1970 Gladiator 1 Ton 6BT 12V Cummins Build

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Resbum
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

WooHoo:drivin: :fsj: :alc: :dancingbanana:


Prestart walk around
[youtube]http://www.youtube.com/watch?v=SsbRrt0oTBE[/youtube]


Initial engine start
[youtube]http://www.youtube.com/watch?v=wuUFwmqcVn0[/youtube]


Engine Break-in
[youtube]http://www.youtube.com/watch?v=GZ6fE9v8TwQ[/youtube]


Exhaust sound at tailpipe 1600RPM. The exhaust note is much mellower than the phone camera recorded.
Deleted- I couldn't stand it. The vid doesn't sound anything like the truck really does


Post break-in idle.
[youtube]http://www.youtube.com/watch?v=g3raL9exycU[/youtube]
Last edited by Resbum on Sat Apr 06, 2013 5:11 pm, edited 1 time in total.
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

Thanks Everyone.

As ross said, I feel this is a huge milestone. Last night, while watching the tube, I could literally feel stress draining out of me. If the truck had a steering column and the brake master cylinder it could move under its own power.

There are several things I need to debug and/or fix, but I expected that.
Quote:
________________________________________
Originally Posted by ross80truck
.... I can rest easy now that I know you have it running. I have been sitting on the edge of my seat in anticipation!
_____________________________________
___

I wish IFSJA had a smiley chewing on its fingertips with nail clippings flying all over the place.

Resbum
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

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The engine has now had three runs on it for hot/cold cycles, totaling about an hour run time. Among other things, that's what Performance Coatings recommended to cure the ceramic coatings. Now I'm going to partially disassemble things and check valve clearance, torques, etc.

I have a couple major concerns that showed themselves in the second and third runs, but will hold off describing them until I talk to people more knowledgeable than myself. I don't want to muddy the water if they turn out to be non-issues.

One thing I'm definitely going to have to do is reflare all my transmission cooler lines. About half the joints have leaked, so I have to assume even the ones that haven't leaked are barely sealed.

Resbum
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

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Quote:
________________________________________
Originally Posted by Resbum
...
I have a couple major concerns that showed themselves in the second and third runs, but will hold off describing them until I talk to people more knowledgeable than myself. I don't want to muddy the water if they turn out to be non-issues
.
________________________________________
I got lucky in that neither appears to be a problem:
1- I was having problems with the trans going into "Park". A tweak on the linkage and once the drive shaft is on the problem should be solved
2- On the second and third runs I had A LOT of white smoke and the engine struggled to come off of idle until it started to really warm up. On these runs the fuel pressure had dropped to barely 20psi. Also, on the first run I had prewarmed the engine with the block heater, but not the second and third runs.

In researching the smoke issue I found the AirDog fuel pressure ball and spring can cause the pressure drop. I took it apart and shimmed the spring up to a steady 29psi now. Another thing I learned was that the stock Overflow Valve (OFV) on the P-pump can cause problems with fuel pressure drop under wide open throttle heavy load applications. Tork Teknology Image
Last edited by Resbum on Tue Apr 16, 2013 12:45 pm, edited 2 times in total.
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

Besides working on the above, I've also reset the valve clearance. The exhaust valves had stayed at .020", but the intake valves had all tightened up .002" so I reset them to .010"

The torque on the headbolts stayed the same. Not one headbolt required tightening.

Beyond that I've been checking all the other nuts, bolts, etc.
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

.
.
Originally posted by ross80truck 11-13-2012 05:33 AM
________________________________________
Thanks for posting the stuff about Larry B's. I am going to have to tackle the fuel shut off solenoid stuff once I get my motor in. Looks like there is a lot of good information on his website. I already have a new solenoid on my pump, but i am going to need all the other stuff to set it up.

Also, one question I have been meaning to ask. How did you wire up your alternator? Does the alternator have an internal regulator?
Last edited by Resbum on Sat Apr 06, 2013 5:13 pm, edited 1 time in total.
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

Quote:
________________________________________
Originally Posted by ross80truck
Also, one question I have been meaning to ask. How did you wire up your alternator? Does the alternator have an internal regulator?

________________________________________
I haven't done any wiring for the alternator yet. Really no need and I'm waiting until I run the wiring harness. It's the stock alternator for the yr/engine. The only time I've really paid it any attention was installing it so I could put the serpentine belt on. Sorry to be vague.

Edit- added- I just went back in the thread. It has some good pics of the alternator.
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

.
.
Originally posted by TPICherokee 11-13-2012 07:56 AM
________________________________________
Quote:
________________________________________
Originally Posted by Resbum
I haven't done any wiring for the alternator yet. Really no need and I'm waiting until I run the wiring harness. It's the stock alternator for the yr/engine. The only time I've really paid it any attention was installing it so I could put the serpentine belt on. Sorry to be vage.

________________________________________

The alternator does not have an internal regulator, it is regulated through the Dodge computer (which goes bad a lot)

All you have to do is get a regulator and plug from a 1992 Dodge Cummins (they were externally regulated) and hook it up to your alternator and viola it will work.
Last edited by Resbum on Sat Apr 06, 2013 5:13 pm, edited 1 time in total.
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Resbum
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

.
Originally posted by ross80truck 11-13-2012 01:16 PM
________________________________________
Did a little research on the external voltage regulator. If you look up a 1992 Dodge D350 with the 5.9L cummins on RockAuto, they sell 2 different voltage regulators. From what I can tell, the only difference is the warranty. One of them cost about $8 and the other one cost about $24. Also, using the same vehicle, they sell a voltage regulator pig tail for a huge $3.49. So, that should take care of wiring in the alternator.

Also, on the Larry B's web site. He sells a wiring harness for the P7100 pump to wire in the solenoid. That will come in real handy as well wiring in the motor. Good information to find.


Originally posted by Mikel 11-15-2012 03:25 PM
________________________________________
Both my Cummins trucks use external regulators from a 1991 Dodge truck. I got the pigtails from the junkyard - Lots of Dodge vehicles of that vintage used that setup.
Last edited by Resbum on Sat Apr 06, 2013 5:13 pm, edited 1 time in total.
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Resbum
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

I swung by RE Electric today, confirmed the info, and got the regulator and pigtail for a 1992. The price was right in the ballpark of what ross found.
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Resbum
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

.
Transmission, Oil, and Power Steering Coolers Install

So, here's what I've been up to.

Since I posted this pic I made a lot of changes. To be honest, I didn't like this arrangement and some people giving me honest feedback finally made me go back and change things.
Image

1- Brooks, the diesel mechanic who's been giving me advice, swung by. He said although the trans cooler would work in this orientation they tend to trap air in the upper plates.
2- Elliot, from the hydroboost thread, dropped me a note and suggested a two pass cooler similar to what's used on the F-350's would be better for power steering cooling.
3- The oil cooler I was going to use has only 3/8" lines and that concerned me.

Solutions:
1- Rotate trans cooler 90 degrees.
2- Use the 20", two pass cooler I had sitting in a box and mount it under the intercooler for the power steering.
3- Take the huge 1/2" line oil cooler I had, that wouldn't fit, cut it up, and make it fit.
Image

Constantly use compressed air to back flush the lines to keep cuttings out. Pry off the unneeded fins.
Image

Salvage the end plate and carefully reinstall it.
Image

Salvage the U-bend and solder back on using an acid flux solder made for radiators. I don't know why, but when I tried to reinstall the u-bend the solder wouldn't wick properly and I didn't trust the new joint for something as critical as my primary oil line. Ultimately, I destroyed it trying to fix the problem and had to fashion a bend out of standard plumbing pieces.
Edit- Since writing the above I decided to take the oil cooler to Preformance Radiator, in Tacoma, to have it professionally silver soldered. Although what I did would most likely have worked, after the issues I had it wasn't worth risking a new engine to save $40.
Image

Now, when I remount the intercooler, this is how things are going to be. The blue tape on the intercooler shows where the body sheetmetal is. I had to keep the main bodies of the coolers between the tape lines, with the powersteering cooler underneath. The oil cooler lines will now make 90 degree bends and come through the sheetmetal into the engine compartment.
Image
Last edited by Resbum on Tue Apr 09, 2013 8:01 am, edited 2 times in total.
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

It's been a long 5 days. I've finished installing the remote oil filter, oil thermostat, and oil cooler. It took a lot more time, creativity, money, and trips to the store than I expected, but I feel confident it will work well. The last thing I wanted to do was skimp on things and risk the new engine to an oil system failure.

I also have all the parts needed to finish the trans and powersteering hyrdaulic systems, so they should be done in the next couple of days.
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Last edited by Resbum on Sat Apr 06, 2013 5:20 pm, edited 1 time in total.
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

Quote:
________________________________________
Originally Posted by Chumley360
Sir did you ever work for PWC? Cause that's a lot of adapters connected to adapters connected to fittings.

But seriously I love the oil cooler mod. I've never thought of doing that, and have spent hours fighting with coolers, grills, and other parts to get stuff to fit. Keep up the good work:thumbsup:

________________________________________

Haha, it's not as "Rube Goldberg" as it looks.

I lost count of all the different ways I tried laying it out.

This turned out to be:
-The most direct & compact
-Offered the most clearance for the hoses
-Didn't interfere with the air filter or inner fender well

While posting the pictures last night I noticed that I may be able to get rid of the two fittings closest to the hoses. When I get to the shop today I'll have to take another look and see if it's an illusion of the pictures or if I really have the 3D space. Every joint eliminated would be a good thing.
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

Maybe this will help make sense of it.
Image
Last edited by Resbum on Sat Apr 06, 2013 5:22 pm, edited 1 time in total.
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Resbum
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

Made brackets out of stainless steel and riveted them to the bottom of the intercooler, then mounted the power steering cooler. I'll finish the mods to the PS pump reservoir tomorrow. Can't do much more with it until I install the hydroboost.
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Last edited by Resbum on Sat Apr 06, 2013 5:25 pm, edited 1 time in total.
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Resbum
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

.
Power Steering Pump, Hydroboost Modifications

I got the PS pump reservoir modified. As can been seen in the picture, all the lines came out and promptly turned into the area the steering shaft needs to be. Because I'm converting to hydroboost the pressure line will not be an issue, but I needed to reroute the two return lines. I bought some #6 AN fittings and trimmed the inner parts down to clear the actual pump casting inside. Once that was done I bent and formed the tubes.
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Last edited by Resbum on Tue Apr 09, 2013 8:02 am, edited 2 times in total.
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Resbum
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

I also had to press the housing out for the middle line so that I could still use the magnet and screen that was over the oiginal hydroboost return.
Image

The face of the nut is flush with the original housing surface so the magnet and screen sat in their original lacation
Image

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The final product. The new pressure line will come straight out and up to the hydroboost.
Image
Last edited by Resbum on Sat Apr 06, 2013 5:33 pm, edited 1 time in total.
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Resbum
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

I got the last of the trans cooler lines finished yesterday. I'm ready to declare the major mechanical fabrication of the project done. From here on I can't really work on mechanicals without knowing how they interact with the bodywork. So, another milestone has been reached.

Time to move on to bodywork.
Last edited by Resbum on Sat Apr 06, 2013 5:54 pm, edited 1 time in total.
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

.
.
Originally posted by lobie 12-10-2012 04:45 AM
________________________________________
Res, I pop in and out of here every so often. I must say what a great job :thumbsup:
Last edited by Resbum on Sat Apr 06, 2013 5:54 pm, edited 1 time in total.
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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Re: 1970 Gladiator 1 Ton 6BT 12V Cummins Build

Post by Resbum »

Thanks lobie. You unknowingly contributed to the work I did. The info you posted about your hydroboost system and PS mods was very helpful, and I used that info while doing mine. The benefits of forum members sharing info in action. :thumbsup:

Resbum
Originally Posted by Resbum
"What year is my truck?... Which part?" Build thread- http://www.fsjnetwork.com/forum/viewtop ... 290#p18290
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