Unchewable, the D170

[kingcrunch]

Ok, so i am a bit behind. The parts in fact showed up on friday. Props to Fedex, really quick. Aaaaand i got around to playing with that stuff which in turn revealed more fitment problems. Argh!



For example, the booster is reeeeeaaaally large. Like really large. I hope it won't interfere with the engine. At least it does not interfere with the steering column.



I got lucky with the brake fluid reservoir. It's close but maintains like 1/2" room around the lid.




I got lucky with the steering rack:



There is no need to c-notch the frame for the rack to clear:



And i think the steering shaft will be easy to build, once i shorten the steering column (about 90mm, 3.5").

Alex

[kingcrunch]

Ok, so i am a bit behind. The parts in fact showed up on friday. Props to Fedex, really quick. Aaaaand i got around to playing with that stuff which in turn revealed more fitment problems. Argh!

For example, the booster is reeeeeaaaally large. Like really large. I hope it won't interfere with the engine. At least it does not interfere with the steering column.



I got lucky with the brake fluid reservoir. It's close but maintains like 1/2" room around the lid.




I got lucky with the steering rack:



There is no need to c-notch the frame for the rack to clear:



And i think the steering shaft will be easy to build, once i shorten the steering column (about 90mm, 3.5").

Alex

[kingcrunch]

Right now, the exchange rates work to my favor and - sorry for that - i'm so gonna exploit that situation.

Of course, there will be delight you guys as well, seing me struggling to get this to work



2300 Eurobucks are about 2700 USD right now.

[kingcrunch]

Getting real.



I kinda know where to cut now. And there is not a lot of room between the booster and the coils on the valve cover.
It fits though. And it looks like i have some room to build 2" headers on each side.


But even if that hole was cut, i can't lift the engine in there right now because i am mounting the chains of my load leveler to bolts on each corner of the engine.

Another bunch of money goes into the special tool for that job. I think i don't want to build that myself.



http://www.ebay.com/itm/MILLER-ALTER...-/122641069456


And i am debating with myself how i want to build the new firewall:

The hole for the heater obviously needs to be shut, several other holes as well.
I am thinking about aquiring a suitable sized piece of 1mm (19 gauge) steel sheet.
Then drilling out all of the spot welds of the original firewall, brace A-pillars and cab floor prior to removing the firewall.

And then diving into recreating the firewall without all of the unnecessary holes and shapes.

I want a stout firewall with a minimal amount of holes in it, to reduce the fire-hazard.
I am also thinking about going with thicker material, like 1,5 or 2mm (17 or 14 gauge).

Yes, that means more weight but since i am modifying structures in that area, i think i want more strength for peace of mind.

[kingcrunch]

Picked up a piece of 26mm tubing today as the final pieces missing for my steering rack jig...

[kingcrunch]

Made a jig for the steering rack.





I stuck a joint and a piece of steering shaft in there to get a notion of the location of the steering shaft - which will have to clear the drivers side exhaust manifold.

Uh, and obviously the frame. A little bit of clearancing needed here. Might be a little less with the final joints and steering shaft.




Here's where it'll get tricky. I will have to create a flat surface for the rubber bushings to sit on:





I still need to throw the engine in there and see how and where stuff interferes...

[kingcrunch]

Shortened the steering column by about 90mm (3.5"). It's about flush with the firewall now. Only the Borgeson joint sticks out beyond the firewall.
The column now has a 1" DD end on it.



With the steering rack in position on the truck and the column in its stock location, the steering linkage only fouls the frame rail by 1/8". Very little clearancing needed.




Waiting for the hemi lift tool before i cut into the firewall... but that's definitely next on the list.

[kingcrunch]

Helluva steep learning curve and it took hours but it's really fun to work with Fusion.

It's not done and based on the metal prototype i made but at least there's some kind of progress.

[kingcrunch]

Ok, so i got my other truck (will be the tow vehicle for this monster one day) road legal, insured and tagged.



Now i can focus on the race truck.
Steering parts show up later this day (franticly clicking the fedex' tracking update button).
Contemplating how i want to proceed with the firewall. Make it by hand or have it laser-cut and cnc-bent... i want to use Fusion.
The sheet metal function is so much fun (and frustration, but that's fun again).

[JustJohn]

Helluva steep learning curve and it took hours but it's really fun to work with Fusion.

It's not done and based on the metal prototype i made but at least there's some kind of progress.

Are you actually detailing your plug weld locations in CAD?

[kingcrunch]

I will have these pieces laser cut, it's a waste of time to drill the plug weld holes myself if the laser can do that at the same time.
This way i am able to check if there is enough clearance around the holes (for my liking, not exactly judging from actual knowledge here).

[kingcrunch]

Been working on the steering setup:





This is all heavy duty Borgeson steering parts, telescoping double-d shaft from the rack to the steering column and the column itself is collapsible as well.

The rack still needs to be attached to the frame. To locate the bolt holes i made a jig from a cutout of the '05s donor frame cutoff i have in my shop.





This jig will be completed with a pair of guide bushings for a 10mm cutter, a regular drill would not work at that angle.
Using this jig i was also able to determine that the rack could be raised another 3/8" for almost flat tie rods.

[kingcrunch]

Been working on/off on this project. Little bits here and there.

Such as the steering column. I tore it apart and found an industry standard 1" / 3/4" DD-tubing slip joint, secured by a molded plastic "insert".

I tore that apart and replaced the lower part with 1" DD tubing and a 1" DD to 1" DD universal joint from Borgeson.
To lock the two individual shafts back together i replicated the holes in the 1" tubing and used a "metal epoxy" glue as a replacement for the factory molded plastic (same procedure, different material).

To gain some more room (and therefore a less invasive frame mod) i shortened the column where it protruded through the firewall.







The bearing and the retainer, as well as the spring have been recycled from the factory setup, albeit the spring is a bit long for what i am doing...








For now, i would consider the steering column and steering linkage pretty much done.
I don't know if it collides with the engine... might as well just test that today.

[kingcrunch]

Finally made up my mind on how to proceed:

Firewall is coming out as one piece. Which means drilling out all of the spot welds.
Buying some square tubing for temporary bracing now... might commence on the weekend.

[kingcrunch]

Some temporary bracing installed to keep the a-posts at their locations and the floor from moving around after i cut into it.



And here it goes, right corner is already loose...
I am having some problems to locate the spot welds on the lower lip.

[kingcrunch]

Was "in the mood" yesterday.







That's a cutout for a 3" engine relocation. I'll be starting from there. Let's see what has to be done...
Within 3-5" of engine relocation the shifter will fall right into place. Not sure where to put the skinny pedal though, the area where that used to reside is completely gone.

[Tincup]

Looking Good, Might want to consider rotating the rack back a little, will make for better steering angles....

[kingcrunch]

Mike,

i don't get it. Rotate the rack in what direction to improve which angles?

[kingcrunch]

Can you see me grin?



Drivers side:





Passenger:






Right now it looks tight as hell.
But there's at least 1- 1.5" clearance between the headers and the frame all around.
I can fit my hand between the headers and the framerail everywhere.

These are the OEM Challenger 6.4 SRT headers that came with the engine!

Also the engine shall be moved back another 2" to gain more clearance.
That will total at 8" relocation...

[2ndroundko]

HECK YEAH!!! looks good in there. I was wondering where you were going o find room for the manifolds. what kind of oil pan clearance are you expecting?