Project Daily Drive 1983 Wagoneer Work Log

[Achilles]

Exhaust Damper

Worked on the exhaust damper some more getting the holes plugged up on it.

I ran a 5/16 drill bet through the bushings in the exhaust damper.



I ran a 3/8 tap through the bushings so that I could plug it up with 3/8 bolts.



The first bushing actually took threads really well.



This is where it went wrong. I started on the opposite side and the bushing started to crumble. I took out the next size tap that would fit and cut threads straight into the cast iron. M12 x 1.75 was the tap I used.



I stopped here and went and looked for bolts to fit the new thread size ( I should of did this before I cut the threads) after several stops I was able to locate them. I knocked the other bushing out and tapped it to M12 also. the bolts fit perfect. I trimmed them down so the would not stick in to far.





I am going to use this to seal the bolts up:



I wired wheeled the damper to clean it up in preparation for painting it. It cleaned up well and will be my test piece for the finish I plan to use, which will be used on both manifolds if it works.

[Charles Kline]

Looking good!

Nice idea on taping the flapper holes.

[Achilles]

Cold enough outside that I did not want any part of it for extended periods of time. I am heating the shop up and tackling small projects. I have enough of the small project to keep me busy for a while.

Today I am working on stripping the last of the rust off of the heat riser to prepare it to be refinished.



I saw a guy on YouTube using this on car parts and I purchased several of these 8 oz bottles a while back to use on bolts and screws. I decided to give it a try on the heat riser.



I started out trying to conserve it and just keep it wet for the 30 minuets it required.







But..... impatience along with it stinking something fierce forced me to go to plan B. I moved it outside and decided to submerge it. I submerged it two times for a total of 60 minuets.



Removing it from the chemical bath!



The instructions said to either rinse it in water and dry thoroughly or wipe it dry. I chose to wipe it as I did not think it was a good idea to put water on raw cast iron. This is the results. A little wire brush work in a couple of spots and it was pretty good.





This worked really well, but due to cost this might not be practical solution for doing the exhaust manifolds.

[Achilles]

Dry fitting exhaust

Trying to stay busy doing what ever I can. Started working on the rest of the exhaust today. Things were not fitting together like they should so I bought one of this.

HFT Exhaust Pipe Expander. It actually worked.





Also picked these up which made cutting exhaust pipe a breeze.





Decided on a DynoMax Super Turbo Muffler.



Seems like I make a mess no matter where I am at.



Everything dry fitted together from the y pipe to the exhaust pipe.



Broke down and waiting to go on to the jeep after I clean up the exhaust manifolds.

[Achilles]

Exhaust Manifolds

Decided to just sandblast the manifolds. Me being the cheapskate I am I just went to HFT and bought the cheapest one I could find.

$35.00






Manifold before





Manifolds After





Manifolds before applying finish



After finish still wet



I will through up a picture of the finished product up after I get home from work today!

[Charles Kline]

Seems like that HF blaster worked well. What media are you using?

What are your painting the manifolds with?

-Charles

[Achilles]

I used sifted play sand. Hesitant to disclose what I painted them with because it is not intended for this purpose and I do not want to steer anybody down this route until I know if it will hold up or not. I will revisit this after the manifolds have been on the motor for a while.

Seems like that HF blaster worked well. What media are you using?

What are your painting the manifolds with?

-Charles

[Achilles]

The finished product after the 24 hour wait time.









We will see how they hold up if they do well I will let you guys know what they are coated with if not no harm no foul.

[Heavy_Metal_Thunder_81]

Looks real good. Hopefully they hold up for you. Nothing like finding out the paint burns right off on first start-up and you have to remove them and try something else...

[Achilles]

It is not really paint pe rse that is why I am a little hesitant to divulge what is is until I see what happens once the heat gets to it.

Put the studs back in and plugged the air tube holes.



Used lots of anti-seize!!!!!!! All this will eventually need to come back off.





Heat riser test fit.



Plugs used for the air tube hoses.






These will be put up until the weather gets a little better and I can get the exhaust back on the Wagoneer!

[Heavy_Metal_Thunder_81]

If it is one of those rub on products (like Calyx) I have heard good things.

[Achilles]

Not a rub on it is actually in a spray can butis not a paint.

[toddthewelder]

Man you are just getting on with it, and it's all looking good

[Achilles]

Still chipping away at small projects when the weather is bad.

Back to the air cleaner housing



Time to paint!!





First coat on outside.



Scored a seal that fits the lid perfectly!!



Removing old seal



All patched up



Seal installed,





Finished, not rusty any more!!

[Achilles]

Time to get this thread Caught up!!!

I will picked up where I left off and will be attempting to catch this thread up.

Out comes the sawzall!!



Exhaust cut and removed by force since it was cobbled together and boogered up by the PO.



Got new Y pipe loosely installed and held in to place with a couple of bungee chords.







Gaskets held on to the exhaust manifolds with un-waxed dental floss to aid in keeping them in place during installation.



Exhaust manifolds slipped into place bolts inserted and floss broken and removed. It worked out really well.



Y pipe connected to the manifolds and I ran out of day light.







Day one Y pipe and exhaust removed. Exhaust manifolds and and new Y pipe reinstalled and connected.