Thread: Monster 6 Turbo Diesel into a 101.

And here's the left hand supply pipe fitted. The RH pipe is now drying after painting. Fitment tomorrow. I also managed to get the clutch working yesterday... with air assist. Not as light to use as I thought it was going to be but still a lot better than standard! Makes that 'hiss' when used too!!

Originally Posted by Sitec

And here's the left hand supply pipe fitted. The RH pipe is now drying after painting. Fitment tomorrow. I also managed to get the clutch working yesterday... with air assist. Not as light to use as I thought it was going to be but still a lot better than standard! Makes that 'hiss' when used too!!

hopefully mine will be half as tidy as this when its done, only one pipe going out through the arch the other comes out of the intercooler and along the inside of the engine cover/inner wing

So how are you keeping the insides of the pipe clean while you weld it? I've had some bad experiences in the past with slag on the inside of welded pipes. Now I only weld where I can physically see and clean the inside of the joint.

Originally Posted by Dougal

So how are you keeping the insides of the pipe clean while you weld it? I've had some bad experiences in the past with slag on the inside of welded pipes. Now I only weld where I can physically see and clean the inside of the joint.

I've had the same! Turbo impeller wheels don't like balls of slag! With each join, I've made sure that they contact all the way round with no gaps to fill... then before welding, using a flap disk I sand a small mitre on the outside edge of each pipe giving me a 'v' to fill with weld. I then tack the two pieces together using 4 tacks spaced evenly. I then weld from atop each tack to the next. (So at no point does it burn thru and form that ball of weld on the inner side). Once continuously welded, the new join gets sanded flat. The pipe then gets cleaned before starting the next join. Each join can be inspected with a torch to make sure there's no 'bits' waiting to fall off... Once complete, I then thread some string thru the tube, and pull a rag thru several times. The ends then get capped and a litre of petrol is swished up and down inside removing the fine stuff.. then Brakeclean, and then the air line.... and only then am I happy that there's nothing in there and I'll paint and fit it.

So, yesterday avo as we're leaving work, Dan our new apprentice at work (also a CFS mate) pipes up... "101'ing tonight? Wanna hand?" Well, yeah and yeah!! So once home, he's like 'what ya want me to do'.. One of the many jobs that need doing is routing and connecting the 101 throttle cable to the Bosch pump. There was a support bracket for the original Daf cable still on the engine. We sized up what was needed and I sketched roughly what I want. 20 min later and hey presto! A plate for the job. He'll b fittin it today as he's keen to do more!

Well, apart from an RCR call and a late start, it was a relatively un disturbed day. Throttle cable now fitted, and operates as it should. The capillary temp sender is now fitted in the back of the Cummins head. With a bit of re drilling, tapping etc and some magical 'Blue Max' the original plug at the rear of the head was modified to suit the 101's temp probe. I'm thinking the back of the head is the best location as this is the area that usually suffers the most heat. Even if the gauge reads on the high side in its 'normal' position, at least it should be fairly accurate.

Next on the agenda was the air intake pipe from the filter to the turbo inlet. This had to be 3" as it matches the turbo housing, but it also had to have an outlet for the compressor pick up pipe, which is conveniently located at the rear of the engine! Here's the finished product.

Looking good so far. Can't be that far off driving now?