86 Silverado K20 12V CUMMINS Build

[brimc]

Well then I got the front xmember cut down some more and then dropped the engine back into the frame to check it out.





Looks much better now. Just have to clean it up and paint it. I am not going to re-inforce it. It will be strong enough plus I have a 2x2 tube welded just in front of it ( below / behind the bumper ) with welded tow hooks.
Started mocking up the exhaust at this point. I am going to try and re-use a stock 2nd Gen front pipe.





Also mocked up the stock 1st Gen driveshaft. It fits perfect.















Time to break it down and start cleaning, re-sealing and painting everything up!

[brimc]

So I pulled the engine yet again and started stripping it of parts and taping up the ports etc for heavy duty oven cleaner, brake cleaner and scrapers and brushes.



Got the exhaust ports and main all covered up.



Cleaned up somewhat then got ready to pull the p7100.





Now for some reason I didn't take any pictures of the IP removal. But I will say that it wasn't hard at all. If it was still in the Dodge, I think it would take forever. I confirmed my "pin" timing was still set. It was bang on ( as far as pin timing goes ) So I at least had a starting point for re-install.





Picked up a plastic tote to use for Clean safekeeping.





Started glassbeading some of the parts like valve covers and intake horn.













Back to scrapping and cleaning.

[brimc]

So after a lot ( a lot ) of cleaning I pulled out the POR15 Marine Clean and started cleaning some more ! This stuff is awesome. Really good, strong stuff!



The remaining rust starts running off after sitting for only a few min. A good stiff brush worked all over the area really accelerates it's performance as well.









Then you get out the POR15 Metal Ready. This is the stuff that etches the metal and leaves the zinc phosphate coating.







Keep it wet for 30 min then let it dry for a couple days before Paint. It has to be absolutely dry.







Let it bake in the sun. Almost dry.



Time for the fun Part. POR15 Gloss Black.

[Dieselwrencher]

Nice work on your truck! Your engine cleaned up really well. Are you going to check to make sure the KDP, aka killer dowel pin, has been repaired in the front gear housing? Have you sat your cab on to make sure everything clears?

[brimc]

Originally Posted by Dieselwrencher

Nice work on your truck! Your engine cleaned up really well. Are you going to check to make sure the KDP, aka killer dowel pin, has been repaired in the front gear housing? Have you sat your cab on to make sure everything clears?

Thanks a lot. I spent a long time cleaning that engine and yea it cleaned up real nice. I tabbed the KDP several years ago. I can't remember exactly but I did it after heard about it/read about it on the internet on one of the Diesel Forums.
I have not set the cab on top with the cummins yet, I did do several quick measurements and a lot of pics for reference. Also a 3inch Body lift is going back on the truck. If I can make that less, I will try, but tire clearance will be a bigger issue. I will be running 35" tires for sure.

[Brockwaykid]

Just a pet peeve of mine, make sure if the body lift is big enough, lift the bumpers!! Nice truck btw, looks great. I may put a 12V in my 75.

[y5mgisi]

Subscribed!

[brimc]

Bumpers always go with the body when I do it. The very first picture in this build thread has a 3" body lift already. It is going back into the truck again.
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[brimc]

I still to this day need to finish the motor mounts and supports and build a new engine xmember. I went ahead and finished welding the mounts and got to sandblasting / cleaning some parts to prepare for paint.















The glass beads in the enclosed sandblast cabinet does a real nice job.
Then I started cleaning up the oil pan. I wanted to do this off the engine because I thought it was pretty rusty. Turns out it wasn't that bad. Took it outside to sandblast. It would have fit in my cabinet, but glassbeads are not as good on heavy rust. I use cheap sand in the pressure pot outside for heavy rust.




I didn't blast it perfectly clean as a bit of rust works better POR15.





Then started the process....



Powerwash after marine clean and metal prep.





Ready or not it's time for paint. The prep for POR15 is a very long process. I sure hope it is worth it in the end.







2 coats of Gloss POR15.



Lots more to come.....

[Mattman2010]

Truck is looking good man! Cant wait to see more.

[brimc]

Originally Posted by Mattman2010

Truck is looking good man! Cant wait to see more.

Thanks. I have lots more for you guys too see. This is going to be a very Long build. My guess is 3 ~ 4 years. I have only been at it 2 years and I don't feel like I'm half finished yet.

[brimc]

So up to this point I have been pretty happy with the POR15 i've used so far. My biggest problem that I have been struggling with is that I want this old Chevy to last a long time, but I want to drive it too. This is something that can't be done in Ontario. All nice rides are put away 6~8months a year or they rot. I worked hard to keep that old Dodge clean but after 15 years with all the salt/sand on these roads, it is just a killer.
I decided to make another POR order. it looks good on all the frame bits and pieces so I did some more research on there High heat Manifold and Engine paints.



I went for a six pack of POR15 Gloss black and a can of there Factory Manifold Grey for the turbo and exhaust. I was liking the red theme and decided I would also get a can of there "Chev Red". It was only $80 for all that and shipped to the door in 3 days. It is a little $$ but if it lasts it is a small price to pay. Time will tell?

[brimc]

Started cleaning up the injection pump. I mounted it on my cheap engine stand and it worked great. It also worked great for the trans. They are very handy. I wish I had one to hold the Cummins. I may try to build myself one. I can see me using it.



Brake cleaner and wire wheel /brush worked good. My goal was just to make it look good painted.

















Still stock...for now.

[brimc]

So I went ahead and checked out the POR15 "CHEV RED"









I gotta be honest, the camera makes it like "pinkish" It does look better in person and better outside than in the garage. It is suppose to darken up also after some heat curing.
I also did the Engine adapter. But Black was the better choice.





I am not going for show quality by any means. I just want clean, and easy to clean.

[brimc]

Before I painted the manifold, I needed to drill and tap for the EGT prob. I never did this before because I was too scared to do it on the engine for fear of metal crap getting inside and causing damage.
I started off with a partially sandbasted part. I did a lot of reading first then figured out where to hit the centre punch.



I bought one of this for the tool box awhile ago and finally had a good reason to use it. ( This is one of those great 70% off sale items that come up at Canadian Tire all the time ! )





Started off small and worked my way up.











Broke my Tap handle awhile back, but that didn't stop me.







Finished.





Temporary Plug for now.

[brimc]

So "CHEV RED" I'm not sold on yet. I really wish I went with a darker red. I guess I got caught up with the name of the paint. Any how I painted the color over the POR15 "primer" coat as per the instructions the next day. There is a 24hour window for 2nd or recoats.



I still have to paint the injection lines and I want to change the valve covers. There is too much red. I think aluminum.




The manifold and turbo came out awesome. That is some good paint. It is not suppose to burn off until after 1400' It will darken after 300+' for 20min of running.



Next I installed the engine adapter, flywheel,clutch, etc and cleaned up, locktight and torqued down for final assembly. ( until I upgrade to a 4500, 5600, G56 when I blow this one up! )









So I still got lots to do but, this brings me almost up to date. I have to go buy some more metal to finish my engine mount supports and build a xmember. Pull all the rear suspension and paint. My goal is to get all that done, then get the fuel tank done with all new lines and lift pump. I can't wait to fire this thing up in it's new home !

[brimc]

This week I got the rear springs and mounts etc. all pulled and cleaned up and painted. Starting getting most of that put back together. Today I picked up some metal at the Barrie Metal Superstore and this weekend hopefully will get my engine xmember built and installed. It is finally at a point in the build when things start coming together. I just wish there was more time to spend on it. ( and money hehe ) I post some more pictures after the progress.

[legendman]

Awesome build thread

Looking good so far, going to be sweet when its done.

Subbed

[brimc]

Been really hot and also a busy week! I did manage to get my engine xmember all cut up, mocked up and now it is ready for finish welding. Hopefully get it all completed this weekend. I have been taken lots of pictures but only have one to share for now until I get them uploaded.

Hopefully have much more to share this weekend!

[brimc]

Originally Posted by legendman

Awesome build thread

Looking good so far, going to be sweet when its done.

Subbed

Thanks. I really enjoy reading threads with lots of pics. I wanted to make sure I had lots to share in return.
I can't wait for it to be done but, trying hard not to rush it.

[brimc]

So I picked up some more metal at the super store.


3/16" 3"angle, flat and 2X3 tube.

Started out with the angle on the bottom side of the frame. Now this setup is going to be somewhat different from others I have seen. I wanted more support than just being bolted, or welded on the inside of the frame.







I figure if the frame is sandwiched between the engine mounts and the removable xmember, it should be pretty strong.
So before I pulled the engine the last time, I made a cardboard template to give me the distance between the frame rails, oil pan, and front axle. I started off with the 2X3 tube 36" long. I made a center mark and measured off the template. I was going to use the saw at work but, I went ahead and did it by hand.



Cut out the notches and then bent it up to fit my template. I then used a strap to hold it as it had some spring to it so I could tack weld it.





4 tack welds held it firmly enough for the next part of the process.

[brimc]

I also cut the tops off so they would be flush with the angle iron already temporary bolted to the frame. I used my floor jack and a block of wood to hold it up into position.







Tack welded that into place after several checks with a tape measure. Then drilled all my holes. There will be 20, Grade 8, 3/8" 1 1/4" bolts holding the engine mounts and xmember onto the frame. ( 10 per side ) Pulled it off for final welding.

[brimc]

I also got the front OE xmember trimming completed and painted to clear the front balancer. I completely finish welded the xmember and set it into the frame and took a couple pics tonight. Now I just have to prep it for paint, pick up my bolt order at Bolts +, and install it.





I know, I am not the best welder, but they are good welds. haha





Hopefully this heat will let up so I can get more done this week. The garage is 40' right now, can't even hardly breath out there!

[mknittle]

Pretty cool build I am a big fan of the Cummins swaps.
Reading through yours makes me want to get restarted on mine.

[legendman]

Engine crossmember looks good, didn't happen to make an extra one? I need to fab up one myself.