Kinda got carried away..... M1028 rebuild

Sharecropper

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There has been a void on this site without your presence Sharecropper.
I trust all went well with your surgery and your recovery is is going well.
Please chime in with some updates if you can.
Ok here’s an update - the surgery was last Tuesday 6/8 at Louisville’s Norton Spinal Hospital. Everything went as expected and I stayed in the hospital exactly one week and was discharged this past Monday 6/14. I had 4 vertebrae in my neck which had rotated into my spinal cord and would have eventually caused paralysis. So the doctors cut those vertebrae out completely and secured my spine with some screws. I am now in a neck brace and must wear the brace for 4-6 weeks until everything grows back together I have plenty of pain meds so I feel just fine. Thanks to everyone for your thoughts and prayers through this ordeal.
Now the good news - on Monday 6/7, the day before I went into the hospital, I wire-transferred 50% of the money for the Supercharger to Bullet in Australia. The engineer at Bullet I’ve been working with indicated that they would need to cast a new aluminum intake which would take about 4-6 weeks, so I figured this could be happening the same time my neck heals up. They have inventory of the intake without the intercooler, however the model which accommodates the intercooler was out of stock. The intercooler is a special aluminum radiator which fits into the intake just below the blower. There is an inlet and outlet fitting milled into the rear of the intake casting, onto which standard 3/4” heater hoses are attached and routed through a 24-volt water pump through another radiator which mounts in the front grille of the truck. There is also a small coolant reservoir and vent cap included in the kit. All parts are off-the-shelf and readily available. The kit will be shipped with a 60 mm snout pulley which will provide 11-15 pounds of boost throughout the entire rpm range, even at idle. Boost can be increased by simply changing the diameter of the snout pulley, however after extensive discussions with the engineer at Bullet, we decided on a 60 mm pulley and 11-15 pounds of boost even though my P400 can handle more.
The engineer at Bullet also said that I would need a marine pump and injectors to reach to the 300 hp capability of my P400. For this I reached out to Jeff Huhndorf at Hucksdorf Diesel in Franklin,Wisconsin. I’ve used Hucksdorf for all my pump work for the past 10-12 years with excellent results. These guys really know their stuff. After discussing with Jeff what I was doing with the supercharger, he recommended building a DB2 5437 pump and setting the fuel to satisfy a fuel flow for 250 hp with the capability of being turned up to 300 hp. That way I could set the fuel based on what my P400 would need. Since this would be uncharted territory and had never been done before, the 5437 marine pump would provide the capability of setting it to whatever it needed to be. He also recommended a set of .330 marine injectors, which I agreed.

Guys this should be a fun project. Once I get healed up and get back to working on the truck I will photo document the whole process.
I almost forgot - my body shop friend will be starting on the bed and fender painting next week. Barry McFadden did an outstanding job enlarging the wheel well openings and adding the M1009 fuel door on the passenger side. I still need to mount and plumb the new tanks but that shouldn’t take long. I’ll keep you guys up to speed on my progress as I move along.
 
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chevymike

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Great to hear surgery went well. Very scary where the are working. One wrong thing could have bad results. Heal up well. Looking forward to truck progress.
 

nattieleather

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Rest and heal up SC. We want to see your build, but not at the risk of you being in chair the rest of your life. So do as the docs and the health care people say and get back into the pink!
 

Sharecropper

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OK I am finally ready to get back on my rebuild after a serious operation last June and a long recovery/recuperation. A quick update -

The P400 / 700R4 / NP241 is still on my engine stand. The aircraft pre-oiler pump has been plumbed with the suction line attached to the passenger-side of the cast aluminum P400 oil pan. I fabricated a mock firewall in order to temporarily mount the pump in the general location that it will be mounted after drivetrain installation. The pressure side of the pump travels through a check valve and then is routed to the large orifice above the OEM oil filter on the driver's side. The pre-oiler pump is 24-volt and will be powered via a momentary switch on the dash. The switch will be energized while the glow-plugs are warming up, thereby flooding all bearing surfaces with oil prior to cranking.

The OEM transfer case shifter has been discarded and replaced with the new cable shifter. I am preparing to cut the small rectangular hole in the cab floor beside the driver's seat to mount the shifter. I will also fabricate, shape, and install a piece of body metal over the OEM shifter hole sealed with GM body sealer/adhesive. The NP241 transfer case was rebuilt and improved by Mark Bendler at Kodiak Truck. It already has the slip joint eliminator from Tom Woods in Utah. After the drivetrain and new driveshaft have been installed, I may elect to mount a disc brake rotor to the flange for an extra emergency brake.

The Supercharger from Bullet in Australia is here and ready to be mounted on the P400. The supercharger has a special cast aluminum intake which replaces the OEM intake, on which the blower mounts. There is an intercooler between the intake and blower which will be plumbed to a radiator mounted in front of the grill. The coolant in the intercooler system is circulated with a 24-volt constant-duty pump with a reservoir. The blower snout extends out to the front of the engine and just clears the throttle bracket and oil fill tube. The OEM fan and clutch will be removed to make way for the crankshaft-mounted 6-rib pulley which will drive the 70 mm snout pulley. This snout pulley will cause the blower to produce 5 pounds of boost at idle and 15 at 2100 rpm. The engineer at Bullet recommended an injection pump to provide sufficient fuel flow to satisfy a minimum of 250 HP. I consulted with Jeff Hunsdorf at Huckstorf Diesel in Franklin Wisconsin, who I consider to be one of the most knowledgeable experts of diesel injection science. Jeff recommended a DB2-5437 pump, which is a marine unit with larger capacity. I purchased a 5437 core from Gib Goodrich at DieselCore in Katy, Texas. I then sent this core to Jeff at Huckstorf, who completely rebuilt it with a new .330 head and rotor and then calibrated it to flow sufficient fuel to satisfy 250 HP. Jeff indicated that the 5437 pump with the .330 head and rotor can be turned up, if necessary, to satisfy 300 HP. So I am good-to-go on the pump. My P400 currently has a Db2-4911 pump which was also completely rebuilt by Jeff Hunsdorf and set to delivery sufficient fuel flow for 200 HP. When I install the Supercharger, I will remove the 4911 pump and place it on my spare parts rack and then install the 5437 pump. After I get the truck back on the road and can see how it runs and feels, I can turn the fuel up if necessary. The engineer at Bullet indicated that the Supercharger with the 70 mm snout pulley mounted on a new P400 could possibly produce upwards of 300 HP, but we will just have to see. I plan to start at the 250 HP settings and play with the timing to get it where I want it, and then see if the engine can eat a little more fuel.

The new Spectre auxiliary fuel tank has been mounted. I cleaned and undercoated the cab bottom before I raised it in position. I was amazed at how clean and rust-free my cab bottom was. It was absolutely like new. I am cleaning and painting the frame as I go. I will now drop the OEM tank and clean/paint that side.

The bed is on saw-horses waiting on my body man to get here to re-paint the sides. I removed the bed and had the wheel wells opened up as described in Post #383
https://www.steelsoldiers.com/threads/kinda-got-carried-away-m1028-rebuild.54469/post-2362501 . I also had a pair of perfect CUCV front fenders opened up at the same time. As soon as I have all the frame parts cleaned and painted, and my body man has the bed sides re-painted, the bed will be reinstalled. I have a Class 4 hitch that I will bolt on before the bed goes back on.

I am ordering the Sherpa 17,000 winch and behind-the-bumper mount today. Thanks to Mad Texan for his assistance with this.

Well, the final saga begins. It has been eleven years since I decided to replace the hood on my truck. Hopefully I can finish this time before something else happens. Stay tuned, more coming.
 
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