Well, I didn't get the engine in the van but I'm closer than I've ever been before.
Here' some photos of what I accomplished over this last week (took it off work to get real cozy with the AAZ - wife was thrilled
).
Hylomar on - note the "safe" position of the pistons
Hylomar new KS head (with one newer valve and lifter
)
Torqued to 125 ft/lbs - 12 mm ARP studs
Laminova WAIC, silicone hose and T-clamps - zero lag
Intercooler/turbo support brace (with integral heat shield)
Re-routed turbo oil feed
Pimping the glow plug wiring
I'll number the 10 Ga wires at the fuse block. I wanted them all the same color - besides, it was cheaper than buying four different spools.
Notice the Hylomar squeezed out from between the head - I think that's about 99.99% of what I sprayed on. I think I used too much
Another shot of the GP wiring and the purdy Giles injectors
It took all day to clean, epoxy cracked mounting holes, clearance for the v-belt, make a 8-6 mm mounting stud and a custom aluminum grommet for the center-bolt, but the timing belt is now safely covered (never had a cover before) - scary.
Re-did my DIY boost controller and hard-mounted it instead of letting it dangle on the rubber hose
Fabbed up two aluminum mounts and set the oil cooler in place. Those are the heater hoses laying there - waiting for the 5/8 silicone to arrive.
New stainless steel pipes going to the new radiator. Had to remove the fuel tank - I'll be sore for weeks.
While I had the tank out, I turned a new shift-rod bushing from a hunk of UHMW - no more shifter wiggle!
That's it for now. I'm going to spend the weekend with my better half - maybe go for a bike ride in the mountains, stay in a cabin - do anything that doesn't involve tools, paint, bleeding knuckles, steel slivers, glycol hair-do and grease.
The list is shorter than it was a week ago but there's still quite a lot to do - too much to list and frankly, I'd rather not think about it.
I have a new Sachs clutch and PP to install along with the larger flywheel - hopefully the recent posts I've read about Sachs being junk is based on a few exceptions and not "the rule".
I am so very thankful to everyone on this forum and all the great advice. This build has taken nearly a year (mostly weekends) but man have I learned a lot. As I've said before, had it not been for you, I would have just sold the broken van for scrap.
This project has been a side-track from the 1000 sq ft addition to the original circa 1953, 450 sq ft house (eight years after work and weekends). I started with the shop and will end with removing the interior walls from the original bungalow. The plan is to use the van to cruise this wonderful continent and look for a good place to retire. Hopefully housing prices will be back up by then.
Thank you all.
To be continued. . .
