Project: Midnight Panic

Next up was battery cables so I could power this thing up finally,

Starting with the cable ends, & a piece of 6061,
IMG_5627.jpg



Just kidding,

You sure got me there. (I look at pics before reading)

On the circuit breakers, I use “Breaker switches”. Nice to not carry fuses and not have to wire another thing in line. Aircraft quality. (May or may not be better quality.)


 
Is there room under the fuse holder cover for a breaker?

P: 1628: Search: circuit breaker

No,
Even a 2.8mm mini diode is to tall & they are only slightly longer than a fuse,

I don’t have an issue with the fuses, especially on these two circuits, (actually very minimal chance of an issue)

I just don’t care for the overall appearance of the package/mess,
Functionality, it’s a 10,
Visually, maybe a 4 imo.
 
Next up was battery cables so I could power this thing up finally,

Starting with the cable ends, & a piece of 6061,
IMG_5627.jpg



Just kidding,


2ga cable & crimp on cable ends feed the main power relays from each battery, The ground side got 1ga since I had a piece just long enough for both cables,

While working in the belly I added a sealed 2 position fuse holder, one fuse is for the main feed relays activation wire, (to the big red button in the dash) the second fuse is for the feed wire back to the accumulator valve relay in the box at the back of the truck,


I really would have liked to move this fuse block location up about 10" to put it closer to the harness, but with rear steer hoses, a RTC cable, & air locker line all moving/shifting around, that area is pretty busy,

I might revisit this before the project is done, this location is really easy access if trouble shooting or maintenance is needed, but I think the install could be cleaner, Maybe a plug in fusable link harness?

For now this will do,
832.jpg



In the last couple hours of my days off I was able to turn on a few switches & listen to some of the components respond back,
And I only popped one fuse,
My 15 amp test fuse wanted nothing to do with starting up the cooling fan, once a 25 amp fuse was installed there was no longer an issue,

The engine even cranked over, There's a pretty good list of things to check over yet, but maybe next days off I'll get some methnol & see if I can light a fire in it,
The only thing I see to make it cleaner is to switch to a trombetta style relay with DT connector on the leads.


The fuse block doesn't bother me at all.
Not a fan of the car audio (clear red) power cable jumper but if it's all you got so be it.


12V_200A_Defender_DC_Contactor_80420_f.png
 
Not a fan of the car audio (clear red) power cable jumper but if it's all you got so be it.
The audio cable is most definitely temporary, I didn't want to waste good power cable, then end up building bus bars later, or possibly change to different relays, the ones you posted are very cool, I'll be looking into those for sure,



So today would normally be update time, but the videos pretty much cover what I did these days off, mostly reassembly & prepare to start the engine,
All in all it was pretty uneventful,
I will say it's a good feeling to crank this thing over, hit the ignition & have it fire first hit, granted, that's all it did was fire, but much better than spit & sputter, messing with the distributor, or have it trying to blow the burst panel out!

Once I cracked the throttle blades a couple thousandths it fired right up & ran, from there I could check timing, making one small adjustment to get in the 35* range, next was fuel, it was very clear it was over fueling & killing one front cylinder, but the rear fur cylinders were making plenty of heat, like they were right about where they needed to be,
834.jpg


We rolled it over & confirmed nothing was wrong mechanically,
After leaning the barrel valve out some & firing it up a few more times I decided to call it a day, take a step back & asses what was going on,

The next morning my "engine consultant" got home from night shift & we hit it again,
I had him watch the temp on the front cylinder that kept going out while I shut the fuel off & let the engine lean way out, as soon as I shut the fuel off that cylinder started making temperature,

About 20 years ago, the first time I messed with mechanical injection, fuel pressure at idle would be set at 5-7 psi, the fuel pressure is set with a poppet/check valve, When ordering parts & did order a 5 psi poppet, & that is what was sent, however, the last couple days before firing the engine I did a fair amount of reading & kept running accross guys saying "8-9 psi"

When you second guess yourself stuff starts going sideways, before starting I bumped idle pressure up to 8.9 psi & that resulted in a fair amount more fuel than I needed,
We set the idle poppet back to 5-6 psi & fired the engine up again, the engine was still rich, but not nearly as much, still enough to put the fire out on cylinder #5, but the temperature on the rear 4 cylinders dropped quite a bit, We figure the rear 4 cylders were likely back buring in the pipes, giving a false reading of making good temp,

Again I adjusted the barrel valve even leaner, & restarted, still rich, but I'm getting closer, at this point I can pick the idle up & start picking the dead cylinder, & I'm starting to get color on the front two pipes,
835.jpg


With no coolant it does not take long to run out of time for tuning, so this is where I left off on that part of the project,
The next step is gathering up a couple good low pressure gauges, (I learned this weekend a few of mine are not very trustworthy) double check all of my poppet settings, & if needed close down the barrel valve even more, but at least I know I'm headed the right direction now,

Yesterday I finished off the weekend by building a small bracket on the dash for the fuel shutoff cable,
Also having used all my red knobs for kill switches, I took an 8 ball from a pint size pool table & whittled it down to a button, (anyone remember when 8 ball shift knobs were cool?)
837.jpg


Hardest part of that project was hanging onto the ball in the lathe,
836.jpg


I'm not sure this knob will stay, but it was fun to cut on, & if I end up with something better I'll toss this one in the "Knobs & handles" box on the shelf,
838.jpg


Hopefully next weekend I'll get the idle tune sorted, Then start on the last few tabs & brackets that need done before the big disassembly,
 
This is so sick. Will there be other projects you will document once this is complete? I can already feel the skipped link update withdrawls setting in...
It’s hard telling what will come later on, but I doubt this will be the last build.

So what is the trick to making it look like you have a plan for everything? :smokin:
One way us to have a plan for everything 😆
There’s as many hours in staring/thought in this project as there is actually working on it.
Only post up about it after you've figured it out, lol.
This is definitely the best way to make it look easy anyway.
 
This is so sick. Will there be other projects you will document once this is complete? I can already feel the skipped link update withdrawls setting in...

Not sure if you were on the old site. Skipped Link is famous for two build threads over there. The Peterbuilt toy hauler is really cool, but by far the “Monster Buggy” is epic. (It also won almost every off-road contest he enters) I hate to send you over to that site, but if you haven’t seen them, it’s worth checking out. I wish he would bring them here, but it would be allot of work.

I can’t wait for him to build a race boat or a helicopter.
 
There’s as many hours in staring/thought in this project as there is actually working on it.
Ok that makes me feel better as I stare at my project....
I use this thread as inspiration to up my game, thanks for sharing the little details that make it what it is.
I can’t wait for him to build a race boat or a helicopter.
How about a helicopter turbine powered race boat? Been done enough times, easy peazy...
 
I just stumbled across this on a search on the axletech 4000 for my next mega truck build, sick of breaking the 2.5s all the time, not to far off from what your doing minus the blower, for now, killer fab work, need to make a trip down to Florida for ironhorse, truck will fit right in.
 
Let’s see, been through a set of days off, back to work for 5, & now back on days off,
I skipped the update since there really isn’t anything interesting to post,

I did spend some time leaning out the fuel & got it idling much better,
Today I put 3 short clips together sort of documenting the progress/difference,
I supposed I better post the link here as well.

 
Top Back Refresh