Author Topic: SquareD Part 5: The build continues and gets more aggressive (Read 423644 times)

Flyin6 · « **Reply #750 on:** January 27, 2015, 11:01:38 AM »

Quote from: EL TATE on January 27, 2015, 10:54:47 AM

Quote from: nmeyer414 on January 27, 2015, 09:22:07 AM
Nice fabrication
BTW, new welding table? is that 3/8" or 1/2" plywood? I'm looking to upgrade my personal welding table at home as well ;)

That's funny!

Yup new 3/4" MDF welding table...!!!

And it is sitting on top of my two Harbor Freight (Real) welding tables!!!

JR · « **Reply #751 on:** January 27, 2015, 01:53:55 PM »

Quote from: Flyin6 on January 27, 2015, 11:01:38 AM

Quote from: EL TATE on January 27, 2015, 10:54:47 AM
Quote from: nmeyer414 on January 27, 2015, 09:22:07 AM
Nice fabrication
BTW, new welding table? is that 3/8" or 1/2" plywood? I'm looking to upgrade my personal welding table at home as well ;)

That's funny!

Yup new 3/4" MDF welding table...!!!

And it is sitting on top of my two Harbor Freight (Real) welding tables!!!

Well it works, and burns and is good for posting.

Oh, and they are one sale right now!!!!!!!!!! (HF table, not MDF)

EL TATE · « **Reply #752 on:** January 27, 2015, 05:04:31 PM »

Quote from: Flyin6 on January 27, 2015, 11:01:38 AM

Quote from: EL TATE on January 27, 2015, 10:54:47 AM
Quote from: nmeyer414 on January 27, 2015, 09:22:07 AM
Nice fabrication
BTW, new welding table? is that 3/8" or 1/2" plywood? I'm looking to upgrade my personal welding table at home as well ;)

That's funny!

Yup new 3/4" MDF welding table...!!!

And it is sitting on top of my two Harbor Freight (Real) welding tables!!!

That is awesome. You should send that picture to HF and gently suggest that they make their tables a bit taller for you pilot types. I thought it was MDF, but also looked like some wood grain in one of the pics. The work it produces is sharp though, so I can't knock the formula. Weld on Sir.

Flyin6 · « **Reply #753 on:** January 27, 2015, 06:07:22 PM »

Weld I will!

OK good news and bad news

Good news is the core support is finished and painted as of this moment

Bad news is there is no way possible to mount the AC Condensor on the core support

The 1st gen truck was all compacted and had a short "Nose"

Within the confines of that snout was a radiator, which was not as big as this monster 2nd gen thing I have used. It had a smallish condenser wedged in between the radiator and a smallish intercooler that again, was about 1/3 as large as the thing I am using.

So it's just physics and real estate. No condenser in the core, which means I am going to have to get rather inventive and maybe stick it in one of the fender wells, or perhaps onto the bottom of the hood, or even on top of the topper...dunno yet

So, here is the final fitting of the IC which fits rather well I think

Flyin6 · « **Reply #754 on:** January 27, 2015, 06:11:47 PM »

Doing a little mockup here and you can clearly see I am out of room

Flyin6 · « **Reply #755 on:** January 27, 2015, 06:13:15 PM »

With the decision made to press on it was time for sanding, grinding, hole patching, cleaning and painting

Here the process begins

Flyin6 · « **Reply #756 on:** January 27, 2015, 06:14:48 PM »

After the wire wheel, there was a lot of shiny steel so I pulled out the acid etching primer and coated those spots

Flyin6 · « **Reply #757 on:** January 27, 2015, 06:15:54 PM »

Next is the epoxy primer/sealer

Flyin6 · « **Reply #758 on:** January 27, 2015, 06:16:53 PM »

Then the 1st coat of the Armee Green

Flyin6 · « **Reply #759 on:** January 27, 2015, 06:18:25 PM »

And a second coat to finish it. I painted the truck with three coats but this part will almost be unseen and covered so 2 coats will suffice

Flyin6 · « **Reply #760 on:** January 27, 2015, 06:19:12 PM »

So that's a wrap for another build day!

Flyin6 · « **Reply #761 on:** January 27, 2015, 06:19:47 PM »

Oh, and C-Max said to say hello!

cudakidd53 · « **Reply #762 on:** January 27, 2015, 06:39:42 PM »

Hey Don-

Did you go hybrid on CMax? What's that yellow cord for? You can't be needing that block heater!? Don't pull mine out till near zero up here in snowland ! :D

Flyin6 · « **Reply #763 on:** January 27, 2015, 08:54:40 PM »

Quote from: cudakidd53 on January 27, 2015, 06:39:42 PM

Hey Don-

Did you go hybrid on CMax? What's that yellow cord for? You can't be needing that block heater!? Don't pull mine out till near zero up here in snowland ! :D

Trickle charger

JR · « **Reply #764 on:** January 27, 2015, 11:23:57 PM »

Dang, you must be ignoring it to put it on a trickle!!!!!!!!!

I have to rebuild the stock filter housing on mine. Pressure keeps bleeding off and have to pump it up.

Just 4 coats on the rad support, might be OK.

ceelibs · « **Reply #765 on:** January 28, 2015, 07:29:00 AM »

Quote from: Flyin6 on January 27, 2015, 06:07:22 PM

Weld I will!

OK good news and bad news

Good news is the core support is finished and painted as of this moment

Bad news is there is no way possible to mount the AC Condensor on the core support

The 1st gen truck was all compacted and had a short "Nose"

Within the confines of that snout was a radiator, which was not as big as this monster 2nd gen thing I have used. It had a smallish condenser wedged in between the radiator and a smallish intercooler that again, was about 1/3 as large as the thing I am using.

So it's just physics and real estate. No condenser in the core, which means I am going to have to get rather inventive and maybe stick it in one of the fender wells, or perhaps onto the bottom of the hood, or even on top of the topper...dunno yet

So, here is the final fitting of the IC which fits rather well I think

What about modifying the o.e. grill or making one yourself? Not too many other suitable places to mount a condenser and still have it get the needed airflow, theres also the size of it (which, if your going to convert the a/c to 135a refrigerant is marginally sized to begin with...btdt...oh and if your doing a 134a retrofit you might want to look into a parallel flow condesner, they are more efficient and are avail in the aftermarket...rock auto has them, just look in the part description, also a couple good r12-134a conversion threads on dtr and cuminsforum).

Flyin6 · « **Reply #766 on:** January 28, 2015, 07:51:37 AM »

Quote from: ceelibs on January 28, 2015, 07:29:00 AM

Quote from: Flyin6 on January 27, 2015, 06:07:22 PM

What about modifying the o.e. grill or making one yourself? Not too many other suitable places to mount a condenser and still have it get the needed airflow, theres also the size of it (which, if your going to convert the a/c to 135a refrigerant is marginally sized to begin with...btdt...oh and if your doing a 134a retrofit you might want to look into a parallel flow condesner, they are more efficient and are avail in the aftermarket...rock auto has them, just look in the part description, also a couple good r12-134a conversion threads on dtr and cuminsforum).

Hmmm, hadn't thought about conversion to R134, perhaps I should since it is more readily available than Freon is.

No way I can cut away the back of the grill to fit it. The way the grill inserts fit in make that impossible. And I am already less than zero clearance, that is, I have to stretch the grill down to the fastener holes.

Nope I'm stuck with the problem it seems

Parallel flow condenser...Rock Auto...Got it!

JR · « **Reply #767 on:** January 28, 2015, 11:26:42 AM »

Has anyone used Envirosafe R12/132 replacement? I just got some for retrofit and topping off my R12 systems. Plus you use less and is easy to get.

Just an idea Don,,,,,,,,,,,,,,,,,

Flyin6 · « **Reply #768 on:** January 28, 2015, 03:58:20 PM »

Quote from: JR on January 28, 2015, 11:26:42 AM

Has anyone used Envirosafe R12/132 replacement? I just got some for retrofit and topping off my R12 systems. Plus you use less and is easy to get.

Just an idea Don,,,,,,,,,,,,,,,,,

OK, I'll look into it

Flyin6 · « **Reply #769 on:** January 28, 2015, 04:04:56 PM »

Pressing ever onward It's time to get some more big parts off the floor and reassembled

Here's the radiator core support after the paint cured

Flyin6 · « **Reply #770 on:** January 28, 2015, 04:06:41 PM »

The lower edges were given a coating of rubberized undercoating because it seems this area sometimes holds moisture, especially if there is some sort of radiator leak

Flyin6 · « **Reply #771 on:** January 28, 2015, 04:07:37 PM »

The front I/C mounts got the same treatment

Flyin6 · « **Reply #772 on:** January 28, 2015, 04:09:48 PM »

I plan to isolate the wheel well area as one big air plenum. Therefore, this opening needs to be closed off. A simple piece of aluminum bedded in RTV did the trick

KensAuto · « **Reply #773 on:** January 28, 2015, 04:13:19 PM »

You can put that condenser anywhere you like,(the aftermarket parallel flow style) as long as you put an electric fan on it.
last year I had the same issue on a 50 Chebee p/u...ended up putting the condenser/fan assembly under the passenger side floorboard, fan blowing down. Note: this will only work if you lay it flat, not standing on either end. A good side benefit from this is ending up with more freon capacity from the longer hoses...in this case 134a. (Freon is slang for refrigerant).
I also agree on converting it (to 134a)...just get it over with.

Flyin6 · « **Reply #774 on:** January 28, 2015, 04:16:10 PM »

Quote from: KensAuto on January 28, 2015, 04:13:19 PM

You can put that condenser anywhere you like,(the aftermarket parallel flow style) as long as you put an electric fan on it.
last year I had the same issue on a 50 Chebee p/u...ended up putting the condenser/fan assembly under the passenger side floorboard, fan blowing down. Note: this will only work if you lay it flat, not standing on either end. A good side benefit from this is ending up with more freon capacity from the longer hoses...in this case 134a. (Freon is slang for refrigerant).
I also agree on converting it (to 134a)...just get it over with.

I am thinking of mounting it on the roof of the truck in that rack I built, or even on the roof of the topper

Flyin6 · « **Reply #775 on:** January 28, 2015, 04:17:02 PM »

While things were curing I reinstalled the front brake lines

Flyin6 · « **Reply #776 on:** January 28, 2015, 04:18:30 PM »

That took just long enough for the undercoating to sufficiently harden, so starting with the mounts, I applied some poly grease to all surfaces

Flyin6 · « **Reply #777 on:** January 28, 2015, 04:21:23 PM »

Then I bolted it in loosely and slid the radiator in. I did this without realizing the I/C must be installed first then the radiator nestles within the recesses in it's large inlet and outlet tubes

Flyin6 · « **Reply #778 on:** January 28, 2015, 04:23:39 PM »

The intercooler was installed, which required another relief cut of the fan shroud, then it all fit and was bolted in for good.
With that in the bag, I sourced my B&D Diesel heavy duty intercooler boots which exceed stock by a wide margin

Flyin6 · « **Reply #779 on:** January 28, 2015, 04:25:30 PM »

They fit well and feature spring supplemented band clamps.

I threw on a new Goodyear lower radiator hose, a stocker for 94-98 trucks

Flyin6 · « **Reply #780 on:** January 28, 2015, 04:26:20 PM »

The truck got a new Goodyear upper hose as well

Flyin6 · « **Reply #781 on:** January 28, 2015, 04:28:20 PM »

The intercooler piping was is great condition with only some small areas of corrosion, so they were sanded off, primed, then painted with the wrinkle black paint along with the turbo discharge piece

Flyin6 · « **Reply #782 on:** January 28, 2015, 04:30:26 PM »

The first coat had some bleed-through, but the second heavy coat covered everything

Flyin6 · « **Reply #783 on:** January 28, 2015, 04:31:30 PM »

That's it for another 6 hour day, build day 210 in this evolving saga!

Nate · « **Reply #784 on:** January 28, 2015, 08:01:32 PM »

Nice progress

Flyin6 · « **Reply #785 on:** January 28, 2015, 09:38:45 PM »

Slowly, but surely!

KensAuto · « **Reply #786 on:** January 28, 2015, 10:29:54 PM »

Gettin' there...almost ready for start-up!

Flyin6 · « **Reply #787 on:** January 29, 2015, 06:16:14 PM »

Not so fast Ken...still a metric tonne of work yet to do!

Here's how those wrinkly parts turned out:

Flyin6 · « **Reply #788 on:** January 29, 2015, 06:17:50 PM »

Here's the turbo side installed

Flyin6 · « **Reply #789 on:** January 29, 2015, 06:18:23 PM »

And the cold side

Flyin6 · « **Reply #790 on:** January 29, 2015, 06:18:51 PM »

Quick shot of the intercooler

Flyin6 · « **Reply #791 on:** January 29, 2015, 06:20:23 PM »

Right now I'm fishing around seeing what fits and what needs to change or get replaced.

The 91 throttle cable is 10" too short so it will go bye-bye in favor of something a bit longer

Flyin6 · « **Reply #792 on:** January 29, 2015, 06:23:18 PM »

Time to get on the wiring harness

The plan is to lay the stocker in and see where I am. I will be cutting lots of things off of it that will never be reused. I will also be adding new wiring for lights, sensors, and various controls. After I get everything where I need it, I'll rewrap the new harness and make it all one piece and factory looking

The stocker before the fireworks:

Flyin6 · « **Reply #793 on:** January 29, 2015, 06:24:08 PM »

Going in here, it is one ugly mess

Flyin6 · « **Reply #794 on:** January 29, 2015, 06:24:56 PM »

After connecting the hood release I wrangled the radiator top seal in place

Flyin6 · « **Reply #795 on:** January 29, 2015, 06:27:28 PM »

The factory fuel filter is fed from the mechanical fuel pump by a pinched down 5/16" line. Framkly it amazes me these motors made so much power with so limited a fuel flow

Anyway the plan will be to use something bigger like the one I already have installed and see if I can connect the factory water in fuel sensor in my aftermarket arrangement

Flyin6 · « **Reply #796 on:** January 29, 2015, 06:30:06 PM »

Here's the first casualty, the old rear anti-lock brake controller.

It is a useless item since there are no longer any of the anti-lock brake junk on this truck

Flyin6 · « **Reply #797 on:** January 29, 2015, 06:31:04 PM »

The harness is starting to get tucked in here

Flyin6 · « **Reply #798 on:** January 29, 2015, 06:32:37 PM »

Next up, the initial fitting of the front battery tray shows the enlarged radiator is now in the way requiring a relief cut

Flyin6 · « **Reply #799 on:** January 29, 2015, 06:34:17 PM »

Also the window washer tank is big time in the way, so it leaves as well. I have that big 6-7 gallon custom tank in the back, so that is where the windshield washer fluid will be coming from now