Another 120 project begins

OK, I think its time to post an update or two on the 120...

... well first off, it's been sporting a Garrett T3 turbo with an ATA FM intercooler for a few years now. Fuel boost is only moderately turned up (~1.25 turns of the fuel screw from memory). EGTs rarely exceed 600*C. No major complaints so far. It's served the intended purpose well, that is overtaking on the freeway & being able to maintain 110km/h regardless of conditions.

I'll dig up pics of the conversion details later in the week, but here's the list of tasks I've tackled since the last post:
- 4 bolt steering box
- new radiator (V8 radiator with outlets swapped),
- dual spin on oil filters with spacer brackets + spin on fuel filter,
- new wingless sump, late 4BD1T dipstick tube + dipstick
- fitted a turbo style rocker cover with an integrated engine breather port connected to a Provent 200
- additional gauges (VDO boost gauge with an inline restrictor (stops the ticking), Auber instruments EGT gauge and thermocouple, EngineSaver TM2 temperature alarm)
- fixed up the small amount of rust found in the firewall
- fitted an ADF type brush bar / PTO winch cradle with a Thomas winch and a pair Hella Rallye 2000 spotlights
- New shocks and springs front and rear (standard Bilstein shocks, ADF 110 front springs, 130 rears (outer springs only))
- Superpro steering and suspension bushes all round - much improved steering and reduced driveline clunk afterwards
- A 130L long range tank
- rear sway bar fitted - made a MASSIVE difference to body roll when fully loaded
- new seat bases, new heater and vent controls, new instrument nacelle & supporting plastic trim / frame (the bits 4BD1s usually chew up) - no more rattles from there, but should have ordered a Raptor metal bracket that the instrument cluster affixes to. I can't see the new plastic one lasting too long.
- new Stainless steel sleeved clutch master cylinder and new clutch slave cylinder. Got tired of bleeding the clutch every 3 months.
- made a 3mm aluminium bonnet protector plate with integrated pioneer tool mounts (so I can take them off / replace with the plain chequer plate if so desired)
- new lights all round (headlights, position lights, indicators and reverse light), new grille and headlight surrounds

Here's a few pics for completeness (they've been posted elsewhere)

https://www.aulro.com/afvb/images/im...013/09/971.jpg

https://www.aulro.com/afvb/images/im...013/09/972.jpg

https://www.aulro.com/afvb/images/im...013/09/973.jpg

https://www.aulro.com/afvb/images/im...013/09/974.jpg

I've been living in the CBD for the last couple of years, so she's mainly been doing city driving. Pottering around town in (LT95) 4th from 40km/h onwards is a great way to save on fuel bills... not so good when you have to plant it to change lanes... SA style! :wasntme:

That got me thinking... wouldn't it be nice to have a bit more low end boost. :angel:

very nice find. Did anyone else notice it came with front and rear Maxidrive diff locks fitted :cool:

I've not seen this thread before!! A very familiar vehicle!!! How'd ya go with those wheels? :)

Thanks Serg,

She was no show pony when I picked her up, but did have a few goodies installed including front and rear Maxidrive lockers in laminated axles. I've been working on the rest of the drivetrain to give the ol' girl a new lease on life.

I came across a couple of things I couldn't say no to, one thing led to another and well, I have a virtually new drivetrain waiting to come together, comprising:

- rebuilt 4BD1T block (new pistons, rings, liners, bearings, camshaft, oil pump)
- new (early) head with rebuilt injectors
- new injection pump from a 4BD2TC
- rebuilt old-school Garrett VNT25 with a mechanical dual port (pressure / vacuum) VNT actuator.
- turbo pressure plate, new clutch and throwout bearing (may need a new spigot bush as well)
- little used LT95 TRB box with bottom mount PTO drive. Not sure of kms travelled, but TC appears to have very little visible wear.
- refurbished PTO winch and drive shaft assembly
- used 70A Hitachi alternator to upgrade my original 40-amper
- rear disc brake conversion bits
+ lots of not so interesting body & interior bits and pieces

Obligatory pics...

Block - top end
https://www.aulro.com/afvb/images/im...013/09/945.jpg
Bottom end
https://www.aulro.com/afvb/images/im...013/09/946.jpg

Head (anyone know if the numbers next to valve stems represent cast date?)
https://www.aulro.com/afvb/images/im...013/09/932.jpg
Being cleaned up
https://www.aulro.com/afvb/images/im...013/09/947.jpg
Injectors
https://www.aulro.com/afvb/images/im...013/09/948.jpg

Injection Pump
https://www.aulro.com/afvb/images/im...013/09/949.jpg

https://www.aulro.com/afvb/images/im...013/09/950.jpg

Turbo complete with early Chrysler T3 (TK100) mount. the turbo has the same 60 trim compressor as Garrett's T25 (39.8mm inducer and 51.4mm exducer), with a variable nozzle turbine housing (0.64 A/R, 52.7mm inducer and 46.2mm exducer). Hoping it will flow enough for ~200 hp with boost on tap from almost idle.

https://www.aulro.com/afvb/images/im...013/09/951.jpg

https://www.aulro.com/afvb/images/im...013/09/952.jpg
Garrett P/N plaque
https://www.aulro.com/afvb/images/im...013/09/953.jpg

LT95 box
https://www.aulro.com/afvb/images/im...013/09/954.jpg

PTO Drive
https://www.aulro.com/afvb/images/im...013/09/955.jpg

Things are starting to come together, so will be asking questions as I go along.

Cheers

Bojan

WOW! it just keeps getting better. Thats a parts list to make a lot of guys jealous. Should be a bloody good set up once done.

keep on truckin

Quote:

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Originally Posted by Sitec

I've not seen this thread before!! A very familiar vehicle!!! How'd ya go with those wheels? :)

---

lol... yeah, keeps disturbing the tranquillity at your place, hey? ;)

Not too bad, the Compomotive centres are ready for soda blasting, but the chrome rims couldn't be restored economically (minimum cost of $250/rim) so I'm having it taken off & then sandblasted - will hopefully have them ready to paint by next weekend. Progress stalled last week - been called in to work a fair bit.

Have to take a few good pics next time I'm over and update my 90 build thread as well. These are the only ones I have at the moment.

https://www.aulro.com/afvb/images/im...013/09/935.jpg

https://www.aulro.com/afvb/images/im...013/09/936.jpg

Cheers

Bojan

Quote:

---

Originally Posted by Offender90

...

Bottom end


Head (anyone know if the numbers next to valve stems represent cast date?)
https://www.aulro.com/afvb/images/im...013/09/932.jpg
...

Turbo complete with early Chrysler T3 (TK100) mount. the turbo has the same 60 trim compressor as Garrett's T25 (39.8mm inducer and 51.4mm exducer), with a variable nozzle turbine housing (0.64 A/R, 52.7mm inducer and 46.2mm exducer). Hoping it will flow enough for ~200 hp with boost on tap from almost idle.

...

Cheers

Bojan

---

I don't know about the cast numbers, but I know the date in permanent ink was marked on my head under one of the posts for the rocker shaft. In your pick I can see similar printing, so have a good look at that.

I'm going to hazard a guess that a compressor wheel with 40 mm inducer is not going to flow enough air and the 52 mm exducer will not give enough boost at reasonable efficiency for 200 HP, but that is simply my gut feel and may be wrong. You could always rebuild it with a larger wheel.

The vnt 25 turbo is ancient and a lot had been learnt about vnt design since then. While it works, any gt22 based vnt turbo will beat it for boost, power and economy.

You can get 200hp worth of air from the 51.4mm t25 compressor on our engines , but only just and as John said, it's not very efficient doing it.

Quote:

---

Originally Posted by Bush65

I don't know about the cast numbers, but I know the date in permanent ink was marked on my head under one of the posts for the rocker shaft. In your pick I can see similar printing, so have a good look at that.

I'm going to hazard a guess that a compressor wheel with 40 mm inducer is not going to flow enough air and the 52 mm exducer will not give enough boost at reasonable efficiency for 200 HP, but that is simply my gut feel and may be wrong. You could always rebuild it with a larger wheel.

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Thanks John,

I saw the writing, but couldn't make out a date - a few Japanese (Kana?) characters. I've blown it up as much as possible if someone else can make out a date.

https://www.aulro.com/afvb/images/im...013/09/923.jpg

The reason I asked about the castings is I have access to three heads at the moment, and all three have different numbers, corresponding to what could be YY M DD dates. See below

Unknown vintage head
https://www.aulro.com/afvb/images/im...013/09/924.jpg

Late 4BD1T head (skinny injectors) - numbers don't come up well, but from memory 89 8 17
https://www.aulro.com/afvb/images/im...013/09/925.jpg

Damn!!! That's not on!! If you are pulling 200hp out of the 4 I'm going to have to wind the pump out on the Cummins!!! Thought I was doing well at 240hp!! Still not sure how well the LT230 is going to cope though!!
Re the rims.. With the centers restored you could always do the 'satin black' option on the rims... There's a lot of the newer rims around now with that black outer look...
As for the Ninety.. Shout if you want pics putting up.... Off to try and find that thread now!! :D