There was a few lines I need to finish up the engine. I found some -3 an line at Summit Racing that is rated for 2500 psi. I made up a line to feed the vacuum pump on the the alternator. I wanted to use straight fittings but there was not enough room so I came up with this.
I used the same line and some fitting from Advanced Adapters to connect the stock clutch master cylinder to the TJ slave.
I should have used a 90 degree fitting at the slave cylinder but I had to use it for the alternator.
Russel make some -6 an line rated for 2500 psi also. With a couple of fitting I swapped over my power steering hose. I wanted to keep the power steering pump from a 98 Cherokee since it has the built in reservoir.
I have been pondering over how to mount my charge air cooler and radiator. I tried to make individual mounts for the top and bottom but I didn't care for them. I had been kicking around the idea to make a frame out of aluminum since I had some pieces of channel that fit snugly over the charge air cooler. I designed it to bolt into the stock radiator mounting and have the radiator bolt to the cac frame. I had never welded on aluminum before but I had a spool gun for my Miller. It turned out ok.
I made some feet that will bolt onto the bottom of the grill shell for add support
I top rail bolts in allowing the charge air cooler to be removed easily.
The radiator will be covered by about 2" off the cac frame on one side, I don't think it should cause a problem. Next step is getting a aluminum radiator. I should have about 3" for an electric fan. I have a Ford Taurus fan but it is 4" thick, might use it on the TJ.
For the lower hose, use a lower from 97-01 2.5 4cyl TJ, assuming the radiator has the ports in stock TJ location.
2007 WK CRD: DD @ 27mpg, tuned by Keith at GDE
1997 100" TJ: Cummins/NSG370/TeraNomore/37's and leaf springs - Gone! Lil Green Bean build thread
2008 Rubi Unlimited: Gone! Smashin' Punkin - 06 Rubi LJ, Cummins QSB3.3, work in progress IndyORV
The intercooler is from a volvo. I might try a 4 cylinder hose, the only problem is with the power steering pump mounted so high the water pump inlet is close to the belt so the hose needs to be angled towards the back of the engine to clear the hose.
Sorry for the extended absence. I did not get much done over the winter. Since the weather turned warmer I have got a few things done. Last week I pulled the tube off and disassembled it to take to the sand blaster to clean up the bottom of the tube and the firewall. From there I sent it to Linex, they coated the whole under side of it, it turned out great!
I painted the fire wall inside and out, cleaned up the rust on the inside and primed it. I am going to put Monstaliner on the inside, I should be getting it this week and hope to get it put on next weekend.
I picked up a roll of header wrap, hopefully this will keep the heat down in the engine compartment and on the floor board.
I replaced the supply line with some 3/8" tubing to make sure it was getting plenty of fuel. I wanted to mount a lift pump and a prefilter up by the tank, originally I thought about putting it on the frame but there was not enough room for the pump and the filter. I think this should work.
I am sorry to leave you guys hanging for so long. Since my last post I have moved and got the jeep running. I have changed a few things, I ditched the serpentine belt set up for v belts, switched to a 120 amp alternator, added hydroboost and finished the dash. I added a boost and pyrometer gauge where the radio normally goes and factory tach ran by a Dakota digital convertor that gets a signal from the alternator.
I went with BF Goodrich 33x10.5R15. They work surprisingly well with the 3.55 gear ratio. I still need to swap the front gears, I wanted to made sure 3.55 was going to work before I changed them. It is surprisingly peppy, feels very similar to the 03 TJ I had that had 30" with stock gears. It loves to run 45-50 mphs in 4 gear, I had no problem running 70 mph on the high way.
It does have a noticeable shake at idle but calms down when you get it off idle. I have only put about 50 miles on it so far but I plan to drive it all next week weather permitting (the top is coming off this weekend). I will let you know how it does on fuel. I will get more pics, it has been raining all week. Let me know what you guys think!
It is a little loud but not unbearable. With the top off I don't think it is any more noisy when on the highway than a gasser. Going through a drive though you have to yell at them buts that the worst of it. The best part is the turbo is quick to spool and you can always here it over the engine.