after breaking some cheap Chinese tools, a good American made ratchet got the job done
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #33 on: October 27, 2014, 08:15:43 PM »
I installed the longer line first, then the shorter line. which fit like it was made for this engine!
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #34 on: October 27, 2014, 08:17:22 PM »
Next up, was the shifter linkage. I had painted the mount pieces and the actual linkage, and that will be nearly impossible to get to when the block is, well, blocking everything, so now is the time
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #35 on: October 27, 2014, 08:18:36 PM »
But not without installing some new nylon bushings just to keep everything factory tight and fresh!
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #36 on: October 27, 2014, 08:20:13 PM »
The first thing that gets installed was the last thing removed, the proportioning valve
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #37 on: October 27, 2014, 08:21:58 PM »
Next the linkage mount and the linkage itself
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #38 on: October 27, 2014, 08:23:28 PM »
Then I could run the front brake line
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #39 on: October 27, 2014, 08:24:58 PM »
Then the back line
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #40 on: October 27, 2014, 08:26:22 PM »
I cut off the excess of each line and did a new double flare, then bolted it up

This flare tool has been in my box since the 80's!
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #41 on: October 27, 2014, 08:28:48 PM »
With that out of the way, I spent over an hour cleaning the area then assembled two new harbor freight welding tables which I will use to overhaul the transmission which starts next!

So let's play tools just a bit here!
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #42 on: October 28, 2014, 07:40:25 PM »
OK, let's get started building a transmission

First a review: We are building (We= me + the mouse in my pocket) an antiquated A518 which is basically a stout Chrycler 727 with an overdrive section bolted on in place of a normal tailshaft. It also has a slushbox converter with no lock up clutches. It is all hydraulic with little to no electrics and no electronics.

I had a converter built what will have a low stall point, but will not transfer shock loads like the later 47RH/RE which does have lockup clutches. Those shock loads are largely responsible for these transmissions failing.

The scenario is you drive around a street and turn onto a side street. All at once you start taking fire from a crowd or some bad guys. While going forward at a slow speed you slam it into reverse and floor it.

Big time shock loads there. What I need to happen is for the truck to shift into reverse and start backwards albeit while frying the tires at the head of 1200 ft lbs of torque.

Everything that I purchased in parts for this transmission, parts totaling nearly $5,000 were thought out and chosen around that premise.

Secondly, the transmission stayed automatic because of a requirement that the vehicle be operational if I only had one useful leg. It stayed old school because in the event of an EMP event, the truck would not know it and remain operational.

So with all of that in mind, first I purchased a sheet of 3/4" MDF and cut it down to 6' X 3' and clamped it to the welding tables

Then I laid out the parts I would be using and cleaners and rags and all sorts of stuff
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #43 on: October 28, 2014, 07:41:19 PM »
Transmission in place, let's start the teardown
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #44 on: October 28, 2014, 07:43:20 PM »
I started off using the ASTG manual, but found that to be lacking the detail I needed as a novice, so I switched to the Chrysler 1991 truck service manual.

It was perfect, a picture for each step!

First the trans pan comes off
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #45 on: October 28, 2014, 07:44:04 PM »
Followed by the valve body
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #46 on: October 28, 2014, 07:46:03 PM »
I noticed right away, the internals seemed pretty clean.
Again proving this truck was a survivor and a rare find indeed

Next the accumulator and then the parking paw linkage
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #47 on: October 28, 2014, 07:47:11 PM »
Under this cover is a snap ring which needs to be expanded to remove the overdrive section from the rest of the transmission
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #48 on: October 28, 2014, 09:12:00 PM »
After the 7 bolts are removed holding the overdrive unit onto the main transmission, compress that snap ring and the overdrive taps off
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Re: SquareD Part 7: The build continues and gets more aggressive
« Reply #49 on: October 28, 2014, 09:13:02 PM »
Then the pump unit comes off
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