S157 FWL - Y61 LWB 2.8 Nissan Patrol GR

[Banshee]

Failure the DPUK Way!!!

Modded my slide hammer and gave it a go, it pulled the threads off the bar 3 times until on the 3rd time it took the thread inside the plug with it too now as I hardened the bar by torching it and then quenching in water

 

[solarman216]

I did say in the beginning take it to a machine shop with the kit to do it, Rick

 

[Flying Torquewrench]

Any progress Banshee?

 

[Banshee]

Any progress Banshee?

Some, plenty pics, but no further forward.

I'll drop a cheeky update now as you've asked

 

[Flying Torquewrench]

Cheers Banshee, the more pics the better even if there is no progress.

By the way, if you ever need a helping hand I am only 20 minutes away at Junction 2 M42.

 

[Banshee]

As promised, I have made a little more movement with the Patrol engine but I'll be honest I have been terrified to go anywhere near this!!!

First things first, I bit the bullet and ended up purchasing this Laser Broken Glow Plug Removal kit. I'd watched multiple videos online and this seems to be a good piece of kit.

Quick measure of an old plug with the calipers told me that I needed to use the larger 9mm shouldered drill bit

Typically, the plug that has snapped hasn't got the best of access due to the rocker cover breather outlet being in the way, I suspect this is how I broke it in the first place as no matter how hard I tried I just wasn't on it true enough :doh Lesson learned :question

Rocker cover off then...............

All armed and ready as I thought I'd ever be I decided to start drilling and soon ran into another issue :doh

I managed to get about 2mm through the glow plug body material before I felt like I'd "bottomed out" on something. It appears that there is still a large amount of Ceramic tip still inside that the drill bit will not touch at all :doh :doh :doh I was drilling straight and true for a good few minutes and the bit didn't get any deeper, when I drew it out of the hole and inspected inside and on the end of the bit, I could see that I'd managed to generate the tiniest amount of grey dust that looked like ceramic swarf, the HSS bit is clearly not man enough to get through the ceramic tip........ DAMN :nenau

I grabbed one of the old plugs and decided I'd go at it the same way I was attacking the one in the head but in the vice as to not do any unnecessary damage to the engine!!!

Low and behold!!!! The HSS bits hardly even break the surface of the ceramic :banghead:

I left it there and cried a little that night :lol :lol

Luckily, my Uncle Elt had been down the motor factors on Saturday morn and found some Silverline ceramic drill bits that also had hex bodies that I will be able to slot into an extension bar still giving me the clearance I need to get on straight.

I'll keep you all posted with progress as I'm going to have another go this week hopefully :bow

 

[jims-terrano]

It’s like it wants to cause as much trouble as it can. Never mind mate when you get it up and running think about the sense of achievement.

Good luck

 

[Flying Torquewrench]

Whilst I agree with Rick that a trip to a specialist would have been quicker and possibly not much dearer. I have the same issue that I am stubborn and like to deal with issues myself.

In the 5th photo it looks like the injector port is open, be careful that no swarf falls into the the cylinder.

Will be following your thread.

 

[Banshee]

It’s like it wants to cause as much trouble as it can. Never mind mate when you get it up and running think about the sense of achievement.

Good luck

Whilst I agree with Rick that a trip to a specialist would have been quicker and possibly not much dearer. I have the same issue that I am stubborn and like to deal with issues myself.

In the 5th photo it looks like the injector port is open, be careful that no swarf falls into the the cylinder.

Will be following your thread.

I hate being held over a barrel by a "specialist" he's only human like me and had to learn somewhere too, it's not like he's got a special limb that I don't have that does a specific job :lol

Progress on this is going to be slow now due to having the remedial work completed on my garage by Bellway

 

[solarman216]

Problem with glow plugs is they all have hard undrill-able metal in them to varying degrees and of course the ceramic ones have "ceramic" now you good machine shop will have the likes of diamond drills and induction heating at their disposal stuff we can only dream of, and if they accidentaly damage the threads or the seat they have the means of a back to original repair, I only ever tried one and failed so should I be faced with another it would be machine shop, Rick

 

[Banshee]

Still not any further on with getting that damned glow plug out but with all this time off work I will certainly be trying my hardest next week but at the moment I'm trying to spread my efforts evenly :naughty

Did manage to get my hands on a lovely Steel Front Winch Bumper from Geoff on here :thumbs

So I got to work fitting that just to get the juices flowing fro the Patrol again :augie

With some help from Barrbeast, I knew what needed cutting up front in order to fit it so out came the angle grinder :naughty

Some more pics of it as I was inspecting it in good light,the light unit quality is awesome and it weighs an absolute tonne!!!

Here we go..................

Lovely :naughty :thumbs

Wanted to see it with the winch fairings......

And then a plate as well, although not mine I might add

Didn't like that idea so now I've gone for a bonnet sticker :naughty

What do you guys think? I know it looks a bit wonky at the moment but it's not been tightened up and profiled yet as the engine still needs to be dropped back in but I' hoping it might get a nice powdercoating before that :naughty

 

[elty001]

Looks the business with that fitted mate:thumb2
Only thing I'm not keen on the two big rubber bump stops:nenau
When normal service is resumed will be able to sort out getting it powder coated :thumb2
Them 35's suit it so well,you keeping them on it???

 

[Flying Torquewrench]

Looks very good!

 

[Rarche2002]

Looks awesome that.
Just out of curiosity how much was the bumper.


Sent from my iPhone using Tapatalk Pro

 

[FerdiNL]

Really looks though with the new bumper and big tyres!
Are you gonna change the rear bumper as well?

Looking forward for some pictures with this truck rolling on it's own power

 

[Banshee]

Looks the business with that fitted mate:thumb2
Only thing I'm not keen on the two big rubber bump stops:nenau
When normal service is resumed will be able to sort out getting it powder coated :thumb2
Them 35's suit it so well,you keeping them on it???

I kind of like the big rubber dampers on the front, I can't quite figure out if they have been attached afterwards though, can't wait to get it fresh powdercoated :naughty

Looks very good!

Cheers mate

Looks awesome that.
Just out of curiosity how much was the bumper.

It was a total bargain at £150

Really looks though with the new bumper and big tyres!
Are you gonna change the rear bumper as well?

Looking forward for some pictures with this truck rolling on it's own power

I'm not sure on the rear bumper yet, I like the standard look of the back of the Patrol, and haven't really seen any Y61 steel ones that I like the contours of, if I'm honest, I'd much rather just do what Barrbeast did and run with no rear bumper and cut the corners off

 

[Banshee]

2021 The Year of the Patrol?

First Patrol post of 2021......

I've found a 3rd engine :lol

The original is in bits and I scrapped the head on the 2nd one snapping 2 glow plugs off in it and haven't got around to sending the head away for someone to try and salvage it :doh

I'll be getting the new engine soon hopefully, Barrbeast is a good egg and saw the guy offering it for sale on Facebook as he's fitting an RB25 in his like Mr K did.

Engine is still in his truck and I'm waiting for some videos of it running :naughty

 

[Barrbeast]

Glad to help bro

 

[Banshee]

Head Update

I sent my worst head away to a place called Blue Star Engines in Balsall Heath in Birmingham.

Mr Singh came recommended by a few local garages as the go to guy whenever they have any work they weren't equipped for such as this and head skimming etc

I got a call from him last night to tell me that they had been able to successfully extract 2 of the broken glow plugs however the 3rd was STUCK STUCK and they can't remove. He told me that if they can't get it out nobody can.

He's apparently left the head in a usable condition and the extraction process they used should mean that it still holds compression, I should be able to use the engine with just 5 glow plugs but me being, OCD Zac, I can't let that be........

I'll be risking my other head with Mr Singh on my spare engine as this only has one broken glow plug and I'm hoping I haven't damaged the threads meaning it needs to be helicoiled etc :nenau

It's looking ever more likely though that this truck isn't going to end up with an RD28 going back in it any time soon. I'm hugely put off by the engine now........

A replacement.........

The TD27 is too underpowered for a LWB Patrol with a kerb weight of over 2T

I was considering the ZD30 as there are lots of LWB Terrano's I could use as donor vehicles including wiring, gearbox etc etc, I still don't even know if this would be a totally viable DIY conversion but if it can be pulled off I certainly think it could be the cheapest

TD42???? Don't get many that aren't imports and STUPID SILLY money, I'll be honest I think I've only ever seen perhaps 1-2 TD42 Y61's in my life :nenau

I'm really really not that keen on going down the M57/OM606/Duramax route as you really are talking stupid stupid amounts of cash and to achieve a build like that I'd want to do as much of it as I could myself which at this point in my life, I still don't think I would be capable of.

Discuss amongst yourself boys :nenau :bow

 

[makeitfit]

Matey boy the 2.7 is capable of plenty of power and often used in Patrols.
If only you were on faceache I could link you to several compound turbo units, plenty on VNT turbo etc.
Easy swap too.
Then there's the Q32 engine. Big brother of the 2.7
At work now .....