Re: Backyard Cummins
 

Got almost nothing done today due to getting sidetracked and everyone coming to talk to me.

Built a cradle for the radiator out of angle, as well as lower mounts for the intercooler. also replaced some of the rusted metal on the support with new sheet, and reinforced it with angle. I figured with everything i removed i needed to make some sort of attempt at strengthening it..

My primer of choice is rust color. Makes this pic confusing.. Tomorrow i plan on finishing this whole setup.

Re: Backyard Cummins
 

Finished up with the intercooler/radiator/fan brackets today. It was alittle tricky getting them all right where i wanted them. Ended up using tons of nuts bolts and aluminum strap. I still need to pull it all back apart to clean it up and paint it.

Anyone need 2.5" aluminum piping? The piping that came with the intercooler is pretty much useless to me, except for 1 piece. I will end up making my own..

Re: Backyard Cummins
 

A few pics of my new found clearances. Have a few inches in front of the engine. Also the stock turbo(that i will be replacing) is very close to the heater box.

Re: Backyard Cummins
 

THE 3 HOUR HYROBOOST! Finally did it today, 1 hour cutting and installing, 2 hours trying to get the brake return spring back in. This is how i did it.

99 chevy 3500 hydrobooster: The bolt pattern was slightly different than the 69's.
-First, i hammered out the studs that come on the HB unit.
-Next, remove snap ring, and large nut with a pipe wrench.

This is necessary to remove the HB mounting plate, which needed to be flipped around for my application.

Re: Backyard Cummins
 

The bolts have the same horizontal spacing as the 69, but different vertical. This makes it easy to utilize 2 of the existing holes on the plate, and the HB unit fits perfectly into the hole in the firewall.

To summarize, the plate needs to be taken off, turned upside down, and flipped backwards. You'll notice a groove on the HB unit that keeps it from spinning on the plate. I was able o use this with NO modification.

Re: Backyard Cummins
 

Here is a pic of the 99 Chevy HB plate next to the 69's studs. Only 2 holes to drill. Easy.

Re: Backyard Cummins
 

Holes drilled, and HB unit stuck in for mock-up of the pushrod..

Re: Backyard Cummins
 

The pushrod on the HB unit is not as long as stock, therefore it will not reach the stock location on the brake pedal. I heald it in place and made a quick template. Used 1/4 inch plate.

I have my instrument cluster out and the interior of the truck gutted. This makes playing around inside the dash wayy easier.

Re: Backyard Cummins
 

This is the first time i have MIG welded, ever. I am impressed with how mush cleaner it is than flux core. I hope this weld holds, as it will be my only hope to stop!

I cleaned up one side of the pedal so that a washer can sit flat.

Re: Backyard Cummins
 

Pics of the modded pedal

Re: Backyard Cummins
 

Here you can see the new pushrod attachment location in relation to the old. I made sure it would have the proper travel and angle prior to welding..

Also, here is the hardware setup i used. Pushrod ID is .625", so i found a brass bearing to fit, ans used a 1/2" bolt inside. washers on either side..

Re: Backyard Cummins
 

Once I put the large nut back on the HB unit, i found that the stock hole in the firewall was too small in diameter by about 1/8" all the way around. I used my cutting disk to turn the hole into a square, sealed it up and am hoping no-one ever sees how ugly it is.

Also, install your brake return spring before putting the pivot-pi through the pedal. I spent wayy too long trying to stretch that damn spring in there before taking it apart again..

Painted and greased all the pivot points. Done.

Re: Backyard Cummins
 

Until next weekend!!

Re: Backyard Cummins
 

Ive been tied up with everything else lately. Finally made some more progress today.

2 weeks ago i got the cummins clutch MC mounted and installed. I had to make a custom mount and weld it to the firewall. I also put in upgraded governor springs in the engine.

Re: Backyard Cummins
 

Due to the fact that I am running electric fans, no fan pulley, and no AC, I had to come up with a belt routing solution. Ended up buying a kit to relocate the tachometer sensor(because diesel tach's dont work off of ignition pulses). The stock tachometer was in the way of my new belt routing.

Once this was done i bought a tensioner pulley at Napa. Of course it wouldnt work with my new serpentine config. It came with a flat pulley(for the back side of the serpentine), I needed a grooved pulley. I ended up finding a pulley for a Powerstroke, and shimming it out to fit perfectly.

Re: Backyard Cummins
 

My new belt config.

Re: Backyard Cummins
 

Finally put on my raised steering arm, and bent up some fuel and brake lines. Im still waiting on a few more couplings and lines, should be here for next weekend.

Re: Backyard Cummins
 

Got around to relocating the filler neck on the tank, and drilling the mounting holes. The tank will be sitting permanently tomorrow. I painted the top just for fun..

Re: Backyard Cummins
 

Looks like your making good progress. I used the same company for my intercooler and piping. In the few miles I put on all is good. I bought there 1000hp intercooler and there 3" tube kit and it works well for my motor. 100hp injectors and the pump cranked up, I can't seem to get it over 1000* on the egt's.

Re: Backyard Cummins
 

Finished mounting the rear tank. Used flat strap, planning on putting in some sort of rubber softener between the steel strap and the tank.

Notice the mounting tabs welded to the tow hitch..

Re: Backyard Cummins
 

Installed the raised steering arm, new steering box, and cleaned/painted the area. Crossover steering would have been unnecessary for my purposes, as i don't plan on articulating the front end to extreme angles..

Also threw in the DPS exhaust manifold.. More Flow! Turbo and intake are on the way, along with hundreds of other parts from yesterday's online shopping spree. Planning on starting this beast in the next 2 weeks!

Re: Backyard Cummins
 

I attacked this beast from all angles this weekend.

-Belt installed, 49.5" 8 groove serpentine
-Fuel/return lines clipped to frame
-radiator support permanently set in frame
-Clutch linkage completed
-throttle cable installed(unfortunately, i broke the firewall mount off of it, new one is on order)
-Set radiator/intercooler/radiator hoses
-Installed some sweet "Trimlok" trim around the radiator to cover up some nasty edges

Unfortunately, many parts did not show up, so i had to wait on the brake system and intercooler piping.

Re: Backyard Cummins
 

Most importantly, i got this beast put in place, and started modifying the downpipe to fit.

Phatshaft 62/65/12 turbo, and 4" downpipe. Hopefully this turbo will give me some good flow, reliability, and somewhat quick spooling.

Also, i had the firewall professionally painted.. By my buddy Rustoleum "semi-gloss" professional enamel.

Re: Backyard Cummins
 

How in the world did you get that steering arm off? I tried heating, Kroil, air chisel, and pounding all to no avail. Project is looking great.

Re: Backyard Cummins
 

Great work! Congrats

Did you do the dowel pin mod?
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