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Old 12-27-2017, 12:13 PM   #351 (permalink)
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Here it is just tacked in place.

In these pics you'll also notice the PSC cooler which I mounted to the bottom of the frame using 1/4"-20 weld nuts from All-Star Performance.
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Last edited by Blak Falken; 12-27-2017 at 12:21 PM.
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Old 12-27-2017, 12:19 PM   #352 (permalink)
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holly shit this is bad ass build
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Old 12-27-2017, 12:31 PM   #353 (permalink)
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Originally Posted by fredycruger View Post
holly shit this is bad ass build
Thanks man! It sat for awhile but its nice to be making some progress on it again. Everything just takes so long...
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Old 12-27-2017, 12:40 PM   #354 (permalink)
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I decided that I didn't want to mess with the added complexity of the controller for the He351VE (more to go wrong), so I sold it and bought a different turbo. For this rig I my goal is to have the quickest spooling turbo possible so I went with a Holset He351CW. The CW was used in the 2004.5-07 commonrail Dodge's and spools quickly due to its 9cm exhaust housing. I plan to upgrade this turbo with a 67mm turbine and 62mm compressor to make more power and keep EGT's down.
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Last edited by Blak Falken; 12-27-2017 at 02:39 PM.
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Old 12-27-2017, 12:47 PM   #355 (permalink)
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I designed mounts in SolidWorks to mount the PSC Reservoir and the Proportioning Valve to mount on the hydroboost.

I cut down the linkage on the F-550 hydroboost and welded on the end of the OEM IH linkage to adapt it to the Scout pedal.

My reservoir is currently at PSC getting a 3rd port added for the hydroboost return line.
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Old 12-27-2017, 12:52 PM   #356 (permalink)
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In the last picture you can see the hydroboost installed. You can also see the He351CW loosely bolted to the manifold for mockup (trying to figure out downpipe and hotside intercooler piping).

I had a company called Savage Fabrication add a couple of breathers to my valve covers as well as a fill plug on the front cover. Instead of repainting the covers black I ended up brushing them.
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Last edited by Blak Falken; 12-27-2017 at 02:40 PM.
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Old 12-27-2017, 01:04 PM   #357 (permalink)
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Now on to the sheet metal work...

The Cummins head and exhaust manifold were almost touching the firewall so I cut out this portion of the firewall and built a doghouse to provide clearance for the engine.

I cut the curved sections of the OEM IH shifter mount off and welded them into the tunnel.
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Old 12-27-2017, 01:11 PM   #358 (permalink)
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My goal here in reworking the transmission + transfercase tunnel was to make it easy to remove the covers and access from the top. The original IH design used sheet metal screws but the holes tend to wallow-out after removing and reinstalling a few times so I came up with a better approach.

I laser cut mounting plates out of 12 gauge and welded 1/4"-20 nuts to the back of them. Makes for a nice solid and robust mount. I'll let the pics do the explaining...

Below is a pic of the front portion tunnel completed.
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Last edited by Blak Falken; 12-27-2017 at 01:11 PM.
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Old 12-27-2017, 01:14 PM   #359 (permalink)
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Looking good. You posted the last time while I was still catching up. LOL. Question, where did you get the flares? Are they fitted or universal?
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Old 12-27-2017, 01:21 PM   #360 (permalink)
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Since everything was opened up I replaced the Cummins OEM freeze plugs with billet aluminum freeze plugs that won't blow out (Achilles heel with the Cummins 12V).

Short of dropping the Np203-205 and Th400 I had to notch the Th400 adapter in-place to get the rear plug installed.
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Old 12-27-2017, 01:22 PM   #361 (permalink)
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There wasn't enough width to mount the Winters Sidewinder Shifter and a Triple Stick Shifter in the IH location so I decided to make my own mount for the Winters shifter and mount it remotely on my Tuffy Console. The nice thing with this is that it will make it effortless to shift since it will be sitting at arm level on the console.

Since the Np205 is a hard shifting transfercase I wanted to keep with direct linkages for reliability. For the sake of time I ended up buying a Triple Stick Shifter from ORD (Off Road Design) but there was massive interference with the shifter linkages and the top of the transmission so I had to modify extensively. In retrospect I probably should have just made my own shifters.

In the below pictures you can see how far down the ORD shifter linkages extend from the mounting plate. You'll also notice the mount that I made for the Winters shifter.
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Last edited by Blak Falken; 12-27-2017 at 01:24 PM.
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Old 12-27-2017, 01:32 PM   #362 (permalink)
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To fix the ORD shifter issue I noticed that on the baseplate there was a common hole in the shift lever mounting tabs (must be used for fixturing). I moved all 3 of the shifter levers up to this position and cut-off the excess end of the tabs.

I also laser cut new shift levers with gussets, cut the ORD linkages off and welded my new levers on.

Part of the issue with these shifters was that they didn't line up with the shifter rails and shift lever on the Ford Np205 and Chevy Np203. I designed my linkages to line up with the Np203 & 205.

The last pic shows the clearance over the transmission tunnel when installed.

I have the linkages built out of all-thread currently but I am going to redo them with solid 3/8" rod and cut threads on the ends.
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Last edited by Blak Falken; 12-27-2017 at 01:35 PM.
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Old 12-27-2017, 01:48 PM   #363 (permalink)
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Here's the rear portion of the tunnel, the goal is to provide clearance over the Np203-205 and give the Tuffy Console a nice flat space to bolt to. Same design approach as the front with 1/4"-20 mounting and removable top plate. 12 gauge mounting plate with 16 gauge sides.

Console mounting plate is 16ga with 5/16" nuts welded to the back side.
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Last edited by Blak Falken; 12-27-2017 at 02:52 PM.
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Old 12-27-2017, 01:49 PM   #364 (permalink)
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After cutting the Tuffy console to mount the Winters Shifter.
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Last edited by Blak Falken; 12-27-2017 at 01:50 PM.
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Old 12-27-2017, 01:55 PM   #365 (permalink)
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I originally thought I could exit the Winters Shifter cable at the bottom of the Tuffy console but the bend was just too tight. Here's how it will be. The 60" cable that came with the shifter was too short. I need approximately an 80" cable...Winters has a 72" and 96" so I've got the 96" on order.

I also figured out that I'm going to have to modify the Th400 brackets that the shifter came with as they won't work with the pan I have on the Th400.
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Last edited by Blak Falken; 12-27-2017 at 02:54 PM.
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Old 12-27-2017, 02:02 PM   #366 (permalink)
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The Corbeau seats were just too tall so I cut some out of the OEM IH seat bases to lower them. Here are some pics of mocking everything up.

I knew this would be an issue, the Triple Stick Shifter levers interfere with the dash when shifted into Low Range so I'm going to bend the levers back - last pic show how much clearance I have on the Winters shifter, plenty of room to kick them back 3-3.5"
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Last edited by Blak Falken; 12-27-2017 at 02:56 PM.
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Old 12-27-2017, 02:05 PM   #367 (permalink)
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I'm going to go with an "under the dash heater" so I welded up the OEM heater core box hole in the firewall. I grafted the patch from some 18ga out of the OEM tunnel and welded it in.
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Last edited by Blak Falken; 12-27-2017 at 02:57 PM.
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Old 12-27-2017, 03:08 PM   #368 (permalink)
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Quote:
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How did you clean/polish your turbo? I'm not interested in doing mine as good as yours, but I worked for two hours and I didn't even get all the overspray paint off.
I sanded it with progressively finer sandpaper on a DA. Ultimately you want to finish it with 1500 or 2000 grit wet sanded by hand. Just want to make sure you’re removing the previous scratches with each finer grit. Then polish with aluminum polish after wet sanding. Takes some time...

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Looking good. You posted the last time while I was still catching up. LOL. Question, where did you get the flares? Are they fitted or universal?
They’re Early Bronco flares from Wild Horses. I installed 2 sets of front flares.

Your build is looking great BTW!
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Last edited by Blak Falken; 12-27-2017 at 03:09 PM.
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Old 12-27-2017, 04:13 PM   #369 (permalink)
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Wow, talk about ultimate up date! Today's update would have takin me a year. It looks like a month of Vodka and OJ just to work out the T-case shifter. You need to space out the updates some. Can't digest that many pics for a few days. LOL.

Carry on!
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Old 12-27-2017, 06:07 PM   #370 (permalink)
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I pulled the gear chunks out of the front and rear Rockwells, installed Yukon Grizzly Lockers in both
you are going to love the Grizzly's. Really diggin' the trans and t-case covers.

Nice truck porn all around!
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Last edited by 'Mad Max'; 12-28-2017 at 08:55 AM.
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Old 01-03-2018, 10:37 AM   #371 (permalink)
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Nice update
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Old 01-06-2018, 06:59 PM   #372 (permalink)
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Here it is just tacked in place.

In these pics you'll also notice the PSC cooler which I mounted to the bottom of the frame using 1/4"-20 weld nuts from All-Star Performance.
I have a brake line right where you mounted that cooler. I even had a bar across there very similar to what you have. I still crushed that hard brake line on a rock.
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Old 01-12-2018, 05:36 PM   #373 (permalink)
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I have a brake line right where you mounted that cooler. I even had a bar across there very similar to what you have. I still crushed that hard brake line on a rock.
Yeah, I thought about the vulnerability when I mounted it there but PSC recommends mounting outside of the engine compartment and somewhere where it gets a lot of air flow. It's somewhat protected with the cross bar between the spring hangers but at some point in the future I'll probably weld in a dimple died (air flow) 10ga plate to guard it a little better.
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