Thread: Isuzu C240 powered Series 3

I just collected the flywheel after balancing so hopefully between rain showers at the weekend I can get the starter motor off, remove the conversion plate and sort out the stripped threads.
If I can get the flywheel fitted I'll be starting her up to check she runs OK.


Colin

I've removed the conversion plate and also fitted the ring gear today. I need to source a heli-coil for the starter bolt because it's a different size to the bell housing bolts. I didn't manage to source any aluminium to blank off the lower part of the conversion plate during the week so I'll get this done during next week.

Picture below of the ring gear about to cook on the BBQ (SWMBO complains when they're done in the oven !). Managed to get the temperature up to 180C for about 10mins and the ring gear 'fell' onto the flywheel with a satisfying 'clang'.

DSCN1279 by Colin Radley, on Flickr

Pressure plate side, you can see the balancing holes on the lower RHS. They tie up exactly opposite the porus patch on the other side of the flywheel.

DSCN1282 by Colin Radley, on Flickr



Colin

I've now made up a blanking plate for the lower half of the conversion plate and re-coiled the damaged threads (7 in total).
The conversion plate is back in so that the engine can rest on the crossmember again (has been supported by an axle stand for most of the week.
The starter motor is bolted back in, this was supported on a length of rope while the conversion plate was removed.

DSCN1289 by Colin Radley, on Flickr

Last night I turned up the 3 dowels for the clutch pressure plate, when the holes were drilled in the flywheel they ended up slightly oversize so I had to make stepped dowels. Pressed them into place and the pressure plate drops on perfectly.
Next I'll turn up a clutch alignment tool and then I need something to bolt onto the flywheel that will rest against the chassis so that I can torque the flywheel bolts.

DSCN1291 by Colin Radley, on Flickr


Colin

Lovely bit of work Colin!

Right up my street as well - making things

Cheers Charlie

Originally Posted by chazza

Lovely bit of work Colin!

Right up my street as well - making things

Cheers Charlie

Charlie,

That's why I have so many 'projects', problem is when it gets to the straightforward stuff I loose interest and look for a new project.

I made a traditional wooden rocking horse for one of my daughters, lost interest part way through and started another (I like the cutting & carving of the timber), lost interest and have a third underway. I did go back to the first at Christmas and finished the leatherwork so she could ride it but there are two more to finish.

Just got the steel cut for my forge (I already have an anvil).

Then there are the 6 Land Rovers.....

Work is starting to interfere with all the projects.


Colin

Managed to get the flywheel & clutch fitted this weekend (between the rain showers).

Sealed up the blanking plate to stop water ingress.

DSCN1292 by Colin Radley, on Flickr

Mounted the flywheel and bolted up. I made a brace to bolt onto the flywheel so that I could torque the bolts.

DSCN1294 by Colin Radley, on Flickr

Fitted the clutch plate after turning up an alignment tool.

DSCN1298 by Colin Radley, on Flickr

I replaced the fuel filter, bled the injector system, checked the oil (needs replacing) and then found I'd lost the keys. After turning my office upside down, going though all the boxes that came with the vehicle, trying all the keys that I could find they eventually turned up.
Then moved a battery from another vehicle but found it very slow to turn the Isuzu over. Put it on charge for a few hours and tried again, 10 seconds of glowplugs and she fired up, produced lots of black smoke then stopped. I managed to get it started a few times but each time it stopped after a few seconds so I'll have to look at the fuel supply.
I didn't check the sedimenter and maybe I'll bleed the system again.

Colin

Originally Posted by gromit

Managed to get the flywheel & clutch fitted this weekend (between the rain showers). Then moved a battery from another vehicle but found it very slow to turn the Isuzu over.

This is about where I rang you.

Put it on charge for a few hours and tried again, 10 seconds of glowplugs and she fired up, produced lots of black smoke then stopped. I managed to get it started a few times but each time it stopped after a few seconds so I'll have to look at the fuel supply.
I didn't check the sedimenter and maybe I'll bleed the system again. Colin

Lots of black smoke = overfuelling for startup.
I have passed the info onto Graham about those pieces you wanting to have folded up.

Alex and myself unloaded a 200TDi engine, gearbox and transferbox today.
The loose plan at this stage is to build them into a 2A shorty, now where to find a chassis? Oh yeah that right .
.

Just had a quick try to re-start it . It turned over OK but wouldn't fire but I did get the distinct smell of plastic insulation melting.
I remembered the PO had mentioned that there was a new glow plug resistor in amongst the spares supplied with the car. Had a look at the resistor fitted and it had a link wire across the 2 terminals, this wire had melted insulation !

Once I'd removed it I found the resistor had failed and as a temporary measure the link wire had been fitted.
Rather than going through all the spares I found one off a diesel I'd parted out a while ago, fitted that and put the battery back on charge.

I'll try again tomorrow....


Colin