Project 80: Codename Grey Ghost

[Chris]

Yeah yeah, I know you are all desperate for an update. Didn't get that far yesterday what with the rain and the fact I didn't get out of bed til 10.30. Eh?

Gave it a good go today and whaddya know, I patched the hole in the sil, got the OEM under slung wheel carrier back on below the new sub tank (that does fit well), got the bumper all back on including electrics and every thing. Now sitting nice and level. Not had time for a drive. Dry all day but feeling chilled now. So time to come in and watch the darts final.

Not very good pics but it went dark. Some major items ticked off the build list today. New roof tent should be here in a week or so.

 

[Ben]

Looks good Chris.

 

[Chris]

OK had a busy morning. My new straight through exhaust arrived last week. Well in kit form at any rate. Sorry about the untidy garage. I am getting there.

Total cost £40. Stainless system £400? Pah.



First thing to go was this lump.



Not much to show after that. I cut cut and welded together bit of new stuff and sections cut from the rear section. It's MKI I suppose just to see how it feels and sounds. It's not that loud. The over axle section was really squashed during manufacture and you have to wonder how that affects performance. Quick wash and change and I'll go for a spin.

 

[Gary820]

Looking good, slider will protect it nicely too I guess?
Stock system is a bit squashed at the rear, plenty space for 2.5" pipe.

 

[Chris]

Thanks Gary. Well blimey, it goes like stink with this new unrestricted flow exhaust. There is noticeable uplift in power and torques. OK it snowed overnight so there is some slipperiness about but I was doing about 25 mph. floored it and spun all 4 wheels. Noise inside with the window closed is no different at all. With it open it's only noticeable when you gun it. Me likey a lot. I will have to work the new steps around it. That's why the last two sections are clamped and not welded yet.

OK so moving on. Next job was to put in the new alternator. Reasons for this were two fold really. A. It's a new alternator and therefore hopefully no problems for the next 100k and B. with having 3 batteries on board, CTEK and two split chargers, I figured that whacking charge into the two leisure batteries at the same time would be easier. When parked for a couple of days running the various vehicle systems does run them down a fair bit and just running the engine for a few minutes tends to only put a bit back as it splits between front an back Optimas. It will still do that but it's got more to give. I haven't looked at the real split but it does seem that the front Optima tends to get the short straw.



As this is the upgraded 120 amp unit, I needed to get right in there so I could change the tensioning bracket too. It's possible to alter this bracket with an angry grinder but this is a posh build and I had chance to get the proper bracket. If you look, it's actually lying on top of the old one for comparison.





This means fan off so you can get the bolts out, AC pump off so you can get to the alternator, air box out etc etc. Gave everything a good clean and grease plus put new OEM belts on the alternator and AC too. Hey genuine dealer part - stamped MITSUBOSHI

The post on the new unit is 8mm whereas the old alternator was 6mm. I had already upped the OEM wiring to carry more current if drawn. I used some 25mm (might have been 35 can't remember) so I needed to drill the crimp lug out a bit. But happy with that for sure.



And then last thing before it got dark, I fitted one of those Nautilus style self contained air horns. Holy crap. That's loud. Not going to miss me coming! The thing in the top of the picture is a magnetic knife holder. I have one in the back for teaspoons etc but this one is under the bonnet for putting clips. nuts, sockets and screws on to stop them getting lost. it works a treat.

 

[Olazz]

Like the new Zorst CJ.

I had mine also exit just in front of the rear wheel, but at the hot gases increased that tyre pressure by as much a 7psi and +20º I had it re-routed to exit behind the tyre. Now your mud flap may prevent that happening but it would be interesting to know.

Air horns rock, had my train horns fitted.. can now be heard 3km away !!!

Like the magnetic bar idea in the engine bay... may just pinch that idea.

 

[Chris]

Very interesting point Lazz. I did wonder about that. When I cut the end, I tried to consider the options and actually wondered about fumes actually wrapping round the tyre, flowing round the arch and finding their way in through the window etc. So I cut it to try and push the fumes outwards rather than back. I have the Tyre guard system after seeing your build video so I shall watch that. This really is MK I as I said. I just wanted to do something. Anything really. And it's shown that I am losing power with the crimped exhaust section. I shall be going up to Cobra when I can to have a quote for a full 3" I will also re route it so it doesn't go over the chassis under the driver's seat. it will just run straight along the sill.

Just been up on the moors to drop the truck off and so I could give the horns a blast. Blimey they really are good.

The magnetic bar was like £1.99 delivered from e bay

 

[Gary820]

I originally thought about the exhaust exiting before the wheel but temp was a concern, more if the engine is running and getting something out from that door.

 

[Chris]

Thought about all of that stuff Gary. But as I have already said, it's MKI just to see if it really makes a difference. I did this to the 12v off roader and never felt it really made a massive performance difference. This time it really has. I figure on a standard 80 you could cu tthe pipe just after the main box and come out of the side very easily saving all that pat over the axle. It would still be nice and quiet but I am sure it'd be better.

 

[stumog]

Mine comes out in a similar place but a bit further forward and straight out. Mine doesn't effect tyre pressure. Doesn't seem to effect loading either.
Love it my best mod. Try it with no air filter!!! Went round the block and couldn't believe the noise of it.
Stu

 

[AndyCook]

Great idea with the magnetic bar, the number of times I have dropped a bolt etc into engine bay...


Sent from my iPad using Tapatalk

 

[Gary820]

Seen posts on fb page where people just have a pipe underneath angled downward, about where the main silencer should be!! That's on diesels too. Some have a small silencer and some don't.

I had to have a silencer for obvious noise issues lol.

 

[Chris]

Off all week. Lots to do. Got to the unit just after breakfast.



Took some heavy duty floor protector that I have had lying around for years. Lovely. it's insulating and you can slid about on it.

By 12.30 the transfer box was out.



See? No transfer box.



Then the real work began. Endless things to disconnect and detach I hope I can remember where it all goes. Ha kidding. Of course I most probably will.

Well, finally by about 16.00 the big lump was out. A combination of tricky bolts, wiggling angles and weight coupled with being on the ground, on my own. And it being bloody freezing.



But there it is. Now, I don't actually think there IS a problem with the release bearing. I actually think it's chatter in the clutch fork. It all seemed very sloppy. I have a new bearing coming tomorrow from Simon so I shall put it in there but it was all very dry and lots of play I thought. It was never speed related and the noise went as soon as you touched the clutch. I shall see if I can take some of that up.

Tough day but a sense of achievement. I shall swap the bell housing tomorrow and start the process of putting it all back together! Put the lever into the new box and gave it a stir. Feels very nice and clicky so fingers crossed.

 

[Chas]

Off all week. Lots to do. Got to the unit just after breakfast.

View attachment 17235

Took some heavy duty floor protector that I have had lying around for years. Lovely. it's insulating and you can slid about on it.

At first glance I thought you'd dug yourself an inspection pit.

 

[Blown80]

Very good job Chris, I can't see any signs of blood of remnants of skin on that gearbox. Sounds like you're having a ball.

 

[Chris]

Not a single screw up, or even a scratch I am pleased to report. But the courier bringing the new bearing is just showing as delayed on their website. So I am stuck here now waiting. I could use the time to swap the bell housing over etc and do some other routing work under the truck. Going to hurt losing a day.

Getting the bolts back in is going to be fun and reconnectiong the bits and bobs will be a PITA too but at least I can put right all the bits that the clutch centre did wrong!

 

[Gary Stockton]

Looks like you can fit a two post lift in there Chris - would certainly make life easier! Even if you only got it 3 feet in the air

 

[Chris]

Gary there is a 4 poster in the unit next door but it's out of test. Truth is that my 80 is so high that getting around under there isn't difficult. Now, having transmission jacks etc, ahh that would have been easier, but the main part of the disassemble wasn't that tough.

 

[Chris]

Simon managed to magic up a release bearing out of thin air and said he'd get to me today Once again cannot fault his service and attention. However, with City Link down the sh***r, he picked Yodel. Well needless to say I am missing one clutch release bearing so the gearbox is still sitting on the floor and my annual leave is ticking away. Tracking really said nothing and by lunchtime it was saying they MAY be a delay but it would be here today for sure. I asked Simon to chase up. They finally got back to him and said it never made it past Hatfield. So, there is a chance that I may get it tomorrow, but typically they deliver sometime after lunch in my village. So that will be another morning gone past. There's not a thing I can do until it arrives. Tracking still not showing any movement. I could go and do something else, but you just know I will come home to a card saying I was out. Almost every experience I have had with Yodel has been crap. I would urge people not to use them. it must be a logistics nightmare running a courier company and people are used to getting things next day. We used to have to wait 28 days for delivery - remember those days? But if you can't manage to get it right, then pack up and f*** off! All of the other big names are typically very reliable.

Our postie is brilliant. I got a card through the door the other day. Bugger. Missed the package. Couple of hours later, there's a knock. It's Postie. Thought I'd pop back and see if you were in he said,. I know you are usually waiting for stuff. How bloody good is that?

 

[clivehorridge]

That's bloody frustrating Chris, at this rate you'll have to tidy up something to kill time, what a nightmare...