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Engine Conversion, spare tire conversion
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Jerry
Posted 2010-03-05 3:20 PM (#998 - in reply to #906)
Subject: RE: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		Engine arrived...



(LY6 uncrated rear.JPG)



(LY6 uncrated front right.JPG)



Attachments
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Attachments LY6 uncrated rear.JPG (144KB - 26 downloads)
Attachments LY6 uncrated front right.JPG (156KB - 20 downloads)
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Jerry
Posted 2010-03-05 3:26 PM (#999 - in reply to #906)
Subject: Re: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		Next we need to untangle all the wires, fab up some mounts (they are about 3.5" closer to the transmission than the previous engine) and remove, wrap and re-install the exhaust manifolds.

We have an electric fan clutch installed (very solid on/off actuation) and are waiting for the dual alternator bracket, 2nd alternator and belt.
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Jerry
Posted 2010-03-07 12:13 AM (#1004 - in reply to #906)
Subject: RE: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		Got the engine in position today for mock up purposes. We made a mark on the ceiling for the centerline of the engine and taped a string on to guide us.

Engine height is about right and we are ready to start fabricating the arms that will reach out to the stock GM motor mounts (the old engine was mounted directly with no (rubber) motor mounts... No vibration dampening w/o motor mounts).

Also, we cleaned up the cross member by cutting off all the extraneous mounts and arms, including the radiator mounts. Yes, we have decided so go away from the behemoth break-your-back cooler to a more modern aluminum radiator with electric fans that will be mounted directly to the back panel (not angled) and without the big factory fan shroud.
This should give a lot more access to the engine compartment.





(LY6 and plumb line.JPG)



Attachments
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Attachments LY6 and plumb line.JPG (145KB - 26 downloads)
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Bair
Posted 2010-03-07 6:58 PM (#1006 - in reply to #1004)
Subject: RE: Engine Conversion, spare tire conversion


Regular

252525
Location: Santa Cruz, Calif.		We're rooting for ya, Jerry. Almost makes me want to drive to Fresno just to gawk.
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Jerry
Posted 2010-03-08 1:16 AM (#1008 - in reply to #906)
Subject: Re: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		Your welcome to come!
Let me know when you are in the area...

We are still trying to figure out the motor mounts, etc. It will be a bit of design and fabrication.

We are trying to get this done for our family Glamis trip on the 19th of March. It is coming up quickly.



BTW, this is a "drive by wire" engine, so we will no longer have a throttle cable. All good, except that there is no non-mechanical cruise control available as I understand it. We will have to adapt some sort of CC actuator to the throttle pedal up front
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Jerry
Posted 2010-04-17 10:48 AM (#1062 - in reply to #906)
Subject: Re: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		It has been a while, and after a family vacation (which we were originally hoping to use the FMC) and a few other events, we are getting back to it. Now that we know the position of the engine and new radiator, we will remove the engine and transmission and begin welding, fitting the dual alternator system (eliminating the battery isolator) and designing a new electrical panel for all the cooling fans and aux. components.
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Jerry
Posted 2010-04-17 10:51 AM (#1063 - in reply to #906)
Subject: RE: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		Here is a rough mock up of the rear electrical panel with the marine fuse box



(Electrical panel fans MOCK UP.jpg)



Attachments
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Attachments Electrical panel fans MOCK UP.jpg (80KB - 26 downloads)
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Jerry
Posted 2010-04-18 8:03 AM (#1070 - in reply to #906)
Subject: RE: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		Here is the dual alternator kit installed on the engine (now out of the vehicle)

One (145a) is for the T105 coach batteries
One (275a) is for the chassis batteries.

This set up will allow us to eliminate the battery isolator and have enough current for all the coolers and electric fans (approx 100 amp) and other accessories while maintaining a reserve.

It will also give a back up in case of failure. Just bridge the two systems together to get to a shop.




(22 Dual alternator set up installed.jpg)



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Attachments 22 Dual alternator set up installed.jpg (161KB - 20 downloads)
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Jerry
Posted 2010-04-23 11:59 PM (#1081 - in reply to #906)
Subject: RE: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		Got most of the old stuff cleared off the firewall (cable cruise control, battery isolator, misc. relays, etc.) in prep for the new power distribution/relay panel.



(24 Old components cleared from Firewall.jpg)



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Attachments 24 Old components cleared from Firewall.jpg (168KB - 29 downloads)
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Jerry
Posted 2010-04-24 1:03 PM (#1082 - in reply to #906)
Subject: RE: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		A little out of order, but this is the firewall before we removed the components:



(25 before removing fire wall components.jpg)



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Attachments 25 before removing fire wall components.jpg (151KB - 23 downloads)
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Bair
Posted 2010-04-24 6:51 PM (#1083 - in reply to #1082)
Subject: RE: Engine Conversion, spare tire conversion


Regular

252525
Location: Santa Cruz, Calif.		Acutally that looks pretty clean compared to the 509's current condition.

Because of a certain project (which I will reveal after it works) , I need to pull new wires from the drivers position to engine compartment. Is the route underneath fairly clean and obvious? Any obstacles to get around?

I'm pulling a single jacketed 10pair of 18awg (because I'm a electrician, I'm a firm believer in spares) and a single jacketed 3 cond of 12awg for a future project. I'm considering pulling a special jacketed CAT 5 and a video coax for future BU camera and/or data to engine.
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Jerry
Posted 2010-06-25 7:44 AM (#1160 - in reply to #906)
Subject: RE: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		Well, after a long pause, we are back mounting things.
This relay panel will tidy up all the misc. wires and relays in the engine bay and make it easy to troubleshoot later on.



(Relay panel close up.jpg)



Attachments
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Attachments Relay panel close up.jpg (76KB - 23 downloads)
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Jerry
Posted 2010-06-25 7:48 AM (#1161 - in reply to #906)
Subject: RE: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		The engine and transmission is out and the wiring can now be completed before mounting everything. There are spare relays and spare terminals for future additions and modifications. The bottom lugs (heavy terminal blocks) are for the supply current from the battery and also from the 275 amp alternator.



(Relay panel and comp 1.jpg)



Attachments
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Attachments Relay panel and comp 1.jpg (84KB - 23 downloads)
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Jerry
Posted 2010-06-25 7:50 AM (#1162 - in reply to #906)
Subject: RE: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		The solenoid in the lower left is for the house/chassis connect. With the two alternators, there is no longer any need for the battery isolator off the alternator.



(Relay panel and engine compartment.jpg)



Attachments
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Attachments Relay panel and engine compartment.jpg (79KB - 35 downloads)
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borrmann
Posted 2010-06-26 8:24 AM (#1166 - in reply to #1162)
Subject: RE: Engine Conversion, spare tire conversion


Contributor

25
Location: Bluevale, Ontario		While you have the engine bay stripped out you should line it with blue styrofoam and then sheet it with stainless or aluminum. Makes for much less heat and noise in the coach. Frank #645
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zimby4
Posted 2010-09-21 7:03 AM (#1258 - in reply to #921)
Subject: Re: Engine Conversion, spare tire conversion


Contributor


I would like to know where you got the 22.5 wheels or how you converted the 5 bolt to a 10 bolt. Thanks zim #831
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borrmann
Posted 2010-09-21 6:14 PM (#1259 - in reply to #1258)
Subject: Re: Engine Conversion, spare tire conversion


Contributor

25
Location: Bluevale, Ontario		Hey Zim,
There were 5 stud 22.5" rims produced but they are hard to come by, Denny has them on his coach, may have got themfrom MCR. Some coaches were converted to 6 stud 22.5" rims. Expensive procedure because you had to modify the brakes as well. Also these rims are old technology and somewhat hard to find ( around here anyway). Don't know of anyone who has used a 10 lug wheel, although anything is possible, I know when i was checking out Alcoa's offerings there weren't any 10 stud with the same bolt circle. Barney mentioned once about making an adapter plate to bolt to the 5 stud up to a current wheel, that would be a nice solution, but someone has to take the initiative and do it. Any volunteers? Frank.
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Jerry
Posted 2011-09-19 12:27 AM (#1518 - in reply to #906)
Subject: Re: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		After long delays, we are back on the project with the installation. Planning to make it for the next rally... photos to come.
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Jerry
Posted 2011-09-19 12:34 AM (#1519 - in reply to #906)
Subject: RE: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		SST exhaust tubing with a LOT of welding.



(FMC exh. tubing.JPG)



Attachments
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Attachments FMC exh. tubing.JPG (81KB - 23 downloads)
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Jerry
Posted 2011-09-19 12:45 AM (#1520 - in reply to #906)
Subject: RE: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		Exh. system temporarily installed for fit and test.
Will be removed and completely wrapped to reduce heat radiation in engine bay



(FMC exh. installed.JPG)



Attachments
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Attachments FMC exh. installed.JPG (57KB - 20 downloads)
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Jerry
Posted 2011-09-21 12:58 AM (#1521 - in reply to #906)
Subject: RE: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		Installed exhaust system.
Still needs to be removed after testing and wrapped with heat insulating wrap



(Exhaust head tubes.JPG)



Attachments
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Attachments Exhaust head tubes.JPG (193KB - 23 downloads)
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Jerry
Posted 2011-09-21 1:01 AM (#1522 - in reply to #906)
Subject: RE: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		Here's a straight on view with the cross member installed. Radiator was removed for easier access.



(Installed engine rear view.JPG)



Attachments
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Attachments Installed engine rear view.JPG (121KB - 20 downloads)
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Jerry
Posted 2011-09-21 1:10 AM (#1523 - in reply to #906)
Subject: RE: Engine Conversion, spare tire conversion



Regular

2525
Location: Clovis, Ca		With the completely electronic engine (even the gas pedal is 'drive by wire'), there is a lot of electrical work to do.



(Installed engine with wires.JPG)



Attachments
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Attachments Installed engine with wires.JPG (86KB - 23 downloads)
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