That is an awesome piece of gear Phil. I have been really enjoying watching your progress on the mammoth.
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That is an awesome piece of gear Phil. I have been really enjoying watching your progress on the mammoth.
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Oh wow that really is very nice. .
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Thanks Chris, its been pretty interesting from my end as well at times!!! The wife continues to ask ' when are you going to stop spending', and I keep lying and saying ' I've finished'. then find something else I simply can't live without and she gets another surprise on the Visa card - she loves surprises!!! I did the right thing though this last roster and said I had a couple more 'small things to pick up', which is sort of true because the interchiller is smallish, and the intercooler core is so small it fits inside the manifold, and the pump is smallish in size and the space to fit it is 'smallish' so I sort of told the truth in my demented mind. I picked up some smallish temp probes and controller today for the pre and aft cooled air to the engine - very small they were.Quote:
Originally Posted by Winnie
Yes, Its neat alright. The shot is from their album, mine is being made now. They will add the boost gauge and temp probe tapping for me as well. The units is a change over on my standard manifold, which is a kind gesture as it will save me some time for sure, but won't get the goods until late Jan it seems - simply too close to Xmas and I think the core might be from ADRAD in SA and tanks in QLD somewhere.Quote:
Originally Posted by Rossco
The wiring strip out has begun. Can anyone identify what this connector is for? Its in the original factory loom, disappears into the front passenger side behind the headlight. I think its something to do with the charge circuit. It reads the same voltage as the alternator, however the alternator is not charging right now - 12.2V - so looking to solve that one also.Attachment 79769
No but you just found a great spot to take a Trigger from under the engine bay if you need it. Is it 12v when the ignition is on? It really could be anything? especially since you have a conversion. Nissan are renowned for fitting full looms and just leaving plugs floating around.
The extended loom, has a crimped eye on the other end - maybe its a spare charge wire to the second battery? Appears the alternator I have fitted must have a sense circuit off a different plug. Its 12V with ignition on or off. I simply don't remember where it came off - was 6 months ago I disconnected the old front end of the motor.
@Rossco, any idea since you have had your looms in pieces?@matfew?
Attachment 79770
Here are the cables, looking at wiring diagram the lug should be the earth, unsure what the smaller one is - maybe off the old a/c clutch - need to check the connector tomorrow
Wiring purged today, undAttachment 79771er bonnet and inside the cabin, plus removal of sat phone and cd stacker and hands free etc - Codan HF coming out for an upgraded model.
Attachment 79773
SIK!! This will be Liberating mate.Quote:
Originally Posted by PeeBee
I feel as free as a moth in a cyclone, liberated NOT, just now realising the job ahead, have not even stared with the rats nest under the dash - that's tomorrow, then into the back of the beast.
Crickies Phil, wouldn't have a clue mate. . Haha sorry but good luck does look like fun . .Quote:
Originally Posted by PeeBee
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BS I call, YOU DO know what it is, stop toying with me.Quote:
Originally Posted by Rossco
OK, new clutch installed, light action, but noise from gearbox increased for first 200m then settled down a bit, gearbox oil changed today as well. Drive is even more savage I guess and acceleration noticeably better, so suspect the original clutch was slipping to some degree. Found a double clutch action eased the shock/jolt on downshifts, alternator now charging - missed a wire on reconnection, so that's a relief on a brand new 300amp unit. Back into the wiring tomorrow for a bit then have to sort the garage out before heading back to site. Happy its getting closer, still have the alignment of belt issue to some degree, however will see what effect the new manifold and intercooler assy have on the issue.
Attacked one of the Diesel particulate filters to remove the guts - what a job - cant drill or hole saw the stuff out, need to punch it out, lot of effortAttachment 79823
One for engineering, one for touring.
New coolant surge tank arrived from China today, 7 days from sketches to on my doorstep. I have lagged it in a foam insulation for temp control.Attachment 79824
Mounted surge tank, insulated, waiting for the rest of the parts to arrive
Attachment 79849Attachment 79848
Back on home on break, more 'stuff about to be added. New inlet manifold with integrated intercooler core, DCDC charger, have lined up the interchiller for end of FEB, going all out with the Stage 2 kit, should be goodAttachment 80040Attachment 80041Attachment 80042
The interchiller looks like it'll cause more harm then good jammed in there like that. I assume it's a proven design and all good, just looks like a big ol obstruction.
This is the w2a heat exchanger, integrated between the outlet of the s/c and located inside the inlet plenum. Its a standard fitment. The interchiller is an additional module that runs off the a/c circuit. Have a look at fi interchillers.com The interchiller circuit cools the w2a intercooler water to circa -20 degC in the stage 2 kit. There are two new heat exchangers in the circuit - a w2a for the air entering the engine and two a/c gas to water heat exchanger to chill the water. The Stage 2 system uses the original car condenser then adds another 2 condensors in series to sequentially suck the heat out of the refrigerant. The heat exchanger in the inlet manifold is made by ADRAD in Adelaide. If its efficiency is as good as the alum ADRAD I have up front, should be no problems.Quote:
Originally Posted by 0-TJ-0
What is deceptive perhaps is the missing interface plate that sits sandwiched between the s/c and the coil - is a pretty neat setup.
Well there ya go, learning every day. I've never touched superchargers so definitely never seen under the petticoat. Interchiller looks like the business. Gunna be a good setup when you've got it all done mate.
I think so too, its been a journey all right and sort of the more you do the more you understand the areas that can be optimised. I am after longevity and a solid package, which is what I should get. I didn't know anything about s/c before I started, and still have a lot to learn as diesel applications have not been as developed or optimised as the petrol variants. I read the books and ask the questions, its all knowledge.Quote:
Originally Posted by 0-TJ-0
How long until the next weekend away Phil?
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Be weary of the cheek old head young shoulders :-) [emoji106]
Bags first for a Yonk outa the soft stuff from the screws [emoji106][emoji106]
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Chris,Quote:
Originally Posted by Winnie
in reality I could be out in it now however its still got '8 things' I am trying to sort out, the 3 biggies are the finalisation of the wiring, another 3 days I reckon, the total resolution of the Intercooler/interchiller setup and the chassis plating. I will hook into the wiring this break, and swap out the inlet manifold, then its maybe the plating of the chassis next break, so that the end of Feb. The Interchiller is going to be ordered mid feb for alignment with 2nd break, then install it mechanically. I would like to think I can get it actually charged up that third roster but might have to wait until mid March break - assuming everything goes to plan. The second condenser location is going to be a challenge, its 500 x 400 x 10mm thick. Its normally supplied with a1600cfm SPAL pusher fan and sits in front of the radiator. I am running out of space with the oil cooler, factory a/c condensor and fan, the additional 2500cfm elec booster fan takes up a bit of space. I might end up mounting it horizontally above the engine , directly below the bonnet scoop inlet as that hole is huge - but that makes the a/c lines longer and plumbing a pain - just a few more problems. I want it on the road asap, but am not going to rush it like in the past. I want to be at Licola this year - work stuffed me up last year, so it definitely will be done by then. I then want it thru engineering before doing much else, but that will be an easy appointment as I have already opened the dialogue with the assessor and am following his lead.
So maybe squeeze in a weekend late April/May - will certainly give you the heads up along with the rest of the herd.
No problem, you can be the driver of the tug!Quote:
Originally Posted by MB
New manifold went on today, holes didn't line up again, just like the first one, however the belt alignment is now perfect, so will run the 6 rib belt just to confirm then swap out to the 8 rib later. Setting up the temp sensors again and also the redarc low water unit.
Next job is the chassis plates.
Inlet air temp probes 1 and 2 installed and operational, needed to run a 1/8" NPT tap thru a socket - $68 later, two probes sitting nice and proud in the airstream. Have extended the looms on the 2 EGT sensors to get them up near the drivers side pillar, along with the boost gauge. Mounted the Codan NGT handset after making bracket no. 2 - the first one was devoured by the garage monster and will no doubt turn up one day. Short day tomorrow, garage hand back day before returning to site.
Will have a look at the opportunity for the additional a/c condenser with luck. Took the beast out for a squirt, the 6 rib belts are squealing under hard acceleration, so I think the 8 ribs will be going on pretty soon also.
Thought I was getting closer, but the list just grew again.
Plate chassis
Low water alarm
Boost gauge
Water mist injection
Aux fuel gauge
Bulge blowers
A/c clutch wire
Windscreen light power
Shuroo
Difflock compressor
Vacuum reservoir
Vacuum pump
Codan connect up
JingPing rear floor
Interchiller installation
Surge tank double insulate
Boost pump wire and speed control
Install boost pump flow meter
Swap out 8 rib belt
Power to roof rack lights
Weld out front diff brace
Weld up rear diff brace for model
Main large compressor and ringmain
Cel-Fi install
Bloody hell, I am getting tired of this right now.
Crikey Philstar, you’ll get there Legend!
If anyone can..........
https://youtu.be/qztuEucrNBc
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Interchiller Stage 2 kit ordered today, 3 weeks leadtime at the moment.
https://fiinterchillers.com/products/
https://youtu.be/ydax3oIz9cA
Progress over the last 2 days, but some more annoying issues
1) Redarc low water alarm fitted
2) Boost gauge installed - VDO direct pressure line - no boost on gauge under WOT.
3) Aux fuel tank gauge refitted - no dash light power feed to gauge - was working before
4) Made bracket for ARB diff lock compressor - mounted up well in different location to original. reconfigure the air inlet filter
5) Made bracket for brake vac pump reservoir. Big reservoir with gauge
6) Hooked up 2nd fuel flowmeter sensor circuit
7) Tidied up difflock wiring loom, reconnected to compressor - no power to the switch
8) mounted new triple gauge cluster with 2 x EGT gauges and Boost - no dash lights in gauges.
9) no smoke testing today.
Tomorrow - if I have the strength/mindset, look into the electrical issues above, however bigger prize is to shift the existing a/c condenser back towards the radiator so the stage 2 interchiller condenser will fit with the existing 12V fans - going to be a painful day I think.
Finished for this roster break. Twisted and bent pressure hose was the culprit on the boost gauge, so 1 hr later, all fixed. Spaced out the electric fans to generate the pocket for the additional condenser. Grill still goes on with a bit of care, so happy days. Still can't find the a/c trigger wire, looks like I will have to try and trace it from the switch, or simply leave it to the a/c guys when they run the new hoses and charge it up.
Few pics of this rosters results. Need to re-stick the pod down though - next roster break.
Attachment 80548Attachment 80549Attachment 80550
OK, interchiller in my hot hands, looking to install this roster break. Plus a new replacement condenser to replace the 23 YO one, and also a power upgrade pulley for the s/c to compensate for the intercooler pressure drop
Attachment 80647
Attachment 80648
Attachment 80649
Progress. Should finish the installation tomorrow to the point I can hook up the water circuitAttachment 80657
Attachment 80658Attachment 80660
Another big day, but steady steady. Interchiller is now mounted in a bomb proof enclosure, high volume 12V fan mounted, needed a new bracket as expected, will start running the lines for gas and water tomorrow. Looking for a slightly smaller oil cooler, circa 150 w x 200 high to get the heat load off the two condensors ( existing is 250 sq.). I will retain the second tube heat exchanger as it works well
Nightmare day, hate this car, glad to go back to work, just not happening, bee stings by the handful.
Need a hug mate?Quote:
Originally Posted by PeeBee
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Better day today, water to air circuit plumbed up with pressure, flowmeter and temperature sensors - just need to power them up now. Lines insulated. Resolved the 'odd ball fitting' off the condenser - metric m20 x 1.5P, Patrol a Part assisted with the solution, great service. Next roster will see the a/c hooked up. Noticed the s/c pulley has been touching the bonnet, so luck would have it the higher boost pulley is in my hands, so will fit it tomorrow morning before shed clean up ritualAttachment 80676
Attachment 80677[ATTACH=CONFIG]80678[/ATTACH)
Have also insulated the pump housing