Rebuilding after 15 years of storage

[PHOENIX-GER]

Job for next weekend is save



Lokar arrived



also some other essential needed parts arrived as o-rings... used the last one in store two weeks ago
oilcooler-line (transmission), fittings



and some new hose-clamps for the cooling system

 

[PHOENIX-GER]

The installation of the Lokar cable shifter unit was really annoying.
I had read about dispappointed customer who report that there is a lot of customizing necessary. Die Stock-Kit doesnt fit generally.

We found following issues:

On the transmission installation was for the stock steering column connection customizinig by grinding the Screw mounting of the cable lever necessary. I do not like to weakening a mounting screw ... but there was no other choice - the connection are still not fastened



To fix the connection we had to grind the Screw Bold as he had to move in the hole



For stock column you should have to use the first hole, also the sqaure hole for the Bold on the transmission doesnt fit - we had to grind this as well
if you had an aftermarket Column than the second hole on the right tip was to use





the next was the shifter lever on the column. You shall mount the columnadapter (cable shall only be pulled not pushed!) with two screws.
Not possible as the lever haven not enough space.



So we descide to use the original hole for the first bolt with a fitting washer (hole) and drill the second hole



As cherry on the top was the fact that the column bracket for the cable not fit with the firewall



The Firewall prevent the mounting of the Lokar bracket on the column. The bracket cannot be used plumb because the firewall is too close to it.
So we need a Plan B



We just used a steelsheet on an existing bolt in the Firewall to fix the cable to the columnadapter. The cable shown up in line on the column adapter.
Not sure if this is a good solution. We will customize a triangle bracket with 3 point connection on the Firewall and than a test will shown if it work.
I dont know which other solution we could have for it.

We bought the Lokar 1804 Kit for Chevrolet stock Steering column Shifter and 4L80e
Maybe we expect to much on such a kit.
They dont make different Kits for different vehicles - so maybe it fit perfect in a Car with a GM Stock Steering column, but in a truck it will not fit without customizing you own cable bracket.
As it was made for the 4L80e should the parts fit on the specific without customizing

 

[PHOENIX-GER]

As we started the adjusting of the cable shifter was obviously that the instructions was not correct
Although we certainly have a stock steering column, the mounting in hole B was wrong.
After minor adjustments to the firewall bracket was then a smooth shifting possible







Rest of the day disambling again for painting and finished the tanklines

 

[PHOENIX-GER]

after complete the column-shifting found we the next challenge on the exhaust system





the exhaust tube running really near to the speedsensor so that we need to protect the sensor of this heat or install in other wise...
also the rubberbearing of the NP205 could involve of heat
Fortunately it exists several solutions of heat protection for such cases

 

[PHOENIX-GER]

A lot of other duties prevent a big step forward on the CUCV
To bring the old exhaust tubes with the new mufflers in place is again a lot of custimizing necessary
We need to protect the additional parts under the truck of the heat. Fortunately there is a lot of avialable which can be used for it.
So we put the parts on our next shopping order and go on with other things like the rewire the military hitch



we bought a new box where we still exchange the cover as it have a german name on it...

 

[Mullaney]

A lot of other duties prevent a big step forward on the CUCV
To bring the old exhaust tubes with the new mufflers in place is again a lot of custimizing necessary
We need to protect the additional parts under the truck of the heat. Fortunately there is a lot of avialable which can be used for it.
So we put the parts on our next shopping order and go on with other things like the rewire the military hitch

View attachment 911429

we bought a new box where we still exchange the cover as it have a german name on it...

View attachment 911430

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View attachment 911432

View attachment 911433

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.
Nicely done!


.

 

[PHOENIX-GER]

This is the colered wiring of our Mil and CIV Hitch

 

[PHOENIX-GER]

Installed the mil trailer electric

And the driveshaft front

Rear


I need to buy still the bolts for the Np205 yoke. They are not the same like in the rear

NP205

 

[PHOENIX-GER]

Still working on the exhaust system
Unfortunately you cant go to the next shop and buy what you need.
Nothing is common here.
We need to use a reducer on the passenger side from the front tube - however
First we had the wrong one and now with the right one is again a lot of prepare on the ends.
It was necessary to cut the old muffles from the tubes and as they was backed together
To separate them with less damage was a goal we got finally


the muffler are stainlesssteel - we paint them all in black (heat protection paint for exhaustsystems) only the tubes are all used

the reducer ist also stainless steel like all exhaust pipe clamps
only at the hangers we used steel again, we had to rebuild 3 of the lower clamps as the original was lost





need to be paint before mount the exhaust

drive side is ready

now it will be a bit delay in that job, as since yesterday we are grandparents and now our grand-daugther and of course their parents have our focus

 

[PHOENIX-GER]

Finally the exhaust system is finished



heatprotection for the speedsensor and the rubberbushing of torque-support of the NP205



also on the fuel distribution of the dualtanks



i wonder if we will got roadlicence with the muffler just 1 cm away from the brakelines.
But this was before the same, we dont change anything of that design.



We will also have to discuss about the passenger side exhaust end tube
It direct the exhaust to people which are waiting at traffic lights
The Sierra have the same, an endtube on the right side and he got road license!
In the past we had weld an 90 Degree angle on the endtube of the passenger side to direct the exhaust to the bottom for road licence.
It is 30 years ago ... we will see next spring what the engineer for road licence will have changed before we got the road licence.
Like usual - US Cars - will not pass direct the test, oldtimer also not. There is always something the need to refuse

 

[87cr250r]

The 6.2 exhaust noise from the stock mufflers is very quiet. All of the racket originates under the hood.

 

[PHOENIX-GER]

The 6.2 exhaust noise from the stock mufflers is very quiet. All of the racket originates under the hood.

It must be quiet as we have value for noise by stand beside and drive ahead in the vehicle documents which will be controlled if you be in trafficcontrol and an officer guess it is to loud. You lost roadlicence if you fail.
Of this we used silent Flowmaster muffler.

"Difficult" will be the emissioncontroltest. We never pass this in all the years in the first round. It need an engineer on the modern emissioncontrol device who knows to handle this old trucks.

If you want real V8 noise than you need to have a gasser. I love it but i love much more the dieselpower.

 

[PHOENIX-GER]

it exists - how could it be otherwise - rules and regulations for measurement of the noise on vehicles in Germany
Any aftermarket muffler muss fullfill these measurements

The Sierra LBZ Duramax have similar values 90 dBA Stand and 78 dBA drive ahead. I like to have a dual exhaust system for him but i fear it will fail the dBA check and with it road licence.... specially where we want add some upgrades on the engine.

 

[PHOENIX-GER]

We finished the tank assembly and bringing all electrical wiring to the front

a documentation of that wiring make sense

also to use waterprotected connectors

the worst part in that job was to make new holes in the firewall on the passenger side
We use the same waterproof connectors like on the light bar


we couldnt finished all as we miss the nuts for the connection, now all shops closed... of chrismas holidays
In the lightbar was enough material to cut a thread
left is entrance for radio antenna, the middle both wire are tank and the right wire is the complete wiring from the lightbar

another hole was necessary for the trailer hitch wiring, here is the entrance on the driver side.

now we have our wiring chaos all together in the cab
we found a small package first-aid kit which could fit in the Military-First-Aid Box

in Germany in every vehicle have to be a First-Aid-Kit - if it is not and you will be controlled.... yes you are right a fee is to pay and as you see there are also standards of it DIN...

worked well

 

[CARC686]

I feel like I live in Mad Max after reading what the vehicle requirements are in Germany. No vehicle inspections of any kind required here. In my years of working on cars, I found a lot of guns, but never a first aid kit. Anyway, I like the way you speak English. You speak in parables sometimes. Merry Christmas and congratulations on becoming grandparents.

 

[PHOENIX-GER]

I feel like I live in Mad Max after reading what the vehicle requirements are in Germany. No vehicle inspections of any kind required here. In my years of working on cars, I found a lot of guns, but never a first aid kit. Anyway, I like the way you speak English. You speak in parables sometimes. Merry Christmas and congratulations on becoming grandparents.

Merry Chrismas and thanks you can follow my English. In my mind does i translate just german to english but we have different sentence structure. I guess it will be funny to follow that. Not to forget the grammar.
About the vehicle requirements - well I have now a lot of experience with the authorities and I can be just as stubborn. You have to beat them at their own game.
If you want to take a driver's license test here, you must also present a first aid certificate. So it make sense to force by law in any vehicle a fist-aid-kit. But you have only to do this one time for the driver's licence test. Mine ist more than 40 years ago. You will be not forced to renew the certification.
In the event of an accident or health emergency, every adult is obliged to provide first aid. If you fail to do so, you can be held legally responsible. In fact, however, many people are overwhelmed by this. Not helping is not yet punished, but watching and not helping is a criminal offense that will be prosecuted. Even worse is taking photos/videos and post them online. I think this is not just a german problem, it is international....

 

[PHOENIX-GER]

Still waiting on the lock nut for the electrical sockets in the firewall. I could got immediatly plastic nuts but i want metal nuts like the sockets itself. So i have to wait. That mean the eletrical wiring have again a downtime
Meanwhile, we took care of the braking system
This is the first time we have done this with a pneumatic tool rather than manually.
This is a significant relief and is recommended to anyone who has access to compressed air and need to refill the complete system again.


We dont reuse the bleeded fluid again, as you can see its dirt inside nevertheless the lines and calipers was new

The bottle size is 1 Liter

We need the complete 1 Liter DOT5 fluid to bleed the system sucessfully.

Another open issue is fixed - the upper radiator hose
The original does not fit anymore about the 6.5 watercross over
And the hose for the 6.5 engine from 98 Squarebodys also dont fit, it is to short

so we use a tube

 

[PHOENIX-GER]

Now let's tackle the electrics. First of all, a bit of tidying up before we start connecting the Dacota Digital and the additional devices



Very timeconsuming - progress is slow
But I'd rather be slow and thorough than make a mistake somewhere that can take an infinite amount of time to find again

 

[PHOENIX-GER]

We couldnt resist to build our own design for a Fire-Barrel






got them from here Elbfighter
Elbfighter has implemented our template very well using laser cutting

 

[PHOENIX-GER]

if you think you have a big truck and enough space to bring all your additional devices in good space... will you learn that it is still a small one

The additonal lights and devices need 8 relays and several fuses and connections
One Fusebox is behind the speaker but this is not at all
We need to bring this also in a space where it is hide and save as also easy to access



Well it is like th usual triangel



you cant have it all
The other will go with a box at the firewall but in the space of the feet from the passenger...
Needed Space is 3200x80x60 mm



We also need a exchangeable lightbar for vehicles as our M1102 will not got roadlicence with the original lights. We dont want adapt the lights. It shall be to fit on the military hitch from the M1008. So we drive on the road with a exchangeable lightbar

Just checked what we have already in the shop:
Found a set new rearlights from our former BUS-Project in 1990 - wow since 33 years in storage
Found also backing up lights, no idea in which project this was left over
Also found a new 13-pin trailer socket - this is a sparepart for our trailers
Frame will be done from solid iron tubes diameter 1,5 inch and a perforated sheet to pick up all lamps and signs


Ours will be more expensive than buying one in the store, but it will meet our requirements for reliability and durability.
Reflectors will need to be purchase as also cable and fog-rearlights.