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Thread: 7K of USA

  1. #121
    Colorado_Baja's Avatar
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    I was planning on working on the truck the whole month of December but I injured my ankle and was unable to walk or stand for 3 weeks. Finally getting back to it.

    The biggest problem ive ran into is the throttle body angle.

    20161105_135922 by colorado_baja, on Flickr

    I decided to make a TB spacer to level it out, this will help with the throttle cable routing too I think.

    20170110_110247 by colorado_baja, on Flickr

    20170110_111550 by colorado_baja, on Flickr

    Still need to cap my tube for the IAC and hopefully it still fits like it did when I test fit it.

    20170111_153221 by colorado_baja, on Flickr

    Got a chance to finish up the TB spacer and work on the intake a little bit today. Looks like its all going to work out, though ill have to use electric fans instead of the mechanical fan.

    20170115_122431 by colorado_baja, on Flickr

    20170115_122508 by colorado_baja, on Flickr

    20170115_122452 by colorado_baja, on Flickr

    20170115_122439 by colorado_baja, on Flickr

    For the intake I'm using the top half of a GMT800 air box. I was going to use the whole box but with the dual battery setup its just too big. I really don't like cone filters so I opted to make this one fit. Planning on building a bracket to hold it in place, the old air intake was bolted to the fender liner right there so it shouldn't be too hard.

    20170115_150449 by colorado_baja, on Flickr

    The intake will sit a couple inches higher then it is in this pic, its just sitting on the fender liner.

    20170115_150403 by colorado_baja, on Flickr

    20170115_150519 by colorado_baja, on Flickr
    197? DJ-5 LHD & 4wd

  2. #122
    Colorado_Baja's Avatar
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    I decided to weld my throttle cable bracket to the spacer. Just made life easier.

    20170204_094803 by colorado_baja, on Flickr

    I used all the Lokar parts on this end to hook it up to the 454 TB.

    20170204_095556 by colorado_baja, on Flickr

    The cable on the left is the Lokar cable end, the one on the right is the stock GMT400 end that hooks to the pedal. Luckily I didn't need the stock cable anymore so I clipped it to get the little plastic end and slid it onto the Lokar cable replacing the aluminum fitting it came with, worked perfectly.

    20170201_093600 by colorado_baja, on Flickr

    Cable routing

    20170204_095615 by colorado_baja, on Flickr

    20170201_130333 by colorado_baja, on Flickr

    Welded up my intake tube.

    20170131_181026 by colorado_baja, on Flickr

    I don't like cone filters so I decided to keep what I could of the stock air box. Makes replacing filters cheap and easy.

    I cut the bottom of the stock air box off leaving only what I needed. the sealing surface for the filter and the 4 bosses the lid screws onto.

    20170204_102421 by colorado_baja, on Flickr

    I made a 3" splash guard and welded some tabs to it to mount it to the fender liner. I still need to drill some holes and find some hardware.

    20170204_145255 by colorado_baja, on Flickr

    The splash guard is pretty flush with the bottom of the fender liner so it should keep the filter pretty clean.

    20170201_125135 by colorado_baja, on Flickr

    I decided to go with GMT800 electric fans from a Tahoe. Took some trimming but I have the shroud flush with the radiator, still need to fab the upper and lower mounts but everything clears... just barely haha.

    20170204_144216 by colorado_baja, on Flickr

    Everything crammed in there.

    20170204_145349 by colorado_baja, on Flickr

    20170204_145311 by colorado_baja, on Flickr

    20170204_164025 by colorado_baja, on Flickr

  3. #123
    tacotoy's Avatar
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    Dude, those are awesome welds! Looking good!
    hookers and blow!

  4. #124
    I showed my Miller 210 those welds. It slapped me.

    Mark

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    ''Wise men speak because they have something to say; fools, because they have to say something.'' - Plato

  5. #125
    Colorado_Baja's Avatar
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    Quote Originally Posted by tacotoy View Post
    Dude, those are awesome welds! Looking good!
    Quote Originally Posted by ScaldedDog View Post
    I showed my Miller 210 those welds. It slapped me.

    Mark

    Sent from my SM-G935V using Tapatalk
    Thanks guys. I've been welding aluminum since 07 and have owned a small business that specializes in production and prototype aluminum parts and cast aluminum repair for the last couple years. Needless to say its my favorite material to make random things out of.

  6. #126
    Colorado_Baja's Avatar
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    Got a chance to work on the upper fan mount this week. Kills 2 birds with one stone covers the top of the radiator, and the gap in between it and the core support and has 2 studs for mounting the top of the Efan..
    Since I cant bend a piece of 1/8" aluminum that wide I decided to gusset and weld a plate that bolts to the core support to a piece of 3x1.5" aluminum channel. I used a couple left over exhaust manifold studs and nuts for the upper Efan mounts.

    20170218_141704 by colorado_baja, on Flickr

    20170218_143127 by colorado_baja, on Flickr

    Need to get fender washers to go under the nuts.

    20170218_143008 by colorado_baja, on Flickr

    Final fit for everything in the front half of the engine bay. Washer bottle, both battery trays, radiator, fans, throttle body and intake.

    20170218_153012 by colorado_baja, on Flickr

  7. #127
    Colorado_Baja's Avatar
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    On to the exhaust. Local shops wanted between 5-800 to make me a new Y pipe. I'm way to cheap for that so I opted to build my own.

    The old small block Y pipe had 2 1/4" down pipes into a single 3" tube with this gigantic old cat converter.

    20170228_133411 by colorado_baja, on Flickr

    I had the exhaust shop flare some 1' pieces of 2.5" tube to mate up with my doughnut gaskets. Once I hung the down pipes, built the cross over and brought the 3" up to span the distance that the cat used to occupy it looked like this.

    20170304_120043 by colorado_baja, on Flickr

    After much thinking, mitering, deburing and tacking this is what I came up with. Its basically a copy of the small block Y pipe with 2.5" down pipes and no cat.
    I tucked it up tighter then the factory small block. I left about an inch around the front drive shaft, should still be able to get it out easily with the Y pipe in place.

    20170304_170636 by colorado_baja, on Flickr

    20170304_171126 by colorado_baja, on Flickr

    I used an extra 3" V band for the connection in the back so it'll be easy to remove the Y pipe later if I need to. The flanges are cut out of 3/8" mild steel.

    20170305_143452 by colorado_baja, on Flickr

    Still need to do a bunch of welding on the pie sections but the hard work is done. I also need to fix a bunch of shoddy work farther back on the exhaust and add a muffler.

  8. #128
    Clod Hopper's Avatar
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    bee-youtifull!
    Proudly un-offended.

  9. #129
    Camp Cook Geek cheftyler's Avatar
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    "Blow and Hookers can change the World. - Gags
    Quote Originally Posted by scottycards View Post
    MJ has no lethal dose. You might crawl under your couch and eat M&M's all day if you get too high, but it ain't gonna kill you.

  10. #130

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    How much work would pre-bent pieces save you? Angles look close to 90s and 45s.

  11. #131
    Colorado_Baja's Avatar
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    Quote Originally Posted by CSP View Post
    How much work would pre-bent pieces save you? Angles look close to 90s and 45s.
    I could have used pre bent pieces but I don't think it would have saved me any time or money.

    The angles look close to 90 and 45 but if I held a square up you'd be able to see how wonky it is. The the bend I posted the close up of is made of 8 10* sections making roughly an 80* bend +/-3* or so because my saw is not awesome. The one above it is 6 sections plus a little spacer so roughly 60*.

    I've always been better at additive process vs subtractive. Sounds easy enough to just take 10* off of a pre bent 90 but you only get one chance to cut that bend on the right plane and get it tight. If your off on the location of your heel/toe by even a couple degrees it creates gaps or you scrap the bend all together.

    An extra 1/4" gap makes all the difference on this piece. I find it a lot easier to be able to make any compound angle I need, if I mess up a cut or a couple sections I can make more since straight tube is plentiful and cheap.

    Looks like a lot of welding but I guess it's all relative, longest time I've spent working on the same weldment was 62 days so 4 8hr days banging this out isn't so bad.
    Last edited by Colorado_Baja; March 8th, 2017 at 07:07 AM.

  12. #132
    The Original Opie-Gone-Bad!!! Aaron's Avatar
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    Keep up the good work

  13. #133
    Colorado_Baja's Avatar
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    Thanks for the complements guys! Getting close to starting it. After the exhaust I need to do fuel lines/pump and install the harness/ecu when I get it back from Howell.

    Well I thought I was clever enough to get this welded up without building a jig. I witness marked all the joints and broke it apart so i wouldn't be putting a ton of heat into the long pipes. I welded up the bends and all the witness marks lined up, I thought I was home free and this is where I made the critical error. I forgot how much shrinkage can occur, I should have rechecked the fit before welding the long pieces to the bends. Had I done that I would have found the cross over 3/8" short and the doughnut gaskets impossible to seat. Unfortunately I had to split the cross over and extend it to get it fitting correctly. It doesn't look as elegant as my original but I only spent a couple hundred fixing my whole exhaust and learned some things so I'm calling it success.

    Got the 02 bungs welded to the down pipes.

    20170309_143335 by colorado_baja, on Flickr

    I bought this truck from a high school kid and in his infinite wisdom he did a muffler delete on it (leaving that enormous cat up front) and did a crappy job of welding the straight pipe in. I got rid of all that and put an Allied street max muffler on it. Guy at the exhaust shop said it wont be too loud. Its straight through perforated tube with a glass packed case. I'm skeptical but it was cheep, only review I could find online is V6 Mustang guys complaing about them being too quiet so we'll see.

    20170308_140531 by colorado_baja, on Flickr

  14. #134
    Colorado_Baja's Avatar
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    Got the Y pipe painted and installed for the last time (hopefully) today.

    20170311_140919 by colorado_baja, on Flickr

    20170311_144232 by colorado_baja, on Flickr

    20170311_144250 by colorado_baja, on Flickr

  15. #135
    tacotoy's Avatar
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    dude....

    that exhaust looks amazing

  16. #136
    Colorado_Baja's Avatar
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    Quote Originally Posted by tacotoy View Post
    dude....

    that exhaust looks amazing

    Thanks! Pretty happy with the end result especially for the $$. Ive built some downpipes and short exhausts for turbo cars before but nothing this complex.

    Did the fluids in the front diff, T case and rear axle today.
    Need to get some of the special NV4500 fluid from the dealer to do the transmission.

    Love the 14 bolt
    20170313_150509 by colorado_baja, on Flickr

    Good to confirm this truck is 4.10. The RPO sticker in the glove box is worn completely off.

    20170313_150538 by colorado_baja, on Flickr

    Got it all buttoned up.

    20170313_152551 by colorado_baja, on Flickr

  17. #137
    Quote Originally Posted by Colorado_Baja View Post
    Got the Y pipe painted and installed for the last time (hopefully) today.

    20170311_140919 by colorado_baja, on Flickr

    20170311_144232 by colorado_baja, on Flickr

    20170311_144250 by colorado_baja, on Flickr
    Holy smokes that's alot of extra welding then needed. Came out nice, but what a hard way to do it. I buy prebends in 90s and 180 degree bends. You can get the same results with less cuts and welds. You got it done and came out right. Just giving an opinion on an easier way.
    CJ/buggy,FI406,465,205,D60,14boltFF on beadlocked 39.50 swampers.See build.
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  18. #138
    Colorado_Baja's Avatar
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    Quote Originally Posted by cheepin View Post
    Holy smokes that's alot of extra welding then needed. Came out nice, but what a hard way to do it. I buy prebends in 90s and 180 degree bends. You can get the same results with less cuts and welds. You got it done and came out right. Just giving an opinion on an easier way.
    Obviously I could have used pre bent mandrels. You guys act like I dont know they exist haha.
    This is cheaper and easier for me, plus a little welding practice never killed anyone.

    My previous explanation from above.
    Quote Originally Posted by Colorado_Baja View Post
    I could have used pre bent pieces but I don't think it would have saved me any time or money.

    The angles look close to 90 and 45 but if I held a square up you'd be able to see how wonky it is. The the bend I posted the close up of is made of 8 10* sections making roughly an 80* bend +/-3* or so because my saw is not awesome. The one above it is 6 sections plus a little spacer so roughly 60*.

    I've always been better at additive process vs subtractive. Sounds easy enough to just take 10* off of a pre bent 90 but you only get one chance to cut that bend on the right plane and get it tight. If your off on the location of your heel/toe by even a couple degrees it creates gaps or you scrap the bend all together.

    An extra 1/4" gap makes all the difference on this piece. I find it a lot easier to be able to make any compound angle I need, if I mess up a cut or a couple sections I can make more since straight tube is plentiful and cheap.

    Looks like a lot of welding but I guess it's all relative, longest time I've spent working on the same weldment was 62 days so 4 8hr days banging this out isn't so bad.
    Got my fuel system sorted out, this is what my filter and lines looked like before.

    20170314_150755 by colorado_baja, on Flickr

    I used the workhorse fuel lines part numbers W0000540 and W0000539. I was lucky they were long enough to reach my fuel filter so I replaced that with Napa #3623. It has the same fitting on the back but a rolled bead on the front like the fitting on the fuel rail allowing me to hook the workhorse line right to the filter.
    For the return I got a repair part from napa to get another rolled bead fitting that fit into the workhosre line and used a small section of soft line to connect it to the original return line.

    20170319_132533 by colorado_baja, on Flickr

    Also got a new fuel filter mount at the yard, someone cut mine at some point to get the filter out I would guess.

    20170319_132548 by colorado_baja, on Flickr

    Replaced my pump with a higher volume unit to supply the 8.1 with all the fuel it needs. The pump that was in there had original hardware on it and plenty of small debris in the sock.

    20170315_153043 by colorado_baja, on Flickr

    While I was at the junkyard I came across a pretty nice square headlight grill.

    20170317_121934 by colorado_baja, on Flickr

    I'm not very patient when it comes to paint and body work so it has some sketchy tape lines and over spray but over all it matches my beat up truck pretty well. A coat of dirt and will look right at home.

    20170319_121925 by colorado_baja, on Flickr

    Still need paint and install the piece of red trim that goes in between the bumper and grill, I just had to see what it looked like on the truck.

    Here's the old grill.

    20150614_175146 by colorado_baja, on Flickr

  19. #139
    Colorado_Baja's Avatar
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    Got the harness mostly routed.

    20170412_154849 by colorado_baja, on Flickr

    Installed the LED for the check engine light in the spot where the Service Engine Soon light was in the dash.

    20170422_150044 by colorado_baja, on Flickr

    Tried to start it up and wasn't getting fuel, pulled the injectors to find this.. I guess I should have known the motor sat for 2 or 3 years.
    I sent the rail and injectors to Injector RX in Houston TX. They did an awesome job cleaning them up.
    Also cranked the regulator up to 67psi at idle.

    20170428_140522 by colorado_baja, on Flickr

    Unfortunately when removing the rail and injectors I lost an o-ring and hat down in the head so I had to retrieve those.

    20170428_135329 by colorado_baja, on Flickr

    Inside is nice and clean

    20170428_150203 by colorado_baja, on Flickr

    I think the intake weighs 35lbs..

    20170505_150848 by colorado_baja, on Flickr


    After all that I got it started! Click for video.

    20170506_153809 by colorado_baja, on Flickr

    Lifters are ticking pretty hard from sitting from so long and I have an exhaust leak on the driver side.

    Who knew you could install the gasket up side down..

    20170510_102428 by colorado_baja, on Flickr

    20170510_102446 by colorado_baja, on Flickr

    Then the electrical shenanigans started.. I had a bad ground on the core support that was causing the wipers to run when ever you turned on the headlights or the left turn signal. I ohmed out all the grounds with the truck off but when you started moving power around things got weird in a hurry. Took a couple days to figure out but its all good now. All my factory gauges and electronics work just like they did before, plus massive TQ.

    Put 100 miles on it in the last 2 days, so glad to have my work truck back!

    20170516_165532 by colorado_baja, on Flickr

    Still have a random DTC to figure out, nothing that effects drivability. Need to get it hooked up to a tech 2 so I can look at some misfire logs and what not.

  20. #140
    tjjared413's Avatar
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    Great up date man!!! Sounds nice and tame!
    rig- 04 TJ for going to the malls and tow pig- 15 F350

  21. #141
    That's awesome!

    Gives me ideas for the 8.1 in my brothers garage.
    Cages: '08 Dodge 6.7CTD, '08 Nissan Xterra Offroad
    Bikes: '05 GSXR 1000, '98 WR400

  22. #142
    Colorado_Baja's Avatar
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    Quote Originally Posted by tjjared413 View Post
    Great up date man!!! Sounds nice and tame!
    Quote Originally Posted by Grant H. View Post
    That's awesome!

    Gives me ideas for the 8.1 in my brothers garage.
    Thanks!

    Its a lot of fun in this truck, Ive been easy on it the last couple days breaking in the clutch. Centerforce recommends 500 miles before applying full throttle or hauling with it so I've been trying to stick to that. Probably haven't applied more then 60% throttle and it romps thru traffic easily when you row the gears.
    250 miles down, should be done by the end of the week.

    Ill be keeping a detailed mileage log, I think it'll get the same or slightly better mileage then I was getting on the 350.

    You had to spin the nuts off the 350 to get it to go anywhere, with the 8.1 I'm shifting at lower rpms and spend most of the time idling around at 1500ish rpm. Don't have to worry about keeping it in the power band since its all power band haha.

  23. #143
    tacotoy's Avatar
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    Quote Originally Posted by Colorado_Baja View Post
    Still have a random DTC to figure out, nothing that effects drivability. Need to get it hooked up to a tech 2 so I can look at some misfire logs and what not.
    Do you have a tech 2? Or know where a good one could be had from? I would like to get one for my sierra and the wife's yukon

  24. #144
    Colorado_Baja's Avatar
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    Quote Originally Posted by tacotoy View Post
    Do you have a tech 2? Or know where a good one could be had from? I would like to get one for my sierra and the wife's yukon

    I think a friend of a friend has one, I need to ask around. I looked around online a little and all the legit looking ones I saw were big money, some for a lot less on sketchy looking china based websites.

  25. #145
    Colorado_Baja's Avatar
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    Little update.. Been piling miles on the truck since getting it on the road. Averaged 13.77MPG over the first 1300 miles.

    The state of Colorado finally got around to making my plates, I wanted "8.1L" but that isn't an allowable combo in CO so I got the next best thing.

    20170615_111736 by colorado_baja, on Flickr

    20170615_111721 by colorado_baja, on Flickr

    Got all the new AC parts installed, new accumulator/drier, lines, compressor and orifice tube.

    20170620_211654 by colorado_baja, on Flickr

    Looks like it was made to clear my throttle cable bracket. Got super lucky on that haha.

    20170620_211708 by colorado_baja, on Flickr

    Ive since moved this relay over and trimmed the relay cover to clear the AC line.

    20170620_212617 by colorado_baja, on Flickr

    I took it to a shop to have it vac'ed out and filled. They were having trouble getting more then 10oz in it and the high pressure side was seeing like 300 psi :Wow1:.. They said the orifice tube must be clogged.. Odd since I put a new one in with all the other equipment.. Could have gotten crud blown into it since I didn't replace the condenser so I'm going to check that first. What really rubbed me the wrong way is I dropped it off on a Thursday evening and was supposed to have it back by 9am Friday so we could hit the road.. Didn't get it back until 2pm after they tried vac'ing it out and filling it 3 times.. Pretty sure insanity is doing the same thing over and over expecting a different result.

    Going to find a new AC shop and revisit it when I have more time.

    Headed up to Terryall Reservoir to camp at one of the spots near the lake. Got there to find out the lake is closed to overnight parking. So we doubled back down Terryall rd to a spot by China wall and got a flat coming up the trail into camp. I need better off road tires haha

    20170623_171137 by colorado_baja, on Flickr

    Got the flat plugged and aired back up, to find the heater not wanting to fire. If its not one thing its another. At least we made it..

    20170623_191211 by colorado_baja, on Flickr

    20170623_181650 by colorado_baja, on Flickr

    20170624_083735 by colorado_baja, on Flickr

    These 2 pics make all the hard work, $$$ spent and problems worth it.

    20170623_203344 by colorado_baja, on Flickr

    20170623_203915 by colorado_baja, on Flickr

  26. #146
    Looking good man! Glad to see she's getting some use. Those 8.1L's are beasts!

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