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  #381  
Old 11-13-2012, 10:05 AM
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ross80truck ross80truck is offline
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Quote:
Originally Posted by TPICherokee
The alternator does not have an internal regulator, it is regulated through the Dodge computer (which goes bad a lot)

All you have to do is get a regulator and plug from a 1992 Dodge Cummins (they were externally regulated) and hook it up to your alternator and viola it will work.


Okay, back to the computer for more research on where to get a plug and regulator for a 92 Dodge Cummins. Thanks for the information TPICherokee. It amazes me the wealth of knowledge you can get on a "good" forum with good people. Thanks.
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  #382  
Old 11-13-2012, 03:16 PM
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Did a little research on the external voltage regulator. If you look up a 1992 Dodge D350 with the 5.9L cummins on RockAuto, they sell 2 different voltage regulators. From what I can tell, the only difference is the warranty. One of them cost about $8 and the other one cost about $24. Also, using the same vehicle, they sell a voltage regulator pig tail for a huge $3.49. So, that should take care of wiring in the alternator.

Also, on the Larry B's web site. He sells a wiring harness for the P7100 pump to wire in the solenoid. That will come in real handy as well wiring in the motor. Good information to find.
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  #383  
Old 11-14-2012, 08:38 PM
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Cool. Thanks
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Quote:
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/view...p=18290#p18290
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  #384  
Old 11-15-2012, 05:25 PM
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Both my cummins trucks use external regulators from a 1991 Dodge truck. I got the pigtails from the junkyard - Lots of Dodge vehicles of that vintage used that setup.
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  #385  
Old 11-15-2012, 06:42 PM
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I swung by RE Electric today, confirmed the info., and got the regulator and pigtail for a 1992. The price was right in the ballpark of what ross found.
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"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/view...p=18290#p18290
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  #386  
Old 11-19-2012, 01:42 PM
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So, here's what I've been up to.

Since I posted this pic I made a lot of changes. To be honest, I didn't like this arrangement and some people giving me honest feedback finally made me go back and change things.



1- Brooks, the diesel mechanic who's been giving me advice, swung by. He said although the trans cooler would work in this orientation they tend to trap air in the upper plates.
2- Elliot, from the hydroboost thread, dropped me a note and suggested a two pass cooler similiar to what's used on the F-350's would be better for powersteering cooling.
3- The oil cooler I was going to use has only 3/8" lines and that concerned me.

Solutions:
1- Rotate trans cooler 90 degrees.
2- Use the 20", two pass cooler I had sitting in a box and mount it under the intercooler.
3- Take the huge 1/2" line oil cooler I had, that wouldn't fit, cut it up, and make it fit.


Constantly use compressed air to back flush the lines to keep cuttings out. Pry off the unneeded fins.


Salvage the end plate and carefully reinstall it.



Salvage the U-bend and solder back on using an acid flux solder made for radiators. I don't know why, but when I tried to reinstall the u-bend the solder wouldn't wick properly and I didn't trust the new joint for something as critical as my primary oil line. Ultimately, I destroyed it trying to fix the problem and had to fashion a bend out of standard plumbing pieces.
Edit- Since writing the above I decided to take the oil cooler to Preformance Radiator, in Tacoma, to have it professionally silver soldered. Although what I did would most likely have worked, after the issues I had it wasn't worth risking a new engine to save $40.



Now, when I remount the intercooler, this is how things are going to be. The blue tape on the intercooler shows where the body sheetmetal is. I had to keep the main bodies of the coolers between the tape lines, with the powersteering cooler underneath. The oil cooler lines will now make 90 degree bends and come through the sheetmetal into the engine compartment.
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Quote:
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/view...p=18290#p18290

Last edited by Resbum : 12-16-2012 at 08:41 AM.
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  #387  
Old 11-25-2012, 07:59 AM
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Nice work
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***I can set you up with hydroboost for your brakes: http://www.ifsja.org/forums/vb/showthread.php?t=106056
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  #388  
Old 11-30-2012, 05:42 PM
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It's been a long 5 days. I've finished installing the remote oil filter, oil thermostat, and oil cooler. It took a lot more time, creativity, money, and trips to the store than I expected, but I feel confident it will work well. The last thing I wanted to do was skimp on things and risk the new engine to an oil system failure.

I also have all the parts needed to finish the trans and powersteering hyrdaulic systems, so they should be done in the next couple of days.







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  #389  
Old 11-30-2012, 08:28 PM
Chumley360 Chumley360 is offline
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Sir did you ever work for PWC? Cause that's a lot of adapters connected to adapters connected to fittings.

But seriously I love the oil cooler mod. I've never thought of doing that, and have spent hours fighting with coolers, grills, and other parts to get stuff to fit. Keep up the good work
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  #390  
Old 12-01-2012, 08:52 AM
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Quote:
Originally Posted by Chumley360
Sir did you ever work for PWC? Cause that's a lot of adapters connected to adapters connected to fittings.
Haha, it's not as "Rube Goldberg" as it looks.

I lost count of all the different ways I tried laying it out.

This turned out to be:
-The most direct & compact
-Offered the most clearance for the hoses
-Didn't interfer with the air filter or inner fender well

While posting the pictures last night I noticed that I may be able to get rid of the two fittings closest to the hoses. When I get to the shop today I'll have to take another look and see if it's an illusion of the pictures or if I really have the 3D space. Every joint eliminated would be a good thing.
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Quote:
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"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/view...p=18290#p18290

Last edited by Resbum : 12-01-2012 at 10:04 AM.
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  #391  
Old 12-01-2012, 09:26 AM
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Maybe this will help make sense of it.
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"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/view...p=18290#p18290
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  #392  
Old 12-01-2012, 08:40 PM
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Made brackets out of stainless steel and riveted them to the bottom of the intercooler, then mounted the powersteering cooler. I'll finish the mods to the PS pump reservoir tomorrow. Can't do much more with it until I install the hydroboost.






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"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/view...p=18290#p18290

Last edited by Resbum : 12-10-2012 at 08:20 AM.
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  #393  
Old 12-04-2012, 09:56 PM
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I got the PSpump reservoir modified. As can been seen in the picture, all the lines came out and promptly turned into the area the steering shaft needs to be. Because I'm converting to hydroboost the pressure line will not be an issue, but I needed to reroute the two return lines. I bought some #6 AN fittings and trimmed the inner parts down to clear the actual pump casting inside. Once that was done I bent and formed the tubes.








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Quote:
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"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/view...p=18290#p18290

Last edited by Resbum : 12-10-2012 at 08:17 AM.
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  #394  
Old 12-04-2012, 09:59 PM
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I also had to press the housing out for the middle line so that I could still use the magnet and screen that was over the oiginal hydroboost return.


The face of the nut is flush with the original housing surface so the magnet and screen sat in their original lacation




The final product. The new pressure line will come straight out and up to the hydroboost.
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  #395  
Old 12-09-2012, 09:09 AM
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I got the last of the trans cooler lines finished yesterday. I'm ready to declare the major mechanical fabrication of the project done. From here on I can't really work on mechanicals without knowing how they interact with the bodywork. So, another milestone has been reached.

Time to move on to bodywork.
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  #396  
Old 12-10-2012, 06:45 AM
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Res, I pop in and out of here every so often. I must say what a great job
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  #397  
Old 12-11-2012, 08:41 AM
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Thanks lobie. You unknowingly contributed to the work I did. The info you posted about your hydroboost system and PS mods was very helpful, and I used that info while doing mine. The benefits of forum members sharing info in action.

Resbum
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  #398  
Old 12-16-2012, 08:33 AM
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I know it's nothing big, but here's the first bodywork I've ever done that wasn't related to some mechanical project. 35 years turning wrenches, zero bodywork experience.

When I moved the intercooler inlet/outlet up 3" it allowed me to put sheetmetal back in along the bottom. It wasn't really necassary, but it gave me some practice in an area nobody will ever see.
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  #399  
Old 12-23-2012, 07:16 AM
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wow

great job
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  #400  
Old 12-23-2012, 08:48 AM
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Thanks, Mario.

Woo Hoo! Merry Christmas to me! The metal fabrication and prep are done on the core support and front valence. This morning, in about an hour, I'm heading to a paint booth to shoot epoxy primer on them. I'll post pics later.

Here's what else I've been working on. I decided to go all LED lights, except headlights, on the truck. The taillights and back up lights are going to be easy to retrofit, but I wondered how I would do the front marker lights. Here's where I'm at now. I may make some minor changes. I'll fabricate stainless steel clips to hold them in the housings. For the original Jeep clear lenses I'm going to try one of the polishing kits, then hit them with a light "smoke" coating.






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