PDA

View Full Version : Swapping a 3rd gen 3SGTE into Jims '93 Alltrac



presure2
01-22-2011, 01:58 PM
So,...Hey guys!!!
For some reason, i kinda lost touch with c-tech for awhile...cant really give a reason for why...just kinda lost touch after the whole mod shake down thing.

anyway, im back, this time with a 3rd gen swap into Jims '93 Alltrac that he recently aquired.
the shell is in ok shape...considering its a '93, as rare as they are, its been abused. the body had some dings and whatnot, but isnt too rusty, so thats a good start, but the engine bay...looked like theyre might have been a fire or somthing in it at some point.
when he bought it, it had a blown motor, and the previous owner removed the head, but left the bottom end in place, hanging by the drivers side tranny mount, and a coat hanger on the passanger side. lol
this is what happen after he arrived with the car.
first, jim came up friday with a '93 alltrac, that had a blown motor with no head on it, attached to the AWD tranny, hanging in the bay by only the drivers side mount.
in the back of his truck was a 3rd gen 3s setup, WRC tranny, and some random parts for the swap.

we got the car in the garage, and once i got the hood off and stared in amazement for a few moments, i started getting ready to litterally drop the motor out the bottom.
the crossmember and stuff was already out, all i had to do was remove the shifter cables, clutch line, and speedo gear.
i took out the 3 bolts holding the tranny bracket to the mount, and out it came with a thud. :laugh:
joe gave me a hand pulling it out from underneath, we hung out for awhile, and that was that for friday night.
saturday morning, we went out and pulled the motor and stuff off the back of the truck, and got it into the garage.
the motor had parts of a TD06 turbo kit on it, and jim and i walked thru how he wanted it setup, and off they went.
today, i went out and got to work.
sorry for the blurry pics, for some reason my camara dont like to take pics under the floresent lights.

the bad 2nd gen and tranny

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture001Medium.jpg

engine bay

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture002Medium.jpg

the new motor (i had already clocked the turbo closer to where it will be in these pics)

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture004Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture005Medium.jpg

minor clearance issue

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture006Medium.jpg

whats wrong with this pic?

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture008Medium.jpg

hrmm..a little gasket maker?

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture007Medium.jpg

clearance issue solved, so lets make a screamer pipe!!

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture011Medium.jpg

presure2
01-22-2011, 01:59 PM
clearance to oil return line

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture012Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture010Medium.jpg

waiting on more pipe to finish it off.

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture013Medium.jpg

alltrac rear mount and bracket, and speedo gear along side the 205 speedo gear

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture014Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture015Medium.jpg

i LOVE having a parts washer.

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture016Medium.jpg

i bolted that and the tranny bracket on the WRC, and called it a night.
tommorow, i should have the parts to put timing belt side back together.

presure2
01-22-2011, 02:00 PM
installed the a/c compressor, and alt bracket

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture019Medium.jpg

retapped some damaged threads on the passanger mount

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture020Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture021Medium.jpg

OMG filthy crossmembers

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture022Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture025Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture024Medium.jpg

much easier to work with when they are like this:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture027Medium.jpg

whoops wrong rear main seal (old one on top, you can see how the new one is just a bit smaller)

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture018Medium.jpg

and a little bracket i made to hold the dipstick since the WG is in the way a bit.

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture028Medium.jpg

presure2
01-22-2011, 02:01 PM
got ready to install the cam gears and timing belt, we recently tried this new "gel" threadlock from permatex. this is the threadlocker i will buy from now on, its absolutly the bomb.
the liquid stuff tends to be runny, hard to tell if there is enough on there, ect.
this stuff being a gel sticks on the bolts, and dont run off, less waste, and works great. i like the blue, cause it holds everything together well enough, but dont permanantly lock things together.

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture029Medium.jpg

i had to retap the lower tensioner bolt hole, you can see the damaged threads in this pic

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture030Medium.jpg

somthing odd about this particular motor. every 3s ive ever seen has notches on the back of the cam caps, and cams, to line them up for timing.
this motor does not have them.

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture033Medium.jpg

cam gears and t-belt installed

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture032Medium.jpg

im also going to be installing an adjustable fuel pressure regulator, so i took a pic as i was removing the stock FPR.

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture034Medium.jpg

we are going to run it in a "deadhead" setup, where the stock return line is eliminated, by using the return on the areomotive FPR.
in a stock setup, the fuel runs like this:
pump - filter - rail - regulator - return
the new configuration will go
pump - filter - regulator - rail, with the return coming out of the regulator.
the main reason to do it that way for me is just ease of install, and its proven to work just as well if not better than the stock setup, also there are less fittings and line this way which makes it cheaper.

presure2
01-22-2011, 02:01 PM
my cousin joe came by and we pulled out the fuel tank
some pics

eww rust!

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture001Medium-2.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture002Medium-1.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture003Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture004Medium-1.jpg

getting ready to clean it up some

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture007Medium-1.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture008Medium-1.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture006Medium-1.jpg

better

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture009Medium.jpg

presure2
01-22-2011, 02:02 PM
http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture010Medium-1.jpg

coated

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture012Medium-1.jpg

painted

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture014Medium-1.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture013Medium-1.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture011Medium-1.jpg

built a bracket for th AFPR, and started mocking it all up, and installed the fuel pump and reinstalled the tank.
pics.

the bracket for the AFPR from aeromotive

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture036Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture046Medium.jpg

some of the AFPR install parts

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture035Medium.jpg

test fit..needed to order a couple diffrent fittings, at least summit has a great return policy!

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture041Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture047Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture048Medium.jpg

and the installed fuel pump

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture044Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture045Medium.jpg

presure2
01-22-2011, 02:04 PM
got the tune up parts, and fuel filter, so i was able to finalize the AFPR install, and got the harness on, tommorow ill throw the last few parts on and get it into the bay.
a few pics

the motor

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture053Medium.jpg

fuel stuff

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture054Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture055Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture059Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture060Medium.jpg

finished up the fuel line install, and spent a couple hrs working on the ignitor and coil bracket.

when tweak did the harness work, he did not set it up to work in the alltrac chassis.
on the alltrac, the ignitor and coil are not attached to the firewall together, like the 6th gen.
since the harness was left as if it were going in a 6th gen chassis, the wiring for the ignitor and coil were together, and wouldnt reach the stock location on the alltrac.
so, i cut up a few brackets, and made one to hold both the ignitor and coil together, like the 6th gen.

pics.

finalized fuel line install:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMAG0108Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMAG0109Medium.jpg

and the ignitor/coil bracket

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture077Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture078Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture076Medium.jpg

and a quick pic showing the start of the piping route for the IC

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture081Medium.jpg

presure2
01-22-2011, 02:07 PM
the screamer pipe welded and painted:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture088Medium.jpg

installed:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture096Medium.jpg

my version of recycling! (ill grind it down and clean it up tommorow before i start welding.

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture097Medium.jpg

hks bov flange

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture094Medium.jpg

the alltrac heater control valve:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture082Medium.jpg

the 205 one:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture083Medium.jpg

the brackets:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture084Medium.jpg

205 control valve, installed:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture086Medium.jpg

and the aerocatch hood latches.

these things are really cool, they come in 2 versions, a top mount version that sits about 1/8" of an inch above the surface, that use screws and nuts to hold them on, or a bottom mount style that goes in from the bottom and mounts flush with a nice flat surface, that use adheasive to mount them.

i wasnt sure about the flush mount style, and knew the top mount ones work on an alltrac (pat c has them on his 200+MPH alltrac with the same hood jim will be using) so thats what we ordered for him.

packaging:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture093Medium.jpg

the latch (open) and pin (hardware is included as well, just not pictured)

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture090Medium.jpg

the pin in place:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture091Medium.jpg

latched:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture092Medium.jpg

these things are quite a bit more than your average hood pins...but man, they are definetly 100000x cleaner, and more secure. they even come in locking versions!

aerocatch.com site (http://www.aerocatch.com)

presure2
01-22-2011, 02:07 PM
got the crossmember bushings, and couplers in today, so i installed them and started fabing up intercooler piping.

a few pics.

the speedsource solid crossmember bushings:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture098Medium-1.jpg

installed:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture099Medium-1.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture100Medium-1.jpg

and the hot side of the IC piping. ill grind down the welds and prep the pipes for coating tommorow:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture101Medium-1.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture103Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture104Medium-1.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture105Medium-1.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture106Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture107Medium-1.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture108Medium-1.jpg

presure2
01-22-2011, 02:09 PM
http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture109Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture110Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture119Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture118Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture117Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture116Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture115Medium.jpg

i also made myself a pipe beader, out of a pair of vice grips, a 3" exhuast clamp, and a washer.
(how to is here: http://www.6gc.net/forums/index.php?showtopic=76924 )
pics of that and the IC piping.

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture123Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture124Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture125Medium.jpg

how it gets used:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture126Medium.jpg

the results:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture127Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture141Medium.jpg

the pipes welded, and then grinded down and beaded

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture121Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture120Medium.jpg

presure2
01-22-2011, 02:10 PM
http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture142Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture139Medium.jpg

and the b-pipe

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture129Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture130Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture131Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture136Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture137Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture133Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture134Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture144Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture143Medium.jpg

presure2
01-22-2011, 02:11 PM
the finished bpipe:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture147Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture146Medium.jpg

installed:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture160Medium.jpg

clearance, clarence.

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture159Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture158Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture157Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture156Medium.jpg

the IC piping:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture148Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture149Medium.jpg

some random stuff.
coolant line for the turbo:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture151Medium.jpg

modded catch can bracket:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture150Medium.jpg

where the fuse box will be mounted:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture155Medium.jpg

and a couple modded brackets for resistor packs:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture154Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture152Medium.jpg

presure2
01-22-2011, 02:12 PM
the finished coolant lines for the turbo, and isolation mounts for the radiator

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture162Medium.jpg

shifter cable bushing:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture170Medium.jpg

modding the throttle cable bracket for the alltrac cable:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture171Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture172Medium.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/Picture173Medium.jpg

got the intercooler tubes back from powdercoat last night, used a wrinkle silver finish on them, i think they look great.

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2318.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2319.jpg

a couple up close pics of the texture of the wrinkle finish.

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2322.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2323.jpg

presure2
01-22-2011, 02:15 PM
http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2324.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2327.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2326.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2325.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2328.jpg

the wire for the battery relocation (the tray should be here today or tommorow)

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2329.jpg

what i had waiting for me when i pulled the kick panel plastics to run the wire:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2330.jpg

haha... also noticed it has a toyota security system...but looks like it was either dealer, or owner installed. definetly not OEM.
worries me a bit..lol

wow.
i've been excited for alot of the projects i've done over the years here, and have had alot of fun doing so, but i gotta tell ya, this morning, when this package arrived, it was one of the best moments i've ever had while doing this stuff.

im excited to show you guys the first "offical" JDM Guy Garage Item (lol), our Optima Battery Tray / Relocation Kit.

a few pics of the Battery Tray itself:

http://i9.photobucket.com/albums/a57/presure2/JDMGuyGarageBatteryTray.jpg

http://i9.photobucket.com/albums/a57/presure2/JDMGuyGarageBatteryTray2.jpg

i had a couple extra hold downs made:

http://i9.photobucket.com/albums/a57/presure2/JDMGuyGarageBatteryTray3.jpg


The full relocation kit will include:

The Battery hold down Tray, with hardware and made to fit Red and Yellow Top 35/75 and 34/78 series Batteries.
High Quality 0GA Power and Ground Cables, cut to length, grommets to run it thru the interior plastics, and copper lugs soldered in place.
Battery Terminals (Optional)
Install Instructions

All the Customer will need to do is install the tray, run the wire, bolt the power cable to the positive battery wire in the engine bay, bolt on whatever battery terminal they choose (we can supply these as well) install the battery, ground it with the supplied ground cable, and make the connections.

The Tray by itself will run ~90$ shipped, the complete kit is TBA, im pricing everything out before i set the price.

presure2
01-22-2011, 02:15 PM
so i went out and installed the tray last night.

its a bit tricky in the alltrac, since the fuel tank is right under the area where i normall install it, and the fuel pump wiring cover and wiring is also in that spot.

so what i did was cut 4 "standoffs" to raise the tray off the floor of the trunk an inch, so the wiring and plugs wont get pinched by the tray at any point.

a few pics:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2348Custom.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2349Custom.jpg

you can see the standoff here in this pic, its the blue thing under the tray:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2350Custom.jpg

presure2
01-22-2011, 02:16 PM
some pics of the battery install.

drilled a couple holes in the body plastic, and installed grommets for the cables to pass thru:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2369Custom.jpg

my process for assembling the cables:

place the lug in a vice (or hold it with some vice grips), and heat it with a propane torch (you can kinda see the flame in the left of the pic:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2371Custom.jpg

some thick silver based solder:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2370Custom.jpg

while heating the lug with the torch, place the solder into the lug, allow it to melt, filling it about 3/4 of the way up. (again, you can see the flame in the left of the pic if you look close)

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2372Custom.jpg

while keeping the solder nice and hot, insert the cable, hold it in place, and remove the heat, and allow it to cool while the solder hardens.

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2373Custom.jpg

some heat shrink over it, and your done!

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2374Custom.jpg

slip the installed cables thru the grommets in the interior plastics:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2376Custom.jpg

install your battery terminals, bolt down your battery, and your done!

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2379Custom.jpg

presure2
01-22-2011, 02:17 PM
http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/th_MVI_2380.jpg (http://s9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/?action=view&current=MVI_2380.mp4)

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/th_MVI_2381.jpg (http://s9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/?action=view&current=MVI_2381.mp4)

since the spherical shifter bushings i ordered for jim only come in one size, and the alltrac has one bushing thats larger than the other, i had the local machine shop cut us a spacer for the larger bushing.

a couple pics.

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2384Custom.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2383Custom.jpg

fits perfectly. for future refrence, the OD of the bushing is ~1.07"

i need to remake the drain line for the turbo, jim supplied some teflon lined SS line and fittings, and the line itself is not flexable at all.
i will be remaking it with earls SS line and fittings.

a pic to illustrate what im talking about.
in it, the teflon line is using a 45* fitting, the rubber a straight. in theory in teflon line has less stress on it because half of the 90* bend im making with the hose is done with the fitting, but as you can see, it clearly kinked before completing the bend, where the rubber liner conforms to the bend shape nicely.

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2386Custom.jpg

presure2
01-22-2011, 02:18 PM
fixed the return line, glad i did, too, the line was definetly starting to pinch shut, and folded up pretty good while removing it.
a couple pics.

most of the damage to the line you see here was from taking it out

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2407Custom.jpg

the damage to the liner

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2408Custom.jpg

this teflon lined stuff is ok, as long as the hose is traveling in a straight line. once you try to bent it and it kinks, you need to remove it and throw it away, cause it permanantly damages it.

presure2
01-22-2011, 02:20 PM
installed the Aerocatch Hood latches today, fun project.

lots of pics.

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2411.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2413.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2414.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2415.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2416.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2417.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2419.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2421.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2422.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2424.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2425.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2428.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2429.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2430.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2431.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2435.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2433.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2432.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2436.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/areocatch%20hood%20latch%20install/IMG_2437.jpg

hood latches installed. in this pic, the hood is not closed, obviously.

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2455.jpg

hood closed:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2456.jpg

the gap thats left, and the reason jim wanted to install hoodpins to begin with:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2457.jpg

hoodlatches closed:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2463.jpg

heatsheid and fuse box installed:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2462.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2452.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2460.jpg

and a few pics of it outside:

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2467.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2466.jpg

http://i9.photobucket.com/albums/a57/presure2/jims%20alltrac%20swap/IMG_2468.jpg

presure2
01-22-2011, 02:31 PM
at this point, all thats really left to do is make an intake, and install a boost controller.
i am waiting on jim to send up licence plates for it, im hoping we can hit the dyno before he comes to pick it up, he's supossed to come up feb 5-6 to get it, and bring up the next project.

Hookecho
01-22-2011, 03:40 PM
I always like reading your project threads. Looks like your well on your way to finishing another quality swap.

junctrac
01-22-2011, 07:06 PM
Very cool build, i really like the shape and how the pins fit the hood good choice.

presure2
01-24-2011, 12:40 PM
thanks guys!

MCcelica
01-24-2011, 03:15 PM
Diggin the project Manny. Very well documented. :)

Luni
01-24-2011, 05:46 PM
Damn dude. Youre doing some badass work Manny. I wish I lived closer to you.