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Engine Conversion Begins
- Thread starter cjohnson1
- Start Date
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Sorry to keep ya'll hanging!
Like Larry said. I've got the engine and transmission hanging in the engine bay. Tight is an understatement! But it fits. Been doing most of the work by myself. As in ALONE. so it's been slow going. Not to mention the wife found a house in the country she had to have. So I've moved since I last posted. (And the puter crashed)
I actually enjoy working alone. even though I don't get as much done in the same time frame I can stop and think it through for future problems.
Enough B. S.
The 5. 9L is a 98. 5 crate motor. It was for a Dodge pickup but never made it. Some guy bought it for his Motorhome but lost interest. I found it in Grandbury at Peak Sales and snapped it up. (Thanks John) The Allison AT 542 is out of a 97 Gulfstream. Seems this guy wanted more gears and did some trading for another Allison. I picked it up with a TQ290 (the big boy) and this should make a big difference. Haven't got much wired yet. But dang, I sure cut a lot of em out! Just finished fabbing the motor mounts tonight. Including the crossover braces. I can pull the transmission with out even jacking the motor up. Ended up putting a Cummins truck front motor mount on and made the rear bell housing adapter mounts. That ol Allison hangs out in the sky blue with nothing to support it. Just like the big rigs.
I used as many of the original braces and parts to speed up the fabrication of the new hangers.
I'm only short a few pieces. Like the Exhaust brake, exhaust pipe, big hoses , air filter and gauges. Everthing else is either bought and paid for or is on a truck on it' way. Will be using a big Ford Radiator intercooler combo to keep it cool. It is a 2000 model that used to cool a Cat motor for a while, and is in Norman's Radiator Shop in Fort Worth getting new "O" rings and tested. The parking brake is in Waco. Should be on it's way as soon as Ray Dobbs of Industrial Transmissions finds all the brackets. He's the owner and a really helpful guy. He has done Motorhome conversions before and knew exackly what I needed.
Can't tell you how many hours I've spent worrying about this project. I've built a lot of crazy cars and stuffed a lot of odd ball engines in my time but this has got to be the biggest one yet. Not to mention failure is not an option. The motorhome was worth a lot of money before I started cutting.
I wish I could say I've got tons of pictures to show everybody, but when your the only one pulling wrenches and the grease is up to your arm pits, it's kinda hard to stop and take pictures.
Funny thing is the day the motor went in, it was only going to be a "Let's see what else will be in the way" kinda thing. It was up there on the lift and all lined up and I thought Aw, What the hell. If I push ,it might just go in. And it was over. There were a few frame parts that got cut and spliced back but, no biggie! The transmission was kinda easy too. It went on with out a fuss as well. Lots more room under that bus than you poor suckers doing pickup conversions.
To sum it up. I'll be pulling the motor out one time, one of these weekends to turn the oil pan around and reverse the pickup tube. Seems the front axle is gonna hit it at the first dip in the road. And, seems I got one of those big truck pans and it's sump is so damn big. Oh, Well. I think that will be a good time to connect all the hoses and wire thingys (tech term) to the engine. Then we can make up the other ends as we built out. We, ha ! like I got a mouse in my pocket or something.
Of all things, Gary Kendrick has moved to Fort Worth. I met him last week at his shop. Very cool Dude! HAs somen really awsome HOT RODING stuff.
Will, I guess I'm going to call it quits and go to bed now.
Later ya'll and thanks for keeping the faith. I nearly gave up once or twice. But, it all down hill from here.
Curtis J
Like Larry said. I've got the engine and transmission hanging in the engine bay. Tight is an understatement! But it fits. Been doing most of the work by myself. As in ALONE. so it's been slow going. Not to mention the wife found a house in the country she had to have. So I've moved since I last posted. (And the puter crashed)
I actually enjoy working alone. even though I don't get as much done in the same time frame I can stop and think it through for future problems.
Enough B. S.
The 5. 9L is a 98. 5 crate motor. It was for a Dodge pickup but never made it. Some guy bought it for his Motorhome but lost interest. I found it in Grandbury at Peak Sales and snapped it up. (Thanks John) The Allison AT 542 is out of a 97 Gulfstream. Seems this guy wanted more gears and did some trading for another Allison. I picked it up with a TQ290 (the big boy) and this should make a big difference. Haven't got much wired yet. But dang, I sure cut a lot of em out! Just finished fabbing the motor mounts tonight. Including the crossover braces. I can pull the transmission with out even jacking the motor up. Ended up putting a Cummins truck front motor mount on and made the rear bell housing adapter mounts. That ol Allison hangs out in the sky blue with nothing to support it. Just like the big rigs.
I used as many of the original braces and parts to speed up the fabrication of the new hangers. I'm only short a few pieces. Like the Exhaust brake, exhaust pipe, big hoses , air filter and gauges. Everthing else is either bought and paid for or is on a truck on it' way. Will be using a big Ford Radiator intercooler combo to keep it cool. It is a 2000 model that used to cool a Cat motor for a while, and is in Norman's Radiator Shop in Fort Worth getting new "O" rings and tested. The parking brake is in Waco. Should be on it's way as soon as Ray Dobbs of Industrial Transmissions finds all the brackets. He's the owner and a really helpful guy. He has done Motorhome conversions before and knew exackly what I needed.
Can't tell you how many hours I've spent worrying about this project. I've built a lot of crazy cars and stuffed a lot of odd ball engines in my time but this has got to be the biggest one yet. Not to mention failure is not an option. The motorhome was worth a lot of money before I started cutting.
I wish I could say I've got tons of pictures to show everybody, but when your the only one pulling wrenches and the grease is up to your arm pits, it's kinda hard to stop and take pictures.
Funny thing is the day the motor went in, it was only going to be a "Let's see what else will be in the way" kinda thing. It was up there on the lift and all lined up and I thought Aw, What the hell. If I push ,it might just go in. And it was over. There were a few frame parts that got cut and spliced back but, no biggie! The transmission was kinda easy too. It went on with out a fuss as well. Lots more room under that bus than you poor suckers doing pickup conversions.
To sum it up. I'll be pulling the motor out one time, one of these weekends to turn the oil pan around and reverse the pickup tube. Seems the front axle is gonna hit it at the first dip in the road. And, seems I got one of those big truck pans and it's sump is so damn big. Oh, Well. I think that will be a good time to connect all the hoses and wire thingys (tech term) to the engine. Then we can make up the other ends as we built out. We, ha ! like I got a mouse in my pocket or something.
Of all things, Gary Kendrick has moved to Fort Worth. I met him last week at his shop. Very cool Dude! HAs somen really awsome HOT RODING stuff.
Will, I guess I'm going to call it quits and go to bed now.
Later ya'll and thanks for keeping the faith. I nearly gave up once or twice. But, it all down hill from here.
Curtis J
Well I hate to be a bummer , but you can not use the pickup tube when you turn the large pan around. The pan bolts up fine but the pickup tube will not... . you will find that Cummins is rather attached to the pickup tubes too $$$$$$ I would trade you the one you need for the one you have ( and I need) but I'm afraid that you will be needing yours before I can get to mine. Mine is packed in my 40' moving Van about 2/3 of the way into the load:-( anyway if you want to sell the rear sump pickup tube after you swap it out let me know!
William... ...
William, How long you think it will be before you get yours dug out? I can wait another week if I need to. My oil pan is one of those deep sump ones but, I'm not sure if that makes a difference. My plan was to just shorten it and bend it to where I needed it. I have done race cars this way for years. But, not having to worry about it breaking off would be a plus. Give me a shout off line @ CurtisDrew@AOL.com if your interested in talking about working out a trade.
Curtis J
Curtis J
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Yep I have the same HUGE pan it holds like 15 qts of Oil, way more than the shallow pan they use on the dodge trucks. Unfortunately I will not have the Van unloaded until I get my shop built ( have yet to sheet it with the metal ) so I can have a place to put all the stuff from the trailer. I too have thought of hacking and cutting the pickup tube, but the piece of mind that would come with a factory one has prevented it so far
Rather strange to think about it I trust my life to my welding every day but not my engine??
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We got smoke but not the GOOD KIND!!!!!
Well, I had a good friend come spend the week with me and we spent all week on the MH wiring and making brackets for the little stuff that take so much time. . Somehow we got some wires crossed and POOF, way too much smoke. Burned up a good strech of the wiring harness behind the dash. Damn, damn, damn
Shouldn't be that bad but what a mess. Mostly Wiper motor wires!
Not to mention we lost a good days work just trying to see how bad we screwed it up.
I pulled the motor Wednesday after the rain quit to get the new harness built. And we got it done and ready to turn over. Left out the water in fuel light and a few other of those little things that can be added later, if I decide I need them. The power steering plumbing and cooler lines are about all that need to be done before I stick it back in. The drive shaft and parking brake will be completed after it's back in the chassis.
I still need to build an exhaust and install some gauges to monitor the engine but the wires are all ready installed for them.
But, I need to know which terminal on the alternator on the 98 Dodge Alt to put the little wire? This alt has two small terminals above the big one. So I'm lost there. I forget the brand but it is from a 98 Dodge Cummins.
Hmmm what else? I'm really tired, so maybe I''ll think of something else tomorrow.
C Johnson
P. S. I saved my original Dodge harness intact. I hear they're hard to find in one piece.
Well, I had a good friend come spend the week with me and we spent all week on the MH wiring and making brackets for the little stuff that take so much time. . Somehow we got some wires crossed and POOF, way too much smoke. Burned up a good strech of the wiring harness behind the dash. Damn, damn, damn
Shouldn't be that bad but what a mess. Mostly Wiper motor wires!
Not to mention we lost a good days work just trying to see how bad we screwed it up.
I pulled the motor Wednesday after the rain quit to get the new harness built. And we got it done and ready to turn over. Left out the water in fuel light and a few other of those little things that can be added later, if I decide I need them. The power steering plumbing and cooler lines are about all that need to be done before I stick it back in. The drive shaft and parking brake will be completed after it's back in the chassis.
I still need to build an exhaust and install some gauges to monitor the engine but the wires are all ready installed for them.
But, I need to know which terminal on the alternator on the 98 Dodge Alt to put the little wire? This alt has two small terminals above the big one. So I'm lost there. I forget the brand but it is from a 98 Dodge Cummins.
Hmmm what else? I'm really tired, so maybe I''ll think of something else tomorrow.
C Johnson
P. S. I saved my original Dodge harness intact. I hear they're hard to find in one piece.
CJ,
I have a 01 an I have a main wire and a 2 wire plastic plug on, I guess it is different but there should be a plce for it. Ususally Alternators dont have more than 2 wires on them.
BTW,
Great JOB! on the MOHO. That should blow away any MOHO on the road!! Now get a bigger plate, some twin turbos... ... . 
That is very good work you are doing, Cant wait to see the results!
I have a 01 an I have a main wire and a 2 wire plastic plug on, I guess it is different but there should be a plce for it. Ususally Alternators dont have more than 2 wires on them.
BTW,
Great JOB! on the MOHO. That should blow away any MOHO on the road!!
Now get a bigger plate, some twin turbos... ... . That is very good work you are doing, Cant wait to see the results!
Well, I guess you could say I had a brain fart the other day. I woke up and realized that if I took off the ALT and took it to an Alternator Rebuilding Shop they'd tell me what wires went where on them. So I did!
The guy looked at me and simply said "OH, big one here and a 12v volt off the key here and a ground here. Doesn't matter which of the little wires goes where, Works the same either way!"Uuuuuuh, OK? Talk about feeling stupid. He also has a 9 groove pully for the old Ford ALT so I could put it on the Cummins if I want. Guess I'll have to look at the amp rating of the Ford Alt before I make that decision. I think he said the Dodge Alt was only100 amps. With all the stuff it has to power I may want the Ford Alt.
Today I put the engine back in again for some measurements. Tomorow, I go to the driveshaft shop and get them started shortening and balancing both shafts. And the exhaust has been measured for the Exhaust shop to start on. They should be able to make the entire thing without seeing the truck.
It's all straight after the engine and makes one 90 deg turn to dump out in front of the front axle.
Tomorrow I pull the motor again to turn the oil pan around. Oil pickup tube gets the axe. THere are a few hydraulichoses I need to figure out.
bluthndr
Just thought I'd check in and see what I need to do to get that harness from you for my v10 to cummins conversion... Still haven't found one!!
Don't know what it's worth, so make a fair offer and we'll see if we can make each other happy. Get with me off line. We'lll exchange phone #'s and figure this out.
EricBu12,
Great JOB! on the MOHO. That should blow away any MOHO on the road!! Now get a bigger plate, some twin turbos... ... .
That is very good work you are doing, Cant wait to see the results!
Thank for the encouragement Eric. I've already stepped on this motor as much as I dare. The Allison is only able to handle 260 HP so that's where it's at for now. I plan on replacing the 542 Allison later if I can find a stand alone computer for the newer ones.
And twin Turbos???? Can't squeeze a PPJ sandwich in there now. It's really tight. But hey, There's a lot more bombing I can do to the Cummins before I need another blower. After all there arn't many Drag Strips that will let me stage a Motohome. Besides the dishes would fall out!!! If I can get milage and performance in the mountains it will be a big sucess.
CJ
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Well, I finally got my pictures posted in my photo albumn, You can see them here!
It's not much, but I'm getting there. Still don't have any pics of the power hydraulic steering or brakes I'm having trouble with.
CurtisJ
It's not much, but I'm getting there. Still don't have any pics of the power hydraulic steering or brakes I'm having trouble with.
CurtisJ
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Well I've been all over the Web site asking questions. Then I remembered, I haven't done an update here yet! So here's where I stand today.
The motor and transmission are in place for the last time. In and out 4 times for fitment. The drive shaft has been modified and it fits. The parking brake is on and ready. The shifter linkages are modified, but not iconnected yet. ( a few hoses are in the way). Motor mounts have been fabbed and modified to allow the 4" exhaust down tube to go past it. Remember, I went to side mounts on the SAE#3 housing. I scrapped the Dodge Mounts. Cross member braces are made and in place. The exhaust down tube is short by about 7 inches. It doesn't drop down below the frame far enough yet. The rest of the exhaust pipes are hanging in place waiting for the down tube to align up. The second hydraulic pump is mounted and the double water pump pully is made. I'm ready for hoses and tubing. This second pump will operate the brakes. It is the same pump that worked the brakes on the Ford motor for simplicity. The stock Cummins pump will operate the power steering. This means I can use the vacuum pump for the A/C, cruise control and rear axle booster brakes. The 16 qt oil pan has been turned around. Now it's a front sump. I may have to change the level of the engine now for better return drainage. The oil pickup tube was replaced with a front sump type. The dipstick has been moved to the front hole. (A whole nother story) Engine wiring harness is made and ready to plug up to the chassis. I used one of the Fords electrical gang plugs for simplicity. The transmission water cooler exchange tank has been mounted to the back of the head and plumbed in. It will work in conjunction with the air cooler radiator in front of the water radiator. Plus a remote spin on oil filter will be plumbed into the fluid return line as soon as I figure out where to mount it. Hoses and tubing have been bought in bulk, so it's a matter of cutting and flairing it all together now. I think I'll use the intank fuel pump to boost the diesel up to the engine pump. Remember we're talking a 37 foot Coach so it has a long way to go. Beside I'm thinking, if I ever run out of fuel, this pump will help prime the engine.
What else? I picked up a Ford radiator and intercooler that cooled a Catapillar engine off a 650 Ford . It's really big. It's been cleaned out at a radiator shop and tested. Mounting it has yet to be tackeled, but it will go.
Should have it running by next weekend.
I'm getting there. And, this has definitly been the BIGGEST engine swap I've ever attempted. Even my 68 Chevy Van swap easier than this. I put a 327 Chevy Motor in it. You remember those Vans! They had the engine mounted between the front seats, in a dog house. I'm thinking deja'vu. Only bigger!
I keep updating the pictures in my photo albumn if your interested. It's link is in the post above this one.
Thanks for playing!
Curtis J
The motor and transmission are in place for the last time. In and out 4 times for fitment. The drive shaft has been modified and it fits. The parking brake is on and ready. The shifter linkages are modified, but not iconnected yet. ( a few hoses are in the way). Motor mounts have been fabbed and modified to allow the 4" exhaust down tube to go past it. Remember, I went to side mounts on the SAE#3 housing. I scrapped the Dodge Mounts. Cross member braces are made and in place. The exhaust down tube is short by about 7 inches. It doesn't drop down below the frame far enough yet. The rest of the exhaust pipes are hanging in place waiting for the down tube to align up. The second hydraulic pump is mounted and the double water pump pully is made. I'm ready for hoses and tubing. This second pump will operate the brakes. It is the same pump that worked the brakes on the Ford motor for simplicity. The stock Cummins pump will operate the power steering. This means I can use the vacuum pump for the A/C, cruise control and rear axle booster brakes. The 16 qt oil pan has been turned around. Now it's a front sump. I may have to change the level of the engine now for better return drainage. The oil pickup tube was replaced with a front sump type. The dipstick has been moved to the front hole. (A whole nother story) Engine wiring harness is made and ready to plug up to the chassis. I used one of the Fords electrical gang plugs for simplicity. The transmission water cooler exchange tank has been mounted to the back of the head and plumbed in. It will work in conjunction with the air cooler radiator in front of the water radiator. Plus a remote spin on oil filter will be plumbed into the fluid return line as soon as I figure out where to mount it. Hoses and tubing have been bought in bulk, so it's a matter of cutting and flairing it all together now. I think I'll use the intank fuel pump to boost the diesel up to the engine pump. Remember we're talking a 37 foot Coach so it has a long way to go. Beside I'm thinking, if I ever run out of fuel, this pump will help prime the engine.
What else? I picked up a Ford radiator and intercooler that cooled a Catapillar engine off a 650 Ford . It's really big. It's been cleaned out at a radiator shop and tested. Mounting it has yet to be tackeled, but it will go.
Should have it running by next weekend.
I'm getting there. And, this has definitly been the BIGGEST engine swap I've ever attempted. Even my 68 Chevy Van swap easier than this. I put a 327 Chevy Motor in it. You remember those Vans! They had the engine mounted between the front seats, in a dog house. I'm thinking deja'vu. Only bigger!
I keep updating the pictures in my photo albumn if your interested. It's link is in the post above this one.
Thanks for playing!
Curtis J
Re: Stiiiill looking....
Sure Allen, I have't a clue what it's worth, but make me a fair offer. Contact me at CurtisDrew@AOL.com I took it off without cutting anthing off. So, it's intact and in a box.
Curts J
Sure Allen, I have't a clue what it's worth, but make me a fair offer. Contact me at CurtisDrew@AOL.com I took it off without cutting anthing off. So, it's intact and in a box.
Curts J
Curts,
Finely got around to looking at your repower pics, nice job. To bad all that work will be hidden underneath when its all done. Oh but what a ride!
Steve
Finely got around to looking at your repower pics, nice job. To bad all that work will be hidden underneath when its all done. Oh but what a ride!
Steve
Thanks Steve. I guess I'll have to carry a scrapbook of the thing everywhere I go. I know I'm gonna get a lot of those," How did you do that" questions. I can't wait to get to drive this thing again. I love going on vacation in it. Only now, it's actually going to like the mountains.
Well, as of tonight it shifts from the steering column just like it's suppose to. Not sure what gear it's in, but, those adjustments will have to made with it running. Which won't be long. Actually it would run if I hooked up a battery to it. Almost all the wires are made up. Only the oil temp sender and tach connections not done yet.
My plan was to set the radiator/ intercooler combo in it for a test fit today, only, one of my friends came over needing help with his project. So I only got in half a days work.
The 4 " exhaust brake is on it's way, along with the gauges. I'm going to bend up an add on gauge console to set it on top of the original dash. And have my bud at the upholstrey shop cover it with leather to match the dash. Will put the water in fuel light and a couple of other idiot lights up there too!
The list is getting very short.
It won't be long now.
With any luck I'll take it to the Waco meet. if not there, I'll definitly have it at Kerrville. Looking forward to meeting the local guys.
CurtisJ
Well, as of tonight it shifts from the steering column just like it's suppose to. Not sure what gear it's in, but, those adjustments will have to made with it running. Which won't be long. Actually it would run if I hooked up a battery to it. Almost all the wires are made up. Only the oil temp sender and tach connections not done yet.
My plan was to set the radiator/ intercooler combo in it for a test fit today, only, one of my friends came over needing help with his project. So I only got in half a days work.
The 4 " exhaust brake is on it's way, along with the gauges. I'm going to bend up an add on gauge console to set it on top of the original dash. And have my bud at the upholstrey shop cover it with leather to match the dash. Will put the water in fuel light and a couple of other idiot lights up there too!
The list is getting very short.
It won't be long now.
With any luck I'll take it to the Waco meet. if not there, I'll definitly have it at Kerrville. Looking forward to meeting the local guys.
CurtisJ
Robin, Let me just say that I will never do another one by myself. Too much work for one man. But now I know what I'm doing it's not sooooo bad.
It's almost done. I should have smoke this Saturday.
It's that close...
Will it be worth it? Only if you plan on keeping it and driving the wheels off it. Which I am! I'm three years away from early retirement, so I'm building my nest (so to speak ) on wheels.
If you've got help and have a fair amount of time. I'dsay if your really happy with your coach, go for it.
Curtis J
It's almost done. I should have smoke this Saturday.
It's that close...
Will it be worth it? Only if you plan on keeping it and driving the wheels off it. Which I am! I'm three years away from early retirement, so I'm building my nest (so to speak ) on wheels.
If you've got help and have a fair amount of time. I'dsay if your really happy with your coach, go for it.
Curtis J
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Issue 128 – Digital Version
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