Rebuild v2.5 - Rally prep

[aloharover]

In April 08 one of my oil cooler lines broke and I didn't notice the loss of oil pressure until the engine locked up.
I have just been too busy to do anything about it until now. A couple of years ago I picked up another 6.2 engine from Mark Freeman as well as all of the 109 body panels that I am using for the V3 build (105" coiler).
So build 2.5 is going to involve rebuilding the new engine, a total redo on the engine compartment of the 88, relocate the batteries, replace the PTO with electric, relocate the heater, an entirely new front end.
The gola is to have it done in time for summer so I can go on a couple shake down trips, and then on to the Rally in October.

Christmas weekend I totally tore down the 'new' engine, measuring ring gap and oil clearances as I went. Everything is within spec so this is just going to be a re-ring, re-bearing, re-build. I am going to use 1984 spec prechambers, injector pump, and injectors in an effort to get 25mpg.

On Sunday morning this is how the truck looked.



And by the afternoon I was here.


I got the old engine torn down. #1 and #2 con bearings are toast. Crank journal is torched, but it looks like the damage isn't too bad. In the future I will be able to turn the crank .030 and get two new con rods. Everything else still looks good to go. So this block will end up getting rebuilt with lo compression pistons for V3.


Spent a couple hours new years cleaning all of the 'new' engines parts.
I put the sump, heads, and valve covers back on the old block. using it to do the mockup for new engine mounts. I am trying to drop it 1" and move it back 3"

All of the new engine parts have arrived this past week.

I don't know if I am going to rebuild the engine this weekend or work on the engine bay.

[Colorado Scott]

Subscribed!

No turbo for this one? What will your final HP & torque be?

[aloharover]

No turbo, just tring to get it on the road. The 105" will have a turbo.

The current engine with all the high performance mods has 300ft tq
This will be more stock ish for a 1984, like 250ish.
i am going for fuel consumption.

[aloharover]

Today I cleaned up my garage and made enough space to actually bring the 88 inside. Go tired of working in the driveway.

Didn't get much actual work done. All the wiring removed from the dash, inside and out.
Made my final measurements, and cut the bulkhead.

The engine is going to be able to move back a whole 5"

[aloharover]

Old Sheet metal removed



Also stripped the dash



I have 1" clearance on each side.
Enough room to remove glow plugs, or the injectors if needed




There is over an inch between the back of the engine and the face of the bulkhead.
For those that never looked before the back or the engine was basically flush with the very front edge of the foot well, so its really recessed now
Unfortunately with the power steering box there isn't room to move the rad to the rear, so no Series front end on this one.

[aloharover]

I have made the card board templates for the new sheet metal.
I am thinking about making the main flat panel removable. 1" lip around the opening.
The new tranny tunnel I am building is going to be flush with the top of the seat box I am thinking. Stock width at the seat box, but much wider at the front.

I am using a stock HMMWV header for the right side, and am rebuilding the left side to fit.

Next weekend I will build the engine, hook up the tranny and t-case and make the new motor and tranny cross members.
Then fibalize the exhaust and then make the tranny tunnel

[Colorado Scott]

Moving quick! Are you going to use a header kit or bend up your own tubing?

[aloharover]

Moving quick! Are you going to use a header kit or bend up your own tubing?

The drivers side hummer header. As you can sort of see, the pass side is designed as just a simple collector and then dumps straight back, its really a nice head hugger design.
The drivers side bends down and out. If you look at the photo of the empty engine bay taken from the LF tire, you can see how the bulkhead outrigger was boxed. The exhaust pipe went down outside the frame using the stock drivers side.
So I am taking that and cutting all four cylinder tubes shorter and then got some 2.5" pipe. I am making my own version that will mirror the passenger side.

[aloharover]

Been very busy with work and replacing the damaged door on the GMC, burnt out window motor and door lock actuator in the other door so that it's ready to sell.

I have started doing the sheet metal work. Got most of the pieces cut and bent. Got my co bottle refilled and some new tips this past week. Want to try and get the bulkhead finished today.

[aloharover]

Ended up spending most of the afternoon putting together an FAL.

I got some of the sheet metal stripped, I had coated the Bulkhead with pickup bed liner. Stuff is as tough of advertised. Wire wheel at 30,000 RPMs and it's slow going.
It also catches fire pretty easy and stinks to high hell if you don't get it all off before starting to weld. lol