75 Dually build

[SCOTI]

Originally Posted by 75Dually

It's done! Finally got my side walk poured today. Oh and it kicked my butt! It was 100 degrees plus today. The reason it took so long is my wife works weekends (she is a charge nurse, and she works nights). So it has been tough to get a weekend when she is not working and the weather was cooperating. It's not perfect, but it is pretty close for us. I'll bust down the forms tomorrow.

Now I can get back to the engine build, again if the weather will cooperate! It has been several weeks with temps over 100, and that has just been too hot to work in the shop, especially with the humidity we have been experiencing. Yeah I know no sympathy, but this is only a hobby...

Stay tuned!

It's usually 112°F inside of my shop @ the end of the work day.
I get it.

[Dieselwrencher]

We've had a cool down the last week but the month before that we had what yo just had and we're getting it back in a few days. Yeehaw. Nice work on the side walk!

[75Dually]

I have been working on the Cummins for the past couple of evenings. I got the head all redone, and then mounted back on the engine. Thanks to my engine hoist for saving my back! Tonight I got all the rocker assemblies mounted and the head torqued down. Tomorrow I hope to have all the valves adjusted, and then start to put all the other items back where they belong.

So some steady progress. I guess it is now time to get the engine slung back in the engine bay and make all those mounts. Now that will be fun!

Stay tuned!

[deejaaa1]

nice progress!

[75Dually]

Originally Posted by deejaaa1

nice progress!

Thanks man!

[75Dually]

Look at the clean and painted manifold! So shiny!

[75Dually]

I got out into the shop early today to try and beat the heat. I got the exhaust cleaned up and coated in a ceramic heat resistant coating. Then I got all the valve covers cleaned up, Yuck that was zero fun, they were nasty, but now are a lot cleaner!

I wrote a list of items I wanted to get completed this weekend. I'm about 3/4's of the way through it. Items I have completed so far: new water pump, new thermostat, install the front main seal, install the front cover, reattach all the fuel supply and return lines, purchase new rubber return fuel line, and supply line. Plus the 2 items above. Oh yeah I took the wife out for a really good lunch and some shopping she wanted to do. So yeah a very full day!

Tomorrow's list goes something like this: install rear main seal, install transmission mounting plate, install flex plate, and then the transmission so I can get everything in the truck for mock-up of the mounting plates. Oh yeah all those items have to be cleaned before installation... Build a Cummins they said... It would be fun they said...

Stay tuned!

[Dieselwrencher]

It will be way more fun than that big block was! Nice work on it. All that clean up is time consuming. I know you pain.

[75Dually]

Originally Posted by Dieselwrencher

It will be way more fun than that big block was! Nice work on it. All that clean up is time consuming. I know you pain.

Of all people you you know the time and the commitment it takes!

Cheers Ryan!

[75Dually]

A major milestone was reached tonight! I got the engine and trans slung in the engine bay!!

Now the fun begins. I will start on the mounts first (engine and trans) and then work on clearance for the AC pump. Then I got to get the driveshaft cut down and the correct yoke for the Dodge trans. Then there is all that wiring... Yuck! Oh well it is just another job to do and check off my list...

Stay tuned!

[75Dually]

Another good weekend in the shop. Been working on getting the engine fully mocked up and getting all the mounts made. I started last night by getting the radiator support mounted so I could see how the dual fans I got would fit. Which then lead me to see about how I was going to fit the intercooler. This is turn showed that I was going to have to use the Dodge radiator instead of the big block Chevy radiator. Bummer! I really wanted the extra capacity and ability to handle a greater heat load in the future. Ah well I guess I will keep it for a future update. I did however try and see if there was anyway I could use the Duramax intercooler, but it is about 3" too tall for this application, so I guess I will use the Dodge unit for now. The core support in these pics is super dirty because it has been sitting in the back of the shop since LST... Lubbock dust... Need I say more...

Today I got busy taking out the old transmission cross member because it raised the transmission too high. The weird thing is the mounting holes on the A518 lined up with the old Turbo 400 trans mounting holes. Too bad because I really thought it would be great to use the old Chevy mount, but no... So I grabbed some steel out of the rack and made a replacement. It was fun to build, and now I just have to drill the holes for the frame mounting and weld everything up.

Stay tuned

[75Dually]

A quick question for you guys who have these Dodge transmissions. Which way does the the lever at the transmission go when it goes into park? Does it go all the way to the rear or all the way to the front? I'm going to have to build my own mechanism for the gear selector and need to know.

Thanks!

[Dieselwrencher]

Originally Posted by 75Dually

A quick question for you guys who have these Dodge transmissions. Which way does the the lever at the transmission go when it goes into park? Does it go all the way to the rear or all the way to the front? I'm going to have to build my own mechanism for the gear selector and need to know.

Thanks!

Nice work on it! I'm pretty sure all the way to the rear is park on these dodge transmissions. (I can crawl under my excursion later and verify) I made a bell crank type mech for the yellow 88 burb I did. On my 72 I went with a lokar cable shift set up.

On the trans mount I have made a new plate to bolt to the overdrive housing and used poly TH400 mounts several times. On some I have just modified the dodge plate and put the TH400 mount on it. I did this on my 40 Ford.

I actually have an auto world AC comp bracket for a VE I haven't used yet. This would mount the ac compressor on the cylinder head. They use a custom dual pulley they make to drive the comp. I just can't remember which pulley I have.

I did get a stock dodge compressor in the frame of my 72 but I had to do a lot of work to get it in there. It is really tight.

[COS399]

Looking good. My 88 still has the chevy 454 heavy duty radiator in it and the second gen intercooler. I can PM you some pictures if you want to look at it. I had Ken, at Autoworld, install it about 14 years ago. He did have to cut the two tubes, rotate them 180 degrees and weld them back together to make it work. Keep us posted and hope to see it in person next time I pass through Lubbock.

[75Dually]

Originally Posted by COS399

Looking good. My 88 still has the chevy 454 heavy duty radiator in it and the second gen intercooler. I can PM you some pictures if you want to look at it. I had Ken, at Autoworld, install it about 14 years ago. He did have to cut the two tubes, rotate them 180 degrees and weld them back together to make it work. Keep us posted and hope to see it in person next time I pass through Lubbock.

Yeah man post a pic of it! I would like to see it.

[75Dually]

The transmission mount is done and in the vehicle!!!

Now on to the motor mounts. I knew I had to get the trans mount finished and the trans located perfectly in the middle of the frame before I started to mock up the motor mounts. So after the trans mount was installed I got out my lasers and levels and got the engine all centered and leveled. I then made a card board template and used it to cut out all the plate this evening.

Tomorrow (or sometime this weekend) I will get the mounts all tacked in, double and triple check all my measurements, and then finish weld everything.

I really like these fun parts of the build process. My list is getting shorter and shorter! Yeah right!!

Stay tuned!

[75Dually]

Started on the engine mounts this evening. Rough cut the supports out last night, and tonight I drilled the through holes for the mounting bolt. What you see here is just a very rough mock up. Tomorrow I will weld it all up and put in a cross brace between the two supports. I will also cut the main mounting plate to the correct size too. Then all that's left is to clean it all up and make it pretty!

Stay tuned!

[75Dually]

The Cummins motor mounts are done!

Man I am so glad those are done and now even painted. Time to yank the engine out and get everything bolted up and paint the engine. Then it is back in for the final time (I hope!).

Now I can move on to getting the intercooler/radiator package figured out.

Stay tuned!

[aboesec10]

nice work man!

[75Dually]

I know you're probably tired of seeing engine photos, but it is now sitting fully on the new mounts. For a DIY guy like myself this is a major milestone! Oh yeah and it's perfectly level, and right on the centerline!!

Can't ask for more than that!

Stay tuned!

[Palf70Step]

Very nice. Just a couple hoses and you're ready to go.

[75Dually]

Originally Posted by Palf70Step

Very nice. Just a couple hoses and you're ready to go.

Exactly!

...and a turbo, radiator, electric fans, fuel lines (both supply and return), power steering lines, drive shaft shortening, York, York mount, AC compressor notch cut out, AC compressor, throttle cable, transmission cables, transmission cooling lines, transmission electrical, transmission shifter, run new exhaust, rewire engine bay, heater hoses, mount intercooler, intercooler tubing....

LOL!!! Yeah just a couple of hoses!!! (this made my day!)

Ug! Death by 1000 cuts!!

[75Dually]

There are always important parts to any build. This pulley is one of them. In many ways it was a show stopper if I could not find one. For those of you who do not know this is the pulley you attach in place of the stock alternator pulley and it allows you to run a York pump and the stock serpentine drive belt.

You will see some more photos coming up as I build the mount for the York and the pulley system to drive it. Stay tuned for that.

If I was unable to find this part I would of had to use electric Viair's or something similar. Not that I don't like them but if you have ever had a York pump verses the old electric pumps you would never go back to the electrics. They just take too long and you really need a lot of juice to run them too. So for me that was a no go. However I will run an electric pump as an emergency backup.

I highly recommend you check out the guys at C U Offroad. They now own the old Kibly Enterprises company. They will have what you need if you want to run something similar to my setup. Their website is: https://www.cuoffroad.com/ and the pulley's are under the Air Boss product line.

I hope this helps you out if you plan on doing this in the future!

Stay tuned!

[aggie91]

you left off something on you list of stuff that needs to be done.

The insides of the front fenders really need to be painted. Maybe a satin black to make it easy on you...

[daddyjeep]

I have a feeling he left about a dozen little things off his list.