Engine rebuild and power mods

[terranosaurusdoug]

Mate that sounded healthy, sweeeeeeeeeet

 

[bbbmmm55]

Great work. Been reading the offroadexpress.kiwi forums and it seems adding a mechanical pump is a fairly common mod over there.

Your trucks going to be a monster, will you still have the lpg injection hooked up?

 

[makeitfit]

LPG absolutely
Hope it all goes well so I can get it on rolling road ☺

 

[terranosaurusdoug]

You had anymore tinker time mate?

 

[makeitfit]

No not a sniff. Being rebuilding a Mazda Bongo camper for my daughter

 

[Fez_uk]

No not a sniff. Being rebuilding a Mazda Bongo camper for my daughter

how rusty is it :lol

 

[terranosaurusdoug]

No not a sniff. Being rebuilding a Mazda Bongo camper for my daughter

Pop top?

 

[bbbmmm55]

With theses manual pump conversions, doea it matter wether you use the pump from a manual or automatic? Doesnt one of them take the speedo reading from the pump directly and would have matching an automatic pump to a manual car cause issues?

 

[solarman216]

As far as I can see it will make no difference, Rick

 

[makeitfit]

how rusty is it :lol

It was very
Now all smashing again. Better than new

 

[makeitfit]

Pop top?

Electric pop top yes and electric curtains :lol

 

[makeitfit]

With theses manual pump conversions, doea it matter wether you use the pump from a manual or automatic? Doesnt one of them take the speedo reading from the pump directly and would have matching an automatic pump to a manual car cause issues?

Makes no odds that I can tell yet. I'm leaving the ecu attached but yet to solve tacho

 

[luke1987]

Thought there was a tacho output on the back of the manual pump? It would just be a case of making a tacho driver then to get the resistance right so it reads correctly.

 

[makeitfit]

Thought there was a tacho output on the back of the manual pump? It would just be a case of making a tacho driver then to get the resistance right so it reads correctly.

That will be handy, I'll have a look again tonight.
I have two wires on the back as I remember. One red one , stop solenoid, and a black one which I was told to be NATS.
I powered them both up 12v pos and the engine runs .

 

[luke1987]

Nats shouldnt be on the back of the pump, just a stop solenoid. Which is controlled by the nats. Coyld yo sebd me a pic of the back of your pump and ill work the wiring out for you

 

[makeitfit]

Found a jar of Mojo on the shelf

Evenin all, been a while, sorry about that, I've had a shed load of issues to deal with all of which were terribly important I'm told :lol
Any way I'm back on the engine
Luke, I can only see two wires on the pump. One red and one black. I had to 12v pos to both to make the engine run. If you can make sense of them great , rev counter even better :clap

 

[makeitfit]

It's going in

Right then, where was I ?
Ah yes an engine on the floor ? That's not a good place for it :lol About that, I'm to do something .
Got the truck on the lift and the engine on another lift and boom here we go
Poor thing all cambered out and ready to receive

We got the engine out in a rush and not according to any books, lol , so I've now undone the gearbox and slid it back. Suspended on the torsion bars . Seemed much easier than faffing with the front diff again.

D
Hanging around looking for somewhere to go :naughty

At last, there it is back at home Engine mounts lined up first hit too.

Continuing on with the mods. I needed to take the micro switch off my old fly by wire throttle and fabricate a new mounting onto the mech pump throttle pedal . Here's the TDi one

I,ve welded on a little bit of metal to hold the micro switch in the right place. Also added a bolt just to make the return spring work harder.

Ready for fitting. Now has the micro in just the rightplace. This is to switch off the LPG on close throttle by the way.

Not the most interesting of mods, but fly by wire to mech pump = this

Who knows what the switch was on there in stock form please ?
Somewhere along the winding road, I lost the ruddy spigot bush, so I'll be shopping for that tomorrow :doh

 

[makeitfit]

A lot more finishing off old projects tonight. More of that elsewhere.
I did rebuild the front power loom though. It had many years of oil, mud and diesel contamination.
All pretty now

Spiggot bush arriving in the morning fingers crossed , then the gearbox goes back :thumbs

 

[makeitfit]

Sheesh, how can one little part cause me so much bother ?
Today the spigot bush arrived from Milners. £3 bargain, BUT on checking it's credentials I found it to be much bigger than the hole it lives in
I know it's meant to be a friction fit but do these sizes seem right to you guys ?
Crank hole diam (int) 20.6mm Spigot o/a diam 20.7mm
I thought too big but went for a friction wallop with Mr Hammer but absolutely no way was that bush going in
I first though a decent drift is needed, so made up the obligatory socket/drift tool solution.

11mm socket was almost bang on

Tried again but still no joy, so now I reckoned freeze the devil
Bought a bag of cold from the garage and put my bush on ice :sly

That worked a bit, about 0.03mm not enough though.
A friend on faceache suggested a pipe freeze kit. Brilliant, and I have such stuff, so went to town in super freeze mode :naughty

Ice, Ice baby

This got me to 20.65
I reapplied the bush to my drift and wallop wallop , boom, right in there :clap

All that nonesense took way too long, so long in fact the boy found a patch he wasn't happy with , cut it out and rewelded it :lol
Maybe tomorrow I'll actually get the box back on :splif

 

[solarman216]

Should not be that hard to get in Pete, hope the first motion shaft enters OK, Rick