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Discussion Starter · #621 · (Edited)
Picked up the exhaust pipes which connect to the downpipe. I had flanges welded on for the V-Band Clamps. I am also fitting a section of flex tube. So far the flex tube is the only thing that is not stainless steel. Picture 1 shows the adapter which will widen the exhaust from a 2.5 inch to a 3-inch exhaust. The second picture is the flex tube that will connect to the pipe in the first picture. 🍺

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Here are the three sections together. The flex tube will attach to this assembly.

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Discussion Starter · #623 ·
I decided to update the thread:

CONDENSER: Still looking and doing more research. I cannot find the condenser (Period!). Every parts store wants to sell the 16x 26 or 27 inch version while mine is closer to 31 inches. I will have to use the existing one (or so it seems at this point).

RADIATOR: I purchased a smaller radiator (for the same truck with a 350 gas engine). It is three row aluminum and should fit. Sorry for the project delay, but I have been plain stumped over this. Is a smaller radiator to be, or not to be... that was the question.

Saying all that, I have no timeline on the truck (other than my better half continually asking me when the project will be done). I do believe she wants her backyard back. The other factor is the south Texas heat. I cant stay too long out there on any given day. The word "BRUTAL" sums that up. I am jealous of those of you who work out of a big garage. In the end, I hope to have a daily driver.
 

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Tom,

If you use the existing condenser, it will need to be flushed to clean out the lubricant oil. The oil used for F12 is not compatible with R134A.

The smaller radiator should work OK. My 4bt runs cool with the replacement radiator specified for a 300 CID Ford gas engine (I did buy the slightly thicker AC version).

Note on both of the above: The condenser has dual electric cooling fans, helps a lot.

Russ

EDIT: p.s. Single pass R12 condensers are not as efficient as the same size triple pass R134A condensers. Using the bigger R12A condenser "probably" compensates... All my AC installations used new condensers (never had a good original condenser).
 

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Discussion Starter · #625 ·
The system was converted to R134A from R-12 years ago. I would like to find a condenser that would work, but so far nada. Here is my last thought... This is a universal condenser for the chevy 81-87. I do not need the drier though. I like the fact that you can choose which side of the vehicle the compressor is on when choosing the condenser. It routes the compressor discharge to the proper side without having to run a length of tube/hose to reach it.

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Discussion Starter · #626 ·
Russ,

Before I disassembled my truck the AC system was working until I broke a line on my compressor. (the compressor mount broke and the solid aluminum part of the hose broke due to vibration). Not sure if this makes a difference, but I suspect the condenser is usable. It needs to be cleaned up and some of the fins straightened.

Tim
 

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Tim,

If the condenser worked before, it should work now. Just give the coils a flush.

Russ
 
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Discussion Starter · #630 · (Edited)
Time to update the thread after the hot summer months are waning. I have worked on fitting a smaller radiator, not just because it was recommended, but to allow me to fit my intercooler piping. I ran into a few snags on the way.

First, the radiator (from Amazon) stated it was for the 6.2 Chevy but was way too short.
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You can see the radiator doesn't reach the supports.

So, I worked on this issue:


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Discussion Starter · #631 · (Edited)
I was able to use the stock lower radiator support hose. It looks great. Even though the radiator is shorter, it fits because the length was knocked off of the driver's side. With the shorter radiator, the intercooler piping will fit as intended.

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The upper hose looked great too.

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I moved my heater return hose to the drain on the driver's side so I could use the stock drain location for the low coolant level sensor. I still need to hook up the transmission cooler lines though.

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After the radiator was in, it felt fairly solid, however, was not satisfied. I decided to shim up the lower supports and that is in progress. I also decided to start the intercooler mounting. That is in progress too.
 

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Discussion Starter · #632 ·
Worked on the intercooler this weekend. It started with an early morning walk at Sunset Lake in Portland Texas. I got the blood flowing to the brain.

. Water Sky Water resources Natural environment Beach


I got to pull out the Jobber Do. (I have become fond of the tool)

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Then worked on Installing the Intercooler and Tubing.
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I ended up one coupler short. It is on order though.
 

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Discussion Starter · #633 ·
Started the day with a 2-mile walk on Shoreline Drive in Corpus Christi. Caught the sunrise in front of the American Bank Center.

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The hump hose came in. Note: I chose a hump hose as it allows for up to a 20-degree bend if case the ends are not in line with one another. This completes the inner cooler piping. On to the cold air intake.

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I put the passenger inner fender on temporarily to figure out the air intake to the HX30. I just need to see how I will make it fit.

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Discussion Starter · #634 · (Edited)
Worked on the Cold Air Intake some more, but I still need a support bracket or two.
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To fit everything up I installed the inner fender, the coolant overfill, the AC line to the Evap, and the battery support to ensure the location I chose would not interfere with anything else.

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I also put some time into the transmission oil cooler lines

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but was curious about the transmission cooling lines and (on the transmission) which port was an outlet and which was the inlet for the 4L80e. Found a good picture online:

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Discussion Starter · #635 · (Edited)
Worked on the transmission cooler brackets today (one bolts to the transmission cover and the other to the front of the engine.)

The front mount (shown below) looks like a musical note. This is coincidental.

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The musical note mount is attached to the engine forward of the front engine mount (below). Since the mount and transmission cooler line is the same color (black) they blend in the picture.

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This is the mount (below) attached to the cover of the transmission.

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The rear mount (below) is attached to the transmission dust cover.

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Cooler lines connected to the transmission inlet and outlet (below)

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This is where I left off for the day. I have to bend both 90 degrees and connect hoses between them and the trans cooler on the radiator.

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Came back the next day and finished connecting the transmission cooling lines to the transmission with hose.

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Discussion Starter · #636 · (Edited)
Worked on the Oil Filter Mount bracket today. I am still trying to design it on the fly. This is what I have so far. The mount bolts to the engine mount hole on the passenger side front block. The other mount points are under consideration.

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Next day update:

Bolted a plate to the alternator support to serve as a support for the filter bracket. I also being up some bars to connect this plate to the oil filter support.

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Discussion Starter · #637 · (Edited)
completed the Oil Filter Mount Bracket. The mount bolted right in. I just need to connect the oil lines. I scuffed the AN fitting a bit upon installation. Ordered the correct tools to prevent that from re-occurring. It looks good though and the filter is easily accessible.


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Later on in the evening: Thinking about this setup, which appears okay at first glance; I may add a removable guard in case the belt ever breaks. I would not want the broken belt whacking the oil filter.
 

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Discussion Starter · #640 ·
Started looking at the wiring today. I purchased a normally open 160-degree sensor. The plan is to connect the sensor to ground. The ground will complete the circuit of the KSB and radiator fans to power them on through a relay. Just thinking out loud at this point but I like the idea.

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Started looking at the wiring requirements as well and found a cool chart to assist with determining the size of wire needed to complete the wiring harness.

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