Intake Mod, other project or two and finally, the ATT.

[NVW]

Sorry to hear that Paul, sounds like a nice way to go though. Prayers sent.

 

[handcannon]

My condolences!! I will be keeping you and your family in my prayers.

I can sort of understand your feelings. I'm not an only child but that doesn't matter when you lose a parent. My dad survived six weeks of cancer pain after the diagnosis. Knowing ahead of time still doesn't reduce the pain of the loss. Fond memories of good times will help get you through this.

Don

 

[Slim Shady]

I am truly sorry for your loss, but I am sure your mother is now enjoying the fruits of her celebrated life. We always honor those we love by sharing their memories with others. I am honored you felt we were worthy of honoring her memory as well,

 

[buddy]

Thankfully you could spend time with her and be there with her to ease her passing.

All of our projects are important, finishing what we start, providing good memories to compliment those of our loved ones, and what makes us happy.

 

[Paveltolz]

Thanks all. She was a great lady who gave me a love for the road (many miles on Rt 66), the wonders of nature (national parks and growing up in AZ and WY), a desire to be helpful (she was the receiver of a lot of help and taught me to pass it on), and a faith that sustains me no matter the trials.

 

[Matt Bachand]

Hang in there bro. Shes in a better place now. Her legacy shall live on within you, and those who knew her. Think of her often, talk about her often, and keep your chin up and show that smile. After all, It's all she wants from you, not a thing more.

 

[Paveltolz]

Thankfully you could spend time with her and be there with her to ease her passing. All of our projects are important, finishing what we start, providing good memories to compliment those of our loved ones, and what makes us happy.

Thank you all again for the kind thoughts and expressions. She is indeed in a better place and truth be told, I'm more relieved than saddened at her passing. She will be missed though.

On the subject of finishing projects, I finally was able to get back to the truck so I could finish this intake spacer project.
I picked out a smaller metal plating company to anodize the spacer. I chose black for the one cut out with the band saw to help hide the striations from the blade and they ran it over a polisher to get rid of the high spots. Came out pretty nice. For the milled unit I wanted to go natural aluminum at first but when I picked up the intake set up from the powder coaters I changed my mind…. The ‘ultra-chrome’ powder coat was a lot brighter than they descibed it would be. They said the clear coating would dull it up (almost to a gray) but it didn’t and the clear also gave it depth. It was much better than what I was expecting that a ‘natural aluminum’ colored spacer would have been invisible in contrast and after all that’s been put into this thing, I want it to stand out. I think it does.





So, I pulled the GM 5 and swapped in the ATT, adjusted my time line to complete the project based on an adjusted learning curve (I’d tell the long story but you’d all die laughing and I don’t want that responsibility just now) took it to the car wash to clean the motor of excess oil etc (learning curve) to get it gussied up a bit and, finally, here’s the finished set up installed and running great.




Thanks for hanging with this thread so long.

 

[buddy]

Well done, I want one!

 

[Paveltolz]

Well done, I want one!

Thank you sir. You and a couple of others have expressed interest for which I am humbled.

Honestly, this has been a fun science project but I’m pretty much done with it from research point. I’ve only enough stock for one more piece anyway and that one has been promised out. Gary’s interest is from a milling aspect and while he has some ideas as to what he would like to do to improve the design neither he nor I have an interest in running a product line.

Right now, Gary's machine is down while he sorts out some issues with the lubrication flow, drainage and an issue with the splash shield that broke apart allowing the fluids to go everywhere which is where the second man came in as mentioned in the same earlier post.

Unfortunately, Gary is in no real hurry to repair it as he wants to fix it only once and he's detailing the plan and deciding just how he wants to proceed. So I’ll be happy just to see the second unit. Which makes promising to create these things for others a hard one to make, let alone keep or believe it will ever happen.

However, Once Gary gets the machine up and running and if he’s still willing to play along, then we’ll see. One member asked about purchasing the code, but that isn’t in his plans either, at least not any time soon. Sorry.

Personally, from a financial stand point, if I had to do it over I would simply have tapped my lower intake only to allow the use of the Peninsular upper. Then if I decided to revert back to the stock upper intake I would only have to have plugged the extra unneeded holes with threaded plugs and call it good. I would have saved a bunch of cash but then again, think of the fun I would have missed out on….

Speaking of fun, I was thinking of starting an "I can't believe I did that" thread to share those special "Ah %^&*" moments we all have at least one story about. Any takers (I'll start with the one about how to decorate your garage walls and create a state sized environmental hazard in 30 seconds) and would the thread be appropriate to the 6.5 forum or general topics?

 

[Slim Shady]

Left the oil line off of the turbo did you ? :WTF: Been there done that once and only once.

 

[Turbine Doc]

Speaking of fun, I was thinking of starting an "I can't believe I did that" thread to share those special "Ah %^&*" moments we all have at least one story about. Any takers (I'll start with the one about how to decorate your garage walls and create a state sized environmental hazard in 30 seconds) and would the thread be appropriate to the 6.5 forum or general topics?

Turned my wife's red TDI bug very black doing same thing once , at least windows were up, at least the garage walls didn't complain like the wife did "LOOK WHAT YOU DID TO MY CAR"

 

[Paveltolz]

So much for starting a new thread....
Yeah, not only left the line off the turbo, it was hanging over the intake and as I was backing out of the garage with the hood up I'm thinking, "I expected a big puff of smoke/dust on start up but it should have stopped and why does the exhaust manifold look like an old coffee perkolator..."
and then chug, chug, silence...except for the drip of oil off the new hood liner, motor, suspension, tires, walls, garage door, trash bins. Sure glad the driveway is shedding its top coat and needs replacing anyway. Did you know without the fenderwells, a 6.5 can be used to propel oil out the empty glow plug holes about 25 feet to each side of the truck? Only the back four plugs were oiled up (5,6,7,8). The other four holes were very dry...Gott sei Dank. Todd Hughes at Heath talked me down off the ledge and after a shot of Brake cleaner (flammable) in each hole and two cans of electrical cleaner (Non-Flammable) and about six 20-30 second cranking sessions leaving the air and paint saturated in misting diesel fumes I let it sit over night before reassemble. Starting with the oil lines I put enough of it back together to see if I had a partialy low compression motor...Kicked over on a three second starter cycle.
Truck is running again but now you know the real reason why it looks so purty in the engine compartment. Between 2+ cans of engine cleaner, two or three pressure wash sessions, and who knows how much engine dressing the car wash guys used to "Detail" it, it should look good.

On the up side, that metal clanking noise is gone. Probably covered the offending parts in residual oil I couldn't get at so it's only a matter of time for it to come back.

Too bad I couldn't have done this in the summer when the mesquitos were in need of killing.

Thanks for the love guys.

Break's over, back on my head!

 

[Paveltolz]

Another mod, born of necessity. The back of the truck is a couple of inches higher than the front because of the miss matched springs with the 3" Rough Country lift (another mistake that will be corrected later). Anyway, I was planning to replace the stock shackles that were reigning in the BDS Springs (6" Lift) with "lowering" shackles but, like all things not pressing, it was on the "to do" list.

Well, one of them failed and now the new Summit Racing Lowering units are in place. Long story here:
http://www.thetruckstop.us/forum/sh...ckled-quot-1996-K1500-6.5&p=327005#post327005

 

[Sunshine]

KQQL....Can't wait until the weather warms up to start upgrading "Precious" as planed...

Thank you all again for the kind thoughts and expressions. She is indeed in a better place and truth be told, I'm more relieved than saddened at her passing. She will be missed though.

On the subject of finishing projects, I finally was able to get back to the truck so I could finish this intake spacer project.
I picked out a smaller metal plating company to anodize the spacer. I chose black for the one cut out with the band saw to help hide the striations from the blade and they ran it over a polisher to get rid of the high spots. Came out pretty nice. For the milled unit I wanted to go natural aluminum at first but when I picked up the intake set up from the powder coaters I changed my mind…. The ‘ultra-chrome’ powder coat was a lot brighter than they descibed it would be. They said the clear coating would dull it up (almost to a gray) but it didn’t and the clear also gave it depth. It was much better than what I was expecting that a ‘natural aluminum’ colored spacer would have been invisible in contrast and after all that’s been put into this thing, I want it to stand out. I think it does.

View attachment 24012

View attachment 24011

So, I pulled the GM 5 and swapped in the ATT, adjusted my time line to complete the project based on an adjusted learning curve (I’d tell the long story but you’d all die laughing and I don’t want that responsibility just now) took it to the car wash to clean the motor of excess oil etc (learning curve) to get it gussied up a bit and, finally, here’s the finished set up installed and running great.

View attachment 24009

View attachment 24010
Thanks for hanging with this thread so long.

 

[Paveltolz]

KQQL....Can't wait until the weather warms up to start upgrading "Precious" as planed...

Paul, Is that what you call your truck, "Precious?" :rof:
Nothing but love my friend, but I got to get back to Norway, you need help.

With the traveling and wedding schedules I got this year, any mods for "Sparky" will have to take a back burner unless part a necessary repair. So far, so good.:thumbsup:

 

[Paveltolz]

1st Issue with the spacer - Connectivity

I should have titled it "Continuity," not "Connectivity"

Installed an Air Inlet Temperature gauge (ISSPRO), finally, and the sender requires a path to ground. Thinking that the IAT for the ECM required a path to ground was part of what caused me to forgo trying to make this thing work with a wood material. (I say "thought" because the IAT was sending info to the ECM before I discovered there was a continuity issue).
The ISSPRO gauge wasn't reading, responding anything and after double checking my wiring to the gauge I then checked the sensor. Power to the sender was good but continuity to any ground from the sender's body wasn't...nothing, zip, nada.

Causes: The upper intake manifold is powdercoated, the bolt holes for the spacer are 3/8" not 9mm, there are now two gaskets seperating the upper and lower intakes and I painted the bolts for bling.

The powder coating on the intake prevented path to ground from the upper intake through the bolts (confirmed with multi meter).
Paint on the bolts prevented good path to ground (confirmed with multi meter).
I eveidently had centered up the spacer on the upper and lowers so the bolts, even if not painted, were probably not in contact with the spacer and thus, no path to ground (again, confirmed with Multi Meter). There was continuity between the bodies of the IAT and the ISSPRO Sender though and checking around the spacer and the sender confirmed the anodized surface wasn't a factor. That's what I was told by the plating company.

Solution:
Confirmed sender was good with pan of boiling water and the body wired to ground point with jumper wire and gater clips.:thumbsup:
Removed the upper intake bolts, removed the paint with wire brush wheel, reinserted the bolts and tapped the spacer over with rubber mallet until I knew it was in contact with the bolts.
Check for continuity between bolts and negaitve battery terminal, ECM ground on lower intake bolt and all good.:thumbsup:
Check for continuity between spacer and negaitve battery terminal, ECM ground on lower intake bolt and all good.:thumbsup:
Check for continuity between IAT Sender and bolts.:thumbsup:
Check for continuity between IAT Sender and and negaitve battery terminal, ECM ground on lower intake bolt and all good.:thumbsup:

Test drive with scanner monitoring ECM IAT readings and the ISSPRO sender was responding. Temps hovered around 103* and the gauge starts at 100* so there wasn't a lot of activity but the needle was now off the bottom peg.

On a side note, I was re-reading Ted's (635) motor build in MaxxTorque and there was one good picture of how Jamie tapped the lower intake for the ECM's boost and IAT sensors. The Boost was done with a small nippled barb. Thus, a small vacuum hose was used to join the sensor to the lower intake. The IAT was apparently tapped much the same as I did the spacer, with a 3/8" NPT. In the picture, there is a shipping plugg in the hole during the build.

 

[turbonator]

LOL... thats the first time i ever heard too much Bling,Bling was not a good thing...:rolleyes5::hihi:

 

[Paveltolz]

LOL... thats the first time i ever heard too much Bling,Bling was not a good thing...:rolleyes5::hihi:

You too.
"Shocked! Shocked I say...."

 

[Paveltolz]

Never Rains….
I got the Reverse HID modified tail lights in as I posted on the other thread. WOW. It's like having headlights shining out the back of the truck when they're on. Picked up a switch for the "trigger." I think I'll wait for my frustration level to drop before I put it in. I'm likely to light myself up for all the frustration of this day.:mad2:

Today I thought I had sufficient time and figured I would do the Metrum Fuel Sender Mod. NOT. Thanks to Direct TV, my day was eaten up way past 1400 hrs.:nonod:
Dropping the tank way too late in the day to finish, I was able to get everything disassembled without much more than a crushed hand. Apparently there was another couple of gallons of fuel left in the tank when it “dropped” off the jack and on to my hand which was protecting the jack….

Once I got the fuel sender out, No small feat in and of itself, I understood why the fuel gauge was possessed. The float fell off and on to the floor. I looked in the tank and found the broken plastic piece sitting in the center baffle. I then pumped out the remaining fuel which was a bit of a mistake as the extractor pump I have from Griotts had been cleaned from the first go round with removing the fuel. Cleaned with hot soapy water but not rinsed and dried so that gallon and a half are contaminated. Dang it. For $5 worth of fuel, I’m not risking it. I’m leary of the other 2 gallons I pumped out. Figure I should dispose of it all and get a fresh 5 gallons and start from scratch.
Other than the plastic piece I took out, the tank was practically spotless inside. A few particles on the bottom but nothing of note. I’ve seen more in the bottom of the Fuel Manager! Yikes. But that was before I installed the Wix prefilter.
So, once I find that @#$%^ locking ring I put in a safe place, I’ll be able to finish the mod and put it all back together. Looking for that thing became a treasure hunt and a rat race. I know that once I pick up another one, I'll find this lost sheep in plain friggen sight.:thumbsup: That's the way of it.

 

[btfarm]

So, once I find that @#$%^ locking ring I put in a safe place, I’ll be able to finish the mod and put it all back together.

You need not say any more... That's just the same as saying "the locking ring I lost...":agreed: