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  1. Yesterday
  2. Stuart...It's all about air volume...The Ingersoll-Rand Garage Mate is great for light air tools, HVLP painting and tire service. It hit the wall, however, when used with the blasting cabinet. Blasting takes a large volume of air and requires a big air tank. At that, even the Air Boy 23 CFM compressor will run intermittently while blasting, which is really a lot of air. The 23 cfm Champion compressor is a beast, so the bead blasting never slows down, even when the compressor is running. I regulate the tank pressure between 125 PSI and 150 PSI, the line pressure is 90-100 PSI. The body shop where this compressor resided for years actually had two large air tanks, the one that came with the compressor and a second tank also filled by this compressor. They had an automatic drain on the compressor and system, which dramatically reduces the risk of the tank(s) rusting out. On that note, I put a Harbor Freight drain on the I-R Garage Mate and need to do something similar (commercial grade) on this 120 gallon tank. I consider myself lucky to have found a big shop grade compressor in good condition. It was used plenty, but not abused, and serviced regularly. There are rebuild kits available for these iron Champion compressor units. If you could find a similar unit, you'd have a lifetime system. Mine is single phase 5 H.P. with a magnetic starter (clunk, clunk!). There are alternatives like the two-stage (not twin-stage) DeVilbiss iron upright unit that I used for years. It had a 230V single phase capacitor start motor and enough CFM for bead blasting; however, it ran at a much higher rpm. That DeVilbiss consumer unit never gave trouble despite rumors that they suck reed valves. I bought the DeVilbiss at Costco in the mid-'nineties for around $800, a bargain in hindsight! Moses
  3. Last week
  4. Wow! I can relate to your story about the compressor. If I do any more of this restoration work I'm moving in next door. 🙂I need to finish this jeep so I can get back to my airplane project.
  5. Very interesting, Stuart...I have a commercial washing cabinet and am always concerned about DIY home garage practices. You're basically getting the same cleaning job done as me, although your clean-up takes a few more steps and follow-up chores. The T18 castings and gears look terrific after cleaning! Your propane "cooker" seems to do the trick, very innovative, you can even barbecue afterward to celebrate how clean the parts look...Cleaned parts look like they came from a cabinet washer! I'm using a commercial wash cabinet with a solution that lasts a long time. When the solution is no longer active, I have a commercial company pump the tank. If left dormant long enough, the water evaporates, and I can scrape the dehydrated cleaner/residue from the floor of the cabinet and simply vacuum it up with my Ridgid 1450 shop vacuum. I then pour another round of Goodson washer cabinet soap into fresh water. The system is approximately 53-55 gallon capacity. Some users claim these cabinets are more effective once dirty grease and petroleum products dissolve into the solution. I bought my Walker (no longer in production) washer cabinet new in the mid-'nineties for our larger shop; this machine has paid for itself many times over. The rotating table can support 1,000-pounds (a Cummins engine block, etc.). The table turns slowly while 45 psi nozzles spray heated soluble cleaner from all angles. I use a perforated metal basket for smaller parts, and all parts clean up well. The Walker machine was designed for automotive machine shops. The washer requires 220V (single-phase) for the 2 h.p. high volume pump, two 4500W heating elements and the rotating table. The tank heats to 140-160-degrees F, and I get away with a setting of 140-145 degrees F. The Goodson Tools PJS-50 non-caustic cabinet soap works very well for iron castings and aluminum. This cleaner is an anti-foaming formula. (Commercial pumping is needed for the toxic debris that comes from dirty parts and castings. The pumping cost is unnecessary when I can allow the tank to evaporate naturally then scrape the settled debris and pick it up from the dry tank with the bag-lined shop vacuum.) After a timer cleaning cycle, I crack the door open; all hot parts, castings, etc., will flash dry and not rust. This machine is a keeper, like my 120 gallon compressed air system. I moved the heavy washer cabinet into my smaller 580 sq.ft. studio/garage in 2009 and bought this used 23-CFM Air Boy compressor with a horizontal tank during the Great Recession: https://www.4wdmechanix.com/Downsizing-and-Air-Compressors?r=1 If you do any volume of parts cleaning, these washing cabinets do come up in used form during shop liquidations and at tool auctions. Like the compressor, the mechanical condition is critical; there are expensive components that can wear beyond repair. At last year's SEMA Show, CRC showed the SmartWasher®, a washing basin and cleaning solution that will be very popular for "green" shops. See the video [go to 13:13 minutes] for details: https://www.4wdmechanix.com/2018-sema-show-new-products/. Moses
  6. Earlier
  7. Moses, The Pro Chem Ferrous Soak came in Powder form and is high in alkaline content. I filled a 20 gallon metal wash basin from the garden section and added the prescribed amount of powder. Then I heated it with a propane burner since it is meant to be a hot process. I think 160 degrees to 200 degrees is recommended. I attached wires to everything I dipped since this stuff is highly caustic it makes getting the parts out easier. You don't want this stuff on your hands. It really goes to work immediately on the grime. I scraped off the big chunks first. It was especially useful when I dipped my intake and exhaust manifolds as it really eats up old rust and all the years of black soot carbon. When done I sprayed each item with a pressure washer. The downside as I said is the messy tub of goo afterwards and no its not reusable but it is bio degradable and environmentally friendly they say. I had gotten this solution from and old engine shop guy who retired and was getting rid of everything. I think this product has been discontinued as I cant find it on the prochem website but they do have several other products similar. It sure did a great job and beat scrubbing for hours.
  8. Pleased that you have the low compound first gear ratio! This is a highly desirable gearbox with plenty of stamina for the fresh 4.2L inline six. Nice work and attention to details, Stuart. (Your closing paragraph is rife with critical tips, valuable to builders.) Your effort will deliver for decades! Thanks for sharing the Pro Chem tip. Interesting how effectively the solution works. You "boil" the parts in the solution? Is heat involved, or is this a cold tank solution? It does a great job and makes the work inviting...Are you able to reuse the Pro Chem? Did you pre-clean the case and other parts before the Pro Chem cleaning? Moses
  9. I was fortunate enough to find a project jeep with the T-18 transmission and coveted low first gear. I decided to go for the complete rebuild since it was out and needed cleaning. Again I opted for the Novack kit. I probably should have done this as a step by step blog with more pictures but hopefully these will help someone. #1 rule take pictures of everything you take apart before hand. #2 get a professional grade set of snap ring pliers. My CJ re-builders manual and shop manual were invaluable. With these and the Novack instructions I made it through with very few tears. I had done the t-98 on my CJ3-B several years ago so decided to dive in. When I opened the case I found things to be in pretty good shape but several years of sitting allowed condensation to spot some things with minor surface rust. My first big challenge was pulling the front bearing which didn't come easy. I about gave up but finally got a very large clam-shell style puller. The snap rings on this transmission are serious business. Safety glasses and a careful approach are required. Once I had the main shaft out I knew I was past the point of no return. I was amazed at how heavy this shaft is along with the counter shaft. This requires strong arms to hold steady during re-assembly. I really appreciated the PTO cover being off as it allowed me to hold things in place during re-assembly. Once I had everything dissembled I boiled the case in Pro Chem Ferrous Soak. For the aluminum bell housing I used the milder Citrus Soak. I finally found a use for this after doing my Corvair engine. The needle bearing installation looks intimidating but really is not thanks to sticky grease and the keystone effect holding them in place. By far the most difficult step was working on the 1rst/2nd clutch hub. It has three large ball bearings compressed against strong springs while the sleeve is slipped over. Definitely get some extra helping hands here. Don't be stubborn like me and try to do it alone. The springs will shoot the ball bearings into every dark recess of your shop trust me. My shop manual describes using the 3rd/4th hub as spacer jig on the bench to hold the assembly just right while you simultaneously press all three bearings into place and slip the sleeve over. After about 20 tries and searches for lost ball bearings I was successful. There has got to be a better way. I'll bet they had a slick jig at the factory for this. Sorry no good pictures of this. My hands were full but here is my 3rd /4th assembly and the 1rst /2nd assembly . Syncros and gears were in great shape. I was happy to get the fresh bearings so I don't regret the time and expense. I invested in a shop press since I needed it for some of the assembly. This transmission is a heavy monster. Get help moving into the press. Seeing the finished work is rewarding. I'm glad I didn't chicken out because I came real close. To finish up I needed to mate it back up to the Dana 20. I was worried about how to do this and not wreck the gasket since things are so heavy. I wound up putting to transfer case on the front of the jeep. Since the grill is off this made a nice bench. I used the hoist to lift the t-18 into place and line things up perfectly. It worked great. Everything got a coat of black pain before going back under the jeep. Final lessens learned. #1 The transfer case shift assembly will not go back on with the bell housing in place. I left it off to make it easier to get under the jeep or so I thought. Don't forget the little spring that connects to the throw-out bearing. It wont go on if the bell housing is on since it hooks internally to the housing. #2 My CJ-7 belly pan has several sets of holes for mounting to various jeep power train configurations. I failed to take note of which ones were used and had a hard time when wrestling with the tranny jack and trying to figure out which ones to use. I got so confused at one point that I was convinced I had the belly pan on backwards. I finally figured it out but should have taken pictures or notes.
  10. Helpful illustrations and comments, Stuart. Those tackling the Spicer 20 rebuild will appreciate this! Great photos, too. For those seeking detailed, step-by-step instructions on this rebuild, I cover the complete rebuild of the Spicer 20, including bearing endplay shimming, in the Jeep® CJ Rebuilder's Manual: 1972-86 (Bentley Publishers). Moses
  11. These radiators did use a shroud, Stuart. It's worth having. As long as the shroud captures the air flow through the radiator, it will work well. There are shorter fan spacers available, too. Maybe a 1/2" spacer would work better? Fan spacers are available from aftermarket fan manufacturers like Flex-A-Lite. Quadratec and others offer a new replacement shroud. This illustration should be helpful if you're looking for a used shroud: https://www.quadratec.com/products/51218_100_07.htm?utm_id=go_cmp-1786233520_adg-68197440694_ad-346566180389_pla-713667809956_dev-c_ext-_prd-25868&gclid=CjwKEAjw__fnBRCNpvH8iqy4xl4SJAC4XERP1R-KZjCF1QKdm_qY9195D2k2kM5vzYCvYfdYqcMTWhoCokXw_wcB Moses
  12. I recently rebuilt my Dana/Spicer 20 transfer case from my 77 CJ-7. After 100,00 plus miles it turned out to be in remarkable shape internally, but outside it was a greasy mess. I decided to use the Novack rebuild kit. I just happened to have a 5 gallon bucket of Pro Chem ferrous soak which took all the hard work out of cleaning the case. This stuff really works! I used a large steel tub and a propane burner for heat. Gloves and safety glasses are required as this is a highly caustic solution. It eats away rust, scale, paint and grease in short order. The downside is you will have a tub of black smelly water to deal with afterwards. The rebuild was straight forward thanks to my CJ rebuild guide and my 1977 shop manual. Trial fitting and walking through each procedure mentally helped eliminate mistakes. There is a certain sequence to follow which I stuck to for the most part. Setting up the front output shaft end play was a critical step which takes time and patience. A magnetic dial run out gauge really helped here. I think Novack makes a billet unit to replace the shims and help eliminate leaks. I used lots of sealer on the shims. The one place I ran into trouble was installing the new Novack super hard intermediate shaft. "super hard" describes the installation process as no amount of persuasion from my dead-blow hammer could force it all the way into the bore on the front of the case. I finally found a socket that fit this bore size and gently lapped the bore with some super fine lapping compound. I did just enough to get the shaft to go in all the way. I did not have a shop press at this point but got one later when I did the t-18 rebuild. I was disappointed with my Novack instructions as they did not mention rebuilding the tail shaft assembly at all other than final assembly where it just says to reattach it. I spent a lot of time on this step setting up the pre-load with the various shims. A lot of trial and error was required here but getting it right is critical so i stuck with it until I was happy. I used Permatex ultra-gray on both sides of all gaskets and sealer on any bolts that are exposed to the inside of the case. I'm hoping for no leaks. I'm happy with the results as the unit turns freely and has proper pre-load on both outputs plus its nice and shiny now to boot.
  13. I have a question about spacing between my fan and radiator. The old radiator was not salvageable and had a thin cross section and the fan used a 1 inch spacer. The new replacement is an aluminum replacement and much thicker. I plan to keep my original fan and using the spacer is not an option. There is now 1-3/16" clearance between the fan and radiator. I don't know what is optimal. If this jeep had a shroud I don't have it. I guess I can make one or find an aftermarket one.
  14. Really looks nice, Stuart...I like your approach, taking time to not overlook details. This should be a 200K-plus engine when you finish. Once past break-in, my recommendation would be either a synthetic motor oil like Mobil 1 or Chevron's Supreme with ISOSYN formulation. This is a long stroke engine with lots of piston travel. Protect those fresh cylinder walls and piston rings, and they will deliver many years of service! Looking forward to the T18 and Spicer 20 details. Quite a restoration...The Model 20 AMC rear axle and Dana 30 front each hold up well. Moses
  15. I have made some more progress. The engine is finally in and I'm slowly going thru the checklist of making sure everything is done. I decided to take time out to rebuild the T-18 transmission and Model 20 transfer case since it was all out and needed cleaning. I will try to make a separate post about that as it all turned out good. I had the clutch rebuilt and resurfaced the flywheel and added a new pilot bushing. Everything was torqued to specs and threadlocker was used. I had a little trouble getting her in and had to use a load leveler and extended hoist but its in. I still need to rebuild the carter carb. In the meantime I'm getting ready to prime it and study my DUI ignition instructions. I used the ARP thread sealer on the #11 head bolt. Just taking my time to make sure I don't forget something like putting the oil in.
  16. Well, Monty, this is restoration!...Paths are not often clear, but you figured out how this works. 50/50 warm air split split sounds right. These heaters/defrosters actually work well when functional. Suggestion if the control is still apart: Put a piece of very fine wet-and-dry sandpaper on flat glass. Lube the paper with WD-40 or a similar penetrant. Work the pieces in your photo in a circular motion on the surface of the paper. An alternative is Autosol Metal Polish placed directly on the glass, use the same motion with the parts: https://www.amazon.com/Autosol-Utosol-0400-Metal-Polish/dp/B003XJ1ODM/ref=sr_1_9?crid=2XSOKCQ8QI8O6&keywords=autosol+metal+polish&qid=1557407568&s=gateway&sprefix=autosol%2Caps%2C205&sr=8-9 .) This will take out any surface warp or scoring. Don't remove any more material than necessary to clean and true up the mating surfaces. The effort will reduce risk of vacuum leaks. Make sure that these mating pieces are tensioned properly to maintain vacuum seal. Moses
  17. Moses, I was trying to figure out how the controler worked. Not having a steady supply of vacuum, I was blowing into the controler to determine how it functioned. Having disassemble the controller, nothing appeared to be worn out or missing, which is good! My original thoughts was that on "defrost" ALL of the the air would be diverted to the defrost vents. That is not the case, it appears that it will be split 50, 50. I've tested the diaphragm's and they are holding a vacuum. Soo all I mite do is refinish the controll panel and put things back together.
  18. Things are looking up there, Speed! The mileage is impressive, and that's the end game with an Explorer...Good progress! Moses
  19. Okay-I got the exhaust tightened up,Got the wheel bearings packed/replaced,and the Exploder is substantially more fun to drive. Still a bit road-wild,due to the right lower ball joint being shot,but FAR better than before. Gassed it up and drove to Carlin and back,and it seems to be better gas mileage around town than on the highway-To Carlin,a wee bit of creeping around town there,and back got 18.2 mpg,but before that,a week of just town driving around Elko got me 20.4 mpg. The mileage COULD be about the same if I kept the highway speed closer to 65-70 instead of 75-80. (80 is about 3000 rpm.) The shop who did the exhaust and wheel bearings gave me a quote to replace the lower ball joints,but the owner said,"Huh-THIS is weird. For only another 3/10ths of an hour flat rate you can get ALL FOUR done." That'll make it around $360.00 plus my cost for parts. Not sure if he's set up to align it but that's not bad. As far as "farmed out" work,that'll be about all I need. The rest of it is just little stuff I can do myself. OH-that reminds me,I was given a '93 Exploder parts car. No title,but it's complete and is a runner. Has an auto. tx and full time 4X4. The guy says he thinks it has a posi rear end too. If that's true,I HOPE it's a 3.73 ratio. That'll also give me a couple of doors and the LF hinges,the inside liftgate cover,and a receiver hitch,and MAYBE even a set of hubcaps. I'm going out to check it out Sunday and do an "inventory" of what I can use. Speed
  20. Hi, Monty! Interesting...So, you're applying vacuum to the port at 10 o'clock? It would seem that you need the option of AIR and DEF functioning at the same time. Otherwise, you would have either defrost only or heat (floorboard) only. If AIR is ambient air ducting through the heater core, that would allow heat without the blower on. Typically, the flaps open with vacuum, not with pressurized air. What you would want is to have vacuum apply to the defroster flap with the DEF pushed in. You would want air to flow from the floorboard vents with the AIR pushed in. That should help determine which port on the switch is the vacuum source. Your vacuum supply source should be vacuum from the engine (manifold), a constant source that is either OFF or directed to the AIR or DEF flaps, depending upon the position of the vacuum switch. Make sense? I'll watch for your reply... Moses
  21. Been plugging away on my "mistress". It appears that the heater control is intact. But the vacuum does not appear to be working right. The hole at the 10 o-clock position seems to be the supply position. When I place the hose on the the hole at 10 o-clock with the DEF pushed in air blows thru the other 2 holes. With the AIR pushed in , air only comes thru the hole at 4 o-clock. With the OFF pushed in no air flows out of either of the holes. Seems to be a problem with the defrost. Is there anything that can be done? Thanks, Roger
  22. Ian, this is fascinating! The derivative Jeep models and even full departures from U.S. models are really something. I like the Combat 6 (Falcon 144/170 powered!) and Nissan diesel engine options. Apparently, the Australian division was given autonomy to serve the country's usage needs. Your CJ10 (J10 'Tonner') and other models look stout and rugged in the marketing photos. There's a bent on utility much like the U.S. vehicles in the day...I like the pragmatism in the design features and continued build of models that worked well—like the CJ-7. Thanks for sharing...Others should really find the information interesting. Jeep had an early presence in Australian. The tall hood CJ-3B happens to be my favorite flat-fender! Moses
  23. Hi Moses just thought i would add this link it has some very interesting info on jeeps down under https://www.cj3b.info/World/AustraliaHistory.html
  24. I'm rooting for Cummins, too, Ian...I publicized the R2.8L turbo-diesel with enthusiasm, including interviews with Cummins' Steve Sanders. Cummins was confident of an E.O. number from California, as Chevrolet got one on the E-Rod crate V-8 engine (which likely had a domestic vehicle installation prototype with EPA approval). Cummins was actually breaking ground with the effort to approve a crate engine without an EPA vehicle donor. The R2.8L engine meets Euro current and go-forward emissions requirements, way in excess of U.S. standards for Cummins' E.O. attempt, which initially targeted a 1999 or earlier chassis application—just to assure a lower bar for emissions levels. Cummins planned to proceed from there, gradually including later chassis like the Jeep JK and such. Several non-compliance ("49-State") examples are in the field now. You'd like the installs on an FJ62 chassis, FJ40s, Land Rovers and a TJ Wrangler or two. Moses
  25. Hi Moses fortunately due to the age of this vehicle it is pre emissions regulations so it wont have to be tested for emissions our ADR's (australian design rules) cannot be retrospectively applied therefore it only has to meet rules that existed when it was first registered but the rule about the engine not being older than the chassis applies over here so most of what the engineer has to do is make sure the conversion was done in a correct safe manner im sure that there would be more involved were it a later model vehicle interesting info i hope that cummins are successful with there bid for compliance on that engine
  26. Speed...Sorry you're health has been a challenge. Rusted bolts can be a huge challenge. For those who have the stamina and patience to wade their way through rusty and broken bolt repairs, here are a couple of useful links. This is HD video coverage on tools specific to this chore: 1) https://www.4wdmechanix.com/otc-tools-how-to-quickly-remove-broken-manifold-studs/ [This demonstration is useful.] 2) https://www.4wdmechanix.com/2018-sema-show-new-products/ [2018 SEMA Show new products; there are a couple of new bolt extracting tools buried in this tour.] Moses
  27. Hi, Ian...The engineer sounds like the California model for Clean Air Resources Board. Engine swaps are legal if two basic criteria are met: 1) engine must be same year or new than chassis and in the same emissions class and 2) the tailpipe tests must show emissions at or below the emissions standard for the original engine in good operating condition. If the swap is legal, the owner takes the vehicle to a "Referee Station" for an inspection around the engine conversion. At California and other states that use this standard, you cannot swap a Class 2 or 3 engine (basically from a heavier light-duty truck or a medium duty GVW truck) into a Class 1 emissions vehicle (a car, SUV or light truck to 6000 pounds GVWR). Our 1999 Jeep XJ Cherokee 4WD is a Class 1 emissions vehicle by this standard: ≤ 6,000 Class 1: ≤ 6,000 lbs Light Duty ≤ 10,000 lbs Light Duty ≤ 10,000 lbs 10,000 Class 2: 6,001-10,000 lbs 14,000 Class 3: 10,001-14,000 lbs Medium Duty 10,001-26,000 lbs Medium Duty 10,001-19,500 lbs 16,000 Class 4: 14,001-16,000 lbs 19,500 Class 5: 16,001-19,500 lbs 26,000 Class 6: 19,501-26,000 lbs Light Heavy Duty 19,501-26,000 lbs 33,000 Class 7: 26,001-33,000 lbs Heavy Duty ≥ 26,001 lbs Heavy Duty ≥ 26,001 lbs > 33,000 Class 8: > 33,000 lbs This stipulation made it impossible to install an Isuzu/GM 3.9L four-cylinder diesel engine into our gasoline XJ Cherokee. (Diesel engine to a gasoline vehicle was not the problem, the engine's use by GVW was the issue.) However, I could put a VW, Volvo passenger car or BMW turbo-diesel engine in this chassis. (Why bother, right?) The requirements are very weird, as the Isuzu engine is relatively clean burning and emissions compliant, but the chassis applications are Emissions Class 2 and 3 trucks. I wanted a 50-State legal result. Advance Adapters was willing to prototype a swap kit, but we agreed that such a venture needed to yield a 50-State legal package. As a point of interest, Cummins is caught in a conundrum with its R2.8L turbo-diesel crate engine. The engine meets requirements for emissions but has no U.S./EPA approved use in a motor vehicle. (Cummins did a joint venture concept vehicle with Nissan. They installed this engine in a Frontier pickup with great results, but the model never went into production, which would have resulted in EPA approval and a legal emissions prototype for certifying the crate engine as a "2019 Nissan Frontier" (Class 1 emissions) engine...Cummins has been trying to certify this crate engine on its own merits to market as a California/50-State legal crate engine package. The California ARB has yet to approve or issue an E.O. number on this engine. The process is in stalemate at present. Moses
  28. Found a shop that "specializes" in rusted exhaust bolts;their shop looks a mess but they have a good rep for doing good reliable work,so I'm getting an estimate to fix the exhaust leaks and do a wheel bearing pack,installing the locking hubs I'll be bringing in. (I have new Timken bearings and National grease seals to use-they're fine with using the parts I bring in,as long as they're not used or "no-name" junk.) I have a brake hose to replace on the right front,but I can do that myself. I also bought some synthetic ATF to use in the T/C when I install the manual shift unit. Still need a couple of pieces of linkage for that-the tab and retaining nut and washer on the T/C,the shift link to the shifter and the shouldered bolt the shifter pivots on. I could make these parts,but I'd need a transmission to attach everything to,to mock it all up and test its operation on the bench.The way I see it,I'm getting close to having the machine I've wanted for quite a while,comfortable,roomy,reliable,set up the way I LIKE it,runs down the 4 lane at 90+ all day long,with decent mileage thrown in while still capable of bashing around the hills-all for under 2 grand. Down the road I might throw a little more into it for a locking rear end,a receiver hitch,maybe a beefier front bumper with a winch,but that's really about all I could want. I have PLENTY of OTHER trucks for other purposes. It must look like I'm lazy,but this last year has wrought havoc with my health,and I've discovered there's a LOT of work I just can't do anymore. Speed
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