Ms Piggy. Black and Blue!

[broncosbybart]

Seat heaters came from Summit Racing and are made by Rostra. They are for both the seat base and backs. I guess I forgot to take pics of the whole process.

The turbo is pretty much together. Had to modify the oil drain line (again). Next step is the intercooler and modifying the core support to mount it. I ended up getting some 1x1.5" rectangular tube to reinforce the core support and to mount the intercooler and radiator off of.

First thing I did was to cut the upper tube to length and then weld some 1/4" nuts flush into it. This is where the upper support tabs from the intercooler will mount to. I capped the ends of the tube and tacked it into place.

Next I cut the lower tube to fit. I had to cut some pockets into the lower tube for the intercooler mounts. The pocets were finished and sleeved as the mounting bolts on the lower tube will install from the bottom and go through the cross section of the tube. Then the tube ends were capped and it was tacked into place.

After that I worked on making the radiator mounts. I will reuse the lower brackets that were cut off of the core support. The upper radiator mounts will be reused as well.

[broncosbybart]

Here are some pics of the lower radiator mounts. I added some 1" square tube to the bottom edge of the 1x1.5" tube. This gave more area to support the brackets.

I've started making the mounting locations for the upper brackets. I was going to mount them on the back side of the upper support tube work but for some reason the radiator angled way in at the top. So, I decided to notch the tube and will put the brackets close to the core support and will box it all in. Not quite done yet. More to come.

[chuzie]

What radiator are you using?

Sent from my GS3 on Cyanogenmod with the older / better version of Tapatalk!

[broncosbybart]

4 core Bronco radiator. Got around to getting some pics of it finished. The pics should explain how it all fits together.

[chuzie]

I don't understand why it isn't the same thickness top and bottom.

Sent from my GS3 on Cyanogenmod with the older / better version of Tapatalk!

[Bronco Biff]

Awesome work!! I'm going outside to play now!!

[broncosbybart]

Not sure either on the offset from top to bottom of the core support. I guess the rad sits at a bit of an angle in stock configuration.

Been working on getting the pedal assemblies configured, starting with the brakes. The injection pump on the engine is sitting right where the brake system should go. So, out came the cutting disc to slice up the Duff's angle booster bracket. After a few trials, it started to take shape and gained enough clearance away from the engine. An Astro van hydroboost unit will be bolted to the bracket. I had to fab up a mount for the booster. A 78'ish Corvette master cylinder is bolted to the booster.

I had to modify (cut down) the push rod on the hydroboost unit as it was way too long. It also needed to be angled a bit so I reinforced the cut to give it some extra strength. It took a good day and plenty of head scratching to get it all figured out but it turned out well and fits within the confines of the engine bay.

The clutch on the NV4500 uses a 1" bore hydraulic slave cylinder, which needs to be paired up to a similar sized master cylinder. The stock Dodge slave cylinder wasn't even close to being an easy install. After a bunch of parts hunting, I decided on a 92-96 Ford Bronco slave cylinder. It is pretty large and is a 7/8" bore. The size of the slave cylinder made it very challenging to make it fit.

An angled shim of sorts had to be made so that the snout of the slave cylinder pointed up a bit in order to clear the inner fender. The angled booster had to be trimmed a bit to make room for the mounting flange of the cylinder. Lastly, I used some snazzy fittings to be able to use 3AN line to connect the master cylinder to the slave. From the factory, a plastic line is used with some rather unusual ends on it that are fitted and held in place with roll pins. The AN adapter fittings do away with that mess. I still have to order the AN hose.

[broncosbybart]

Got the front dress figured out. The stock alternator was rated at a pitiful 65A. Found a 120A replacement and decided to order it. The new alt is a Chinese unit, so I'm sure it will be short-lived. A genuine Bosch unit was north of $300, closer to $400!

Since I won't be running the mechanical fan, I wanted to try and eliminate the pulley and bracket for the fan. The water pump and alternator are the only things needed. After doing some head scratching, here is what I came up with.

The pic with the long belt is the original belt. The new one needed to be a good bit shorter. I had to drill a new hole for the tensioner to clock it some from the original mounting position. The original tensioner pulley was smooth but needed to be ribbed. Found a new/open box replacement assembly with a ribbed pulley on ebay for a good price. After a couple guesses, I found that a 49.5" belt works perfectly. I think that this mod will work well. Time will tell. Less is better, IMHO.

Still have to paint the bracket and tensioner arm. The paint on them is the original cummins paint- which has held up pretty well

[snipes243]

What fan are you going to run?

[ParadisePWoffrD]

Not running PS? Seems like a lot of machine to not have any steering assist.