The Jalopy Journal
Intake hard pipe clipped for the flange, pipe turned on the lathe with retaining bump for spigot and welded in place. The ø2.5" 90° silicone hose...
Thermostat housing had a blanking plug in one position; Now modified for stock DT bulb to drive the temp gage. [ATTACH] [ATTACH]
Transmission cooler mounted on frame cross member under cab. [ATTACH]
About 2 days print time, split into halves to fit on the printer bed.
Nice thing is the model is fully parametric and stable, so all that is 5 min worth of mouse work: [ATTACH] [ATTACH] [ATTACH]
Moving back from 2-3 to 3-4 gives lots more room for the intake pipe. Will move the foot up 1" to give clearance for the wastegate against the...
More detail on what isn't modeled, and yet is in the way: Oil dipstick tube and frame-wastegate clearance. [ATTACH] [ATTACH]
So there's good reason for printing these test items out. Seems like a brilliant design at 6AM, 100 miles away from the truck- and slightly less...
Since the intake is going to exit downwards to get to the intercooler, a straight shot between frame rail and engine while avoiding the starter...
So the turbo foot is correct, the manifold studs line up and the manifold generally fits. Block side plates stick out 1.5", more than expected so...
Got the printed manifolds in place for a fit check: [ATTACH] [ATTACH] [ATTACH]
48 hours and 37 minutes later we have two halves of the manifold ready. They fit properly on my spare head which is always a nice thing to see....
A friend of mine suggested to do a compound turbo. Hmmm [ATTACH]
Low and rear manifold is also possible. [ATTACH] [ATTACH] Comparison of low/rear vs high/front for the turbo location: [ATTACH]
There is also the option to flip the turbo up. Am considering this as a fabricated part, or also as a printed and cast piece. Issue is that I'm...
More detail on why it has to be this way... Stock location has the compressor wheel rearwards, which puts the compressor into the cab firewall....
First go with the CAD is high and forward. Changing the turbo foot from the stock Isuzu to be TD04 from a Saab and moved between cylinders 1 and...
Turbo location is an issue. As stock, it is not possible to simply bolt on due to the steering column and brake master locations. Two options,...
Steering connected. Nice to be able to turn the wheel and have wheels move. [ATTACH]
As I left her, ready for the fuel tank to be fitted. I have an actual Isuzu in frame tank, with the correct brackets, so next trip will be...
There's a lot going on here that isn't visible- the air bags needed adapter plates to spread their force to the frame. And with lots of rivet...
Shock upper mounts attached to frame, more drilling. Took the driveshaft out, it needs to get stretched 9.5" [ATTACH]
Leaf brackets had the pivot points moved up by 4" to set the pinion angle correctly. [ATTACH]
Back for more. Lots of frame drilling, bracket drilling, hole drilling. Got the panhard bar mounted, with 1/2" steel plates welded to the axle....
Tires on, axle within 1/16" (±sharpie width) of where it needs to be. Air leaf mounts welded to axle. Still need to grab the panhard bar, and...
Axle delivered. (Forklift makes it so much easier!) Leaf spring was a quarter inch narrower than the new air arm- argh. Plasma torch and grinder...
Air ride arms and brackets mocked up. More chances to drill large holes through high grade steel... Yippee. [ATTACH] [ATTACH]
Took long enough, but progress made. Frame cleared of leaf spring and other brackets. Each rivet had to be drilled through before the plasma...
[ATTACH] [ATTACH] 16" rear rims removed. Accuride 28157's located and purchased. 4 of the 6 brought back to the house... Next desert trip will be...
I have access to one, but can't get access to the rivet head with the bracket still mounted. For the frame holes, absolutely.
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The Jalopy Journal
