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Re: Project: Tow-Rat (Lil' Blue)
shutting these doors is sooo satisfying. hopefully the vent windows aren't on backorder too long.
https://i.imgur.com/81GKwYc.mp4 |
Re: Project: Tow-Rat (Lil' Blue)
parts started coming in, first turbo is on site. credit card still trying to recover from Black Friday ... ugh
then it was on to re-doing the core support mounts and radiator mounts. wish i had done this from the start, but whatever it's there now. i even drilled and tapped the frame for am extra bolt in the face to help bumper mounts later, something about going into the new paint was panful :lol: the old body mount hole and the new face bolt should make the bumper mount easy enough. after getting the new mount tacked in place while everything was held by the old mounts, was time to burn. when i cut the bottom off with the old mounts, i had to move the mounting for the cross bars and the lower tube up too. just cut and welded, doesn't look perfectly symmetrical but it aint going nowhere. had to bend the rad mounts quite a bit to get it to angle forward at the bottom vs straight up and down, now clears the fuel lift pump mini-belt just fine. what it didn't clear however was the dang water neck getting past the belt tensioner :dohh: right freakin into it! is an aftermarket belt routing kit already, so i just modified the brackets a bit and good to go. ordered what i hope to be all the parts for rad hoses, cross your fingers that should be doooone then. something else i ordered was new valve springs to hand the higher R's and PSI, made sure the rear valve cover came off and it cleared by less than 1/2", all win with that! https://i.imgur.com/n1xBMfYl.jpg https://i.imgur.com/NC5md6Zl.jpg https://i.imgur.com/zfdYWNbl.jpg https://i.imgur.com/wlMNBtWl.jpg https://i.imgur.com/AUZ0xWLl.jpg https://i.imgur.com/JoeOoXpl.jpg https://i.imgur.com/q2dJllHl.jpg https://i.imgur.com/QylxJ2gl.jpg https://i.imgur.com/7Fqtbpcl.jpg |
Re: Project: Tow-Rat (Lil' Blue)
been bouncing around working on everything and anything to get myself a fat check mark on the list. as much as i hate christmas tree style clips, these zipties with one molded on are pretty solid. cut the tree n not reuse like a normal ziptie vs trying to save it.
working on black friday sale parts, i got the upgraded "60lb" valve springs all installed. #6 was a wanker to get to, but we got it! valves are lashed, but i feel like i want to re-check them after running it for a while. also got the 4k governor spring in the pump to let this thing eat. i had forgotten to seam seal the new eyebrow plate i welded in before paint. not really a big deal and i'll leave it like it is, at least she's sealed now. actually did the whole tape both sides, smear it, and peal for nice lines. i'm pretty happy with it. this is not the same 3M Urethan i had used on the cab before, it's SIKA 221. seams like awesome stuff. got the other turbo and started planning for how to cram it all in there. the normal flipped manifold was just all kinds of wrong. worst part was i only had 3" from the v-band on the back of the turbine to the firewall. then factory 2nd gen turbo location was basically in the middle of everything so i ended up making an angle adapter. normal manifold orientation, but will tuck the "small" turbo down under it closer to the engine. should have better room for piping, and more room for the atmospheric turbo. crossing my fingers the design was good, had send-cut-send laser cut all the parts and hopefully i see em soon. the chineese short throw shifter i bought was hot garbage. didn't realize it until i bought a second one for my other truck. swapped that one out for a CORE shifter and loved it, so just swapped this one too. they are hands down the best shifter i have ever used. i even got one for the jeep i like em so much. just tight n right. the hurst style stick for the ram however didn't quite work in the 55 :lol: i'll have to cut n weld that later. https://i.imgur.com/7tRMVczl.jpg https://i.imgur.com/qAc7PFBl.jpg https://i.imgur.com/yZvGdb3l.jpg https://i.imgur.com/l4XuCPml.jpg https://i.imgur.com/4YcBgFxl.jpg https://i.imgur.com/qLY6PFwl.jpg https://i.imgur.com/sPm1MUAl.jpg |
Re: Project: Tow-Rat (Lil' Blue)
Started getting things torn down and reassembled in the rear axle for new gears. going from the axles factory 4.10s to as high as i possibly can at 3.21. the Cummins loves load, and this way i'll be able to do highway speeds with the 30" tires :lol:
front shocks are on, and got the little bracket i made the other night on after the paint dried. something satisfying about a little stupid tab that the brake lines can ziptie too. just a nice KISS thing. also cut down the shifter. makes ya cringe grinding into new chrome, but it's 1000x better. custom cut shifters that fall exatly where your hand is just makes the whole feel. and the fact it stood straight up is kinda cool. https://i.imgur.com/1bv1n2zl.jpg https://i.imgur.com/QdVEAyBl.jpg https://i.imgur.com/yhvQLLYl.jpg https://i.imgur.com/XjnzVyMl.jpg |
Re: Project: Tow-Rat (Lil' Blue)
drivers side vent window showed up yesterday and i got to work SUPER excited to assemble a door. that didn't happen. part was my own learning of what's what, what goes where, and how it fits ... but in the end it just wasn't lining up. i even went to get the OG vent windows to compare. 3 of the 4 mounting tabs around the glass don't line up with the factory holes.
they aren't close enough to re-drill the tabs ... do i really just re-drill the door? not sure why i'm having issues with this option. thinking i should get the main glass in and rolled up before i re-drill anything. why can't throwing money at a problem for bolt-in parts actually just be bolt-in ... |
Re: Project: Tow-Rat (Lil' Blue)
I know, right? It seems the high quality parts just means they are close to the same shape so slightly easier than building something from scratch. Very frustrating. And it's not like you can say you get what you pay for, cuz parts ain't cheap either.
You'll figure it out like you always do, nice build so far. Not my personal style, but well planned and done. Keep posting up your progress. |
Re: Project: Tow-Rat (Lil' Blue)
Way cool build man, you have some solid fab skills.
Looking forward to seeing what you do with it. |
Re: Project: Tow-Rat (Lil' Blue)
thanks!
got after the crazy door assembly again last night ... why were the stupid horizontal lower felts even more ridiculous to install than the vent window!?!?! 4 clips, just pop em in, the dude on the youtube said it was easy ... i blame the aftermarket for copying GM vs doing something better when GM made a crap design. but it's together, it's functional and smooth, and i like it. though, i don't like how much paint i chipped. i'm not sure if it's my application, or the paint itself, but i'm getting flakes vs scratches in all 3 colors. https://i.imgur.com/e5QSit5l.jpg https://i.imgur.com/FJljd4wl.jpg |
Re: Project: Tow-Rat (Lil' Blue)
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Re: Project: Tow-Rat (Lil' Blue)
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so i first went for doing the lower horizontal window felts last ... but found out they need messed with early. my plan of action for the passenger door now having only assembled one ever ... i didn't even stay at a holiday inn express last night. - install window crank mech - hold the outer window channel and felt strips in place, trim felt/backing even with edge of the window channel so it's not behind/in it. - install window felts, cuss as needed - throw the main glass in the door, let it rest down inside the door out of the back channel and all way to the rear of the door. - partially install the vent window. i missed needing to get the tab in the slot to start with, 3 of my holes didn't line up but easy enough to drill a new hole for a screws. - form and fit the outer window channel to the door/vent frame, then leave the top hanging out of the door ... mine is tight but missing the lower clip that rusted off. i'll put a few RTV dots behind it if it starts to slip down with the window. - unbolt the vent window and let it hang with the bottom of the track in the door pushed forward some. - lift the glass up into the outer channel and the vent channel and bring it up thru the felts. fingernails only holding it on the trim worked to push it up for me, a ducttape handle might be safer. lots of space due to the window shape, but you can push the vent back into place as it comes up if you tipped it way in. - slip lower window slider bracket thingy onto the crank mech (holes are more forward) set the glass on it and bolt to the glass - bolt the vent assembly in place - re-fit the outer channel rolling up the window to hold all that in place nice and final finagling - fit window surround trim - install latch bar/crank - install door trim panel and crank handles it's almost entirely 1/4-20 x 1/2" screws. i have little stainless button heads, and countersunk for the panel. i think it was #10x1/2" countersunk for the trim, much smaller for the 4 on the vent window. |
Re: Project: Tow-Rat (Lil' Blue)
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Re: Project: Tow-Rat (Lil' Blue)
wife helped me last night, there was definitely a learning curve to the windshield install. still only took us about 30min, and afterwards she said we'd be way faster the next time. even offered to help other ppl if she got paid :lol:
only thing i broke was when i knee'd the flasher button on the new column ... little jerk broke off inside :dohh: https://i.imgur.com/LtU3Vdvl.jpg |
Re: Project: Tow-Rat (Lil' Blue)
Glad to see you back at it. I was hoping you weren't going to leave us hanging. The truck is looking good.
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Re: Project: Tow-Rat (Lil' Blue)
nice. you guys could open your own "old car windshield shop" and make a killing. most glass shops don't wanna attempt an install on anything that doesn't glue in.
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Re: Project: Tow-Rat (Lil' Blue)
still haven't gotten back to the rear gears, but i got the turbo angle adapter all burnt in! i enjoyed the crap out of building that. welded and welded again to get the exterior corner radius on the plate, then internally ported back to smooth again.
50deg, T4 to T3, as compact as possible. https://i.imgur.com/YI2rWl7l.jpg https://i.imgur.com/Fk94Hzel.jpg https://i.imgur.com/31nfU8Gl.jpg https://i.imgur.com/ApZPWnWl.jpg https://i.imgur.com/bZi8IuWl.jpg https://i.imgur.com/MNbSrm7l.jpg |
Re: Project: Tow-Rat (Lil' Blue)
if someone ever asks you to help them install the windshield on a truck with the gasket vs glue-in ... do it, it's a cool process and pretty satisfying. plus it's a 2 man job, help a dude.
if someone asks you to help them with the rear window on a truck with the gasket style and the locking strip ... you punch them in the face and walk away. what an epic process of hateful things! the seal is missing a chuck where the lock strip goes, so it's extra floppy and unstable to get the glass into the basic opening. then the lock seal needs tucked into the groove under both edges, but the gasket is all over the place without it. the corners are especially hateful where it's all collapsing. took me 2 nights cuz the first night i had to take a break to throw stuff around the shop and start over last night :lol: but it's in! it's clean, it works, it's good to go! https://i.imgur.com/asZ3al9l.jpg https://i.imgur.com/n1BB16Vl.jpg |
Re: Project: Tow-Rat (Lil' Blue)
yeah, REALLY looking forward to the glass install. I am far away from that though.
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Re: Project: Tow-Rat (Lil' Blue)
I understand the frustration, my headliner issue was a 2 day job and I was exhausted mentally and physically when done.
As the window work, front and rear, and I also have a sliding glass rear window, I knew 2 people would be the ticket. I had to buy the glass anyway, so I bought my glass from a glass installer, they delivered, I paid an extra $100.00, and both were done in a couple of hours. It was the only thing I paid for assistance on the truck, good for you to hang in there. |
Re: Project: Tow-Rat (Lil' Blue)
got after getting the 2nd turbo mounted. everything looks like it'll work out really good for the entire cold side, and the manifold adapter and exhaust exiting under the cab should be good ... this hot pipe between the turbo's is just TIGHT. it's going to requires a lot of small radius work.
3D printed some more jigs too, the one pictured is just to slide into position and draw a straight line around the tube. i made another to mark out a 10deg pie cut from the bend. https://i.imgur.com/XNUrHIAl.jpg https://i.imgur.com/0gNostIl.jpg https://i.imgur.com/WmgowhFl.jpg https://i.imgur.com/WyK7nWEl.jpg |
Re: Project: Tow-Rat (Lil' Blue)
Dang that's a big Turbo! Looks good
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Re: Project: Tow-Rat (Lil' Blue)
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S362/65/.7 ... S475/96/1.32 |
Re: Project: Tow-Rat (Lil' Blue)
the pie-cut and straight cut stencils were awesome, highly recommend. the pie cut made quick work of adding some angle and tightening up the bend. it was a 10deg print, but i cut on the sharpie lines so probably more like 12-14 actual. the straight cut needed some tube for alignment, can't just cut off a sliver with it hanging off the end. before i started cutting back the start of the pipe i made multiple marks. ended up trimming it 3x, made it easy easy when already marked.
https://i.imgur.com/ADZ4ayml.jpg https://i.imgur.com/nss2Cl3l.jpg |
Re: Project: Tow-Rat (Lil' Blue)
i hate how my exhaust welds look, they are always nasty ... not going anywhere, but ugly. good thing it's getting painted and fully wrapped for that SEMA look :lol:
i am super excited this is together, and it's crazy sturdy when assembled. wish i had more room to make this pipe more racecar, but she should be fine. it's tight, but it's big at 3.5". should also have good room that i can get the 4" down pipe past the tire easy without rubbing it at full lock too. cross your fingers for me the outlet flange shows up soon. https://i.imgur.com/rBu71dAl.jpg https://i.imgur.com/JjdPJnZl.jpg https://i.imgur.com/Co8TQcQl.jpg |
Re: Project: Tow-Rat (Lil' Blue)
Awesome work! I love doing turbo piping but it is a lot of work. Would you sell some of those cut jigs? Those would be really handy.
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Re: Project: Tow-Rat (Lil' Blue)
Amazing work!! Well beyond my skill level. That will make some serious power. Steve
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Re: Project: Tow-Rat (Lil' Blue)
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know anyone with a printer and just want the files or wanna pay shipping on some? the problem is ya have to print a different one for every radius bend and pipe size. but once you have the file built, it's easy enough to change a few dimensions in the CAD and re-print. i'm also thinking about making them split with an adjustable screw, the bends warp differently thru them. |
Re: Project: Tow-Rat (Lil' Blue)
was at the in-laws over the weekend, but still got some stuff done.
- Manifold turbo is officially installed (measured for oil lines) - installed dash to windshield trim - got sensor bungs on the hot pipe - the wife cleaned the inside really good - started fab of the intercooler mount - installed seatbelts i really like how the seatbelts came out. should be way better than just a lap belt or retrofitting a 3-point. also pretty comfy with no cutting into my neck or pulling bad. https://i.imgur.com/P6GwNFUl.jpg https://i.imgur.com/tF9jDIYl.jpg |
Re: Project: Tow-Rat (Lil' Blue)
I don't know anyone with a 3D printer. I have been kicking around the idea of getting one though. Those seat belt mounting plates turned out nice. I much rather would have the belts like you have versus an over the shoulder lately.
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Re: Project: Tow-Rat (Lil' Blue)
hot pipe in paint, fully wrapped, and installed with the s475. i really like the one boot cold side connection. turbo oil lines are ordered, so i really need to get on mounting that charge cooler!
no it will not have a hood stack :lol: https://i.imgur.com/QQLCVYDl.jpg https://i.imgur.com/07FvHPTl.jpg https://i.imgur.com/cQr7A4Cl.jpg |
Re: Project: Tow-Rat (Lil' Blue)
wrapped up the intake this weekend, that's officially sealed and tight. other than once the front clip is on i'll just need to figure out an air filter. so i figured what angle the intake stack needed to be, then in 3D i cut a model of 3.5" pipe and measured the arch length around the miter. i then made an ellipse of the same arch length that fit inside the intake mounting holes and had some plate cut. chopped some pipe, squished it, and I'm super happy with the transition.
i did add some weld bead around the top edge of the pipe to keep the coupler n clamp from slipping off. i don't particularly like the look of the cooler on top of the engine. it's a nice compact packaging though, it's free space under the hood that isn't used for anything else, and the air path is really good. hard to argue with all that. https://i.imgur.com/nuVHuell.jpg https://i.imgur.com/BN6uiACl.jpg https://i.imgur.com/Z11Q4eWl.jpg https://i.imgur.com/mS68tUDl.jpg https://i.imgur.com/U57vhbBl.jpg https://i.imgur.com/pVXRHxel.jpg |
Re: Project: Tow-Rat (Lil' Blue)
then moved on to the down pipe where thing got close, but they fit! 4" down pipe snaked :metal:
even pre-added some sensor bungs if i ever want them. https://i.imgur.com/ige3i9pl.jpg https://i.imgur.com/idusLoNl.jpg https://i.imgur.com/oCUNf43l.jpg https://i.imgur.com/7WxQP68l.jpg |
Re: Project: Tow-Rat (Lil' Blue)
That looks nice. Where did you get the cooler? Does it have it's own cooling system?
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Re: Project: Tow-Rat (Lil' Blue)
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the 2 radiators n the back under the bed are for charge cooling water. |
Re: Project: Tow-Rat (Lil' Blue)
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Re: Project: Tow-Rat (Lil' Blue)
Do you have the part numbers? Thanks
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Re: Project: Tow-Rat (Lil' Blue)
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there's a lot of ppl skeptical about the water to air. from ppl running engine coolant thru the cooler to poor water cooling that lets it heat soak, etc. i guess we'll see hopefully soon enough. i specifically sized the radiator to be slightly bigger than the core of the charge cooler, in theory the system should be able to ditch more heat than it can take in. plus at some point it'll also have an aluminum reservoir in the bed that would shed even more heat. |
Re: Project: Tow-Rat (Lil' Blue)
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https://www.frozenboost.com/air_wate...ers-p-218.html Water to Air Intercooler, 16"x12.25"x4.5", O/S I/O (Type 18) you can get different size cores with lots of different inlet/outlet directions. |
Re: Project: Tow-Rat (Lil' Blue)
this is the water chiller i used
https://www.frozenboost.com/water-to...er-p-1026.html Water to Air Intercooler Radiator - 26x7x3.5 (Type 101) |
Re: Project: Tow-Rat (Lil' Blue)
Thanks I'll save that information.
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Re: Project: Tow-Rat (Lil' Blue)
door parts finally came!! it's officially "dry'd in"
not sure if it's just the re-pop parts or what, but these doors are a pain in the junk to assemble. completely different problems left to right. https://i.imgur.com/TeG22All.jpg |
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