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ZMotorsports Shop Projects 2.0

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zmotorsports

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Mike, what does the tire carrier use as a latch? Nice work on the pulley!

Robert, the carrier latch is just a De-Sta-Co toggle clamp to hold the carrier closed and a spring loaded push-pin as the retainer to keep the carrier in the open position. I will post up some more detailed pictures once I get the parts back from the powder coater and install them for the final time.

Thanks for following along Robert.
 
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zmotorsports

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The wife and I took off for a few days for some much needed R&R in Moab.

Getting ready to hook up.
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Hooked up and ready to hit the road.
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Our campsite in Moab.
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Airing down on Friday morning.
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Looking down from the top of Gemini Bridges.
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Top of Bull Canyon looking down.
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Jeep parked on top of Bull Canyon overlook.
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Only issue that I need to address. At full stuff and steering at full lock my tires just come in contact with the front bumper. A little trimming is in order as I don't want to add any more bumpstop because it flexes so nicely. The rear tires just come in contact with my inner splashshields so a little heating and forming of the inner shields will be necessary but very minor.
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All in all a great short little getaway with the wife. I was pretty happy with the way the Jeep handled seeing as how it has undergone a few changes since last year.

Thanks for looking.
 

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bmxdad

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When will you be adding built in tire inflation? :)

Every time I look at your Jeep, I think he could do this, but then I notice it's already done. Amazing piece of work :thumbup:

I used to run tall tires too, but they were narrow 34x9.5 swampers on a '66 CJ-5 with the 225 V6. Only thing I did for the suspension were 1" extended HD shackles and 3" add-a-leaf springs. No clearance issues and the mud, when running the gas lines at Johnson's Creek in Washington, was contained for the most part.
 
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When will you be adding built in tire inflation? :)

Every time I look at your Jeep, I think he could do this, but then I notice it's already done. Amazing piece of work :thumbup:

I used to run tall tires too, but they were narrow 34x9.5 swampers on a '66 CJ-5 with the 225 V6. Only thing I did for the suspension were 1" extended HD shackles and 3" add-a-leaf springs. No clearance issues and the mud, when running the gas lines at Johnson's Creek in Washington, was contained for the most part.

Thanks for the comments.

As for airing up, this was my first trip with the Powertank CO2 setup and it was nice. Very fast and back on the road, even the wife commented that I was done already.:bounce:

Several were trying to talk me into the 13.5 version of this tire but I prefer the 12.5, now seeing that I have a slight interference I'm even more happy I stuck to my guns and didn't get the 13.5 wide Ridge Grapplers.

Thanks for following along.
 
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zmotorsports

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The contractor who I worked with right after high school had an air compressor for running tools and used his roll bars for the tank. :beer::beer:


Good idea

I built a TJ for a guy about twelve years ago that I used a York A/C compressor for the air and built an enclosed front bumper as the tank. It worked pretty well but I really like the roll bar idea.

On a GS1100 powered sand drag quad that I built and raced about ten years ago I used part of the chassis as the conduit for the oil cooler which also worked well.


Sent from my iPhone using Garage Journal
 
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zmotorsports

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Parts arrived today for next week’s project.

Injectors, high pressure lines and gaskets for an LB7.
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This will be the recipient of above mentioned LB7 injectors, my son’s 2002 Duramax.
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jbmatth

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BMXDAD, That would be great but as many of the hummer owners found out with the system they had that if you get a leak in the system all 4 tires go flat. If there was a way to isolate each tire that would help but there are still more risks than rewards in my opinion.

Mike,
Good luck with the injectors, I have done a couple and didn't enjoy it, especially on the drivers side the back allen bolt really tested my dexterity. Do you use RTV to seal the upper valve cover to the lower or do you have another trick?

JB
 
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zmotorsports

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BMXDAD, That would be great but as many of the hummer owners found out with the system they had that if you get a leak in the system all 4 tires go flat. If there was a way to isolate each tire that would help but there are still more risks than rewards in my opinion.

Mike,
Good luck with the injectors, I have done a couple and didn't enjoy it, especially on the drivers side the back allen bolt really tested my dexterity. Do you use RTV to seal the upper valve cover to the lower or do you have another trick?

JB

Thanks JB. Yeah, that driver's side is definitely a PITA which is why I generally do it first and get it out of the way. I have a fondness of GM's ES (Engine Sealant) which seems to be about the only sealant I use these days.
 

jbmatth

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Thanks Mike,
Do you happen to have a link to the GM ES? I found a few options and would like to give it a try in the future.

JB
 
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zmotorsports

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Thanks Mike,
Do you happen to have a link to the GM ES? I found a few options and would like to give it a try in the future.

JB

JB, the GM part # is 88864346. You can purchase it at your local GM dealership but I have found it slightly cheaper if you're not in a rush online. I bought my last couple of tubes off of ebay for around $12.50/each whereas at the dealership it will be around $18~ish.

This is GM's gray engine sealant that is O2 compatible. If memory serves they call it oil pan sealant but I use it for most applications that call for RTV because it has a somewhat different consistency than regular silicone based RTV. I use it on seal OD's in axles to transfer cases when I seal the halves back together. This is very similar to a product I used to use on motorcycles/ATV's/snowmobile engines years ago made by Threebond, seems like it was 1108 or 1184 can't remember exactly. Now I just use the GM ES even on motorcycles and other small engines. I cut the end of the nozzle very slightly to allow only a small bead, maybe 1/16" is all, and use my squeeze handle to apply a very small even bead. This is one of those that less is more, otherwise you'll be cleaning up the perimeter for hours. About the only place I don't use it is on differential covers where I use the cheap black RTV as I usually have a few tubes floating around that come with gearsets.
 

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Your trip looked like way too much fun. So other then the tire rub, how were all the other aspects of performance Mike? Did you notice any significant increase or decrease in range and or ability?
 

HEEP

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Mike, I replaced a set of injectors on my old LB7. I had rather replace injectors than replace the fuel pressure regulator. That was a pain. Those trucks are golden. I kind of wished I hadn't gotten rid of it.

Bill
 
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zmotorsports

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Mike, I replaced a set of injectors on my old LB7. I had rather replace injectors than replace the fuel pressure regulator. That was a pain. Those trucks are golden. I kind of wished I hadn't gotten rid of it.

Bill

Agreed Bill. I've done a few sets of injectors now and a couple of fuel pressure regulators and I'll take the injectors.:lol_hitti

After all, it's just nuts and bolts, nothing more.
 
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zmotorsports

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Your trip looked like way too much fun. So other then the tire rub, how were all the other aspects of performance Mike? Did you notice any significant increase or decrease in range and or ability?

Cam, thanks for the comments. Yes the trip was a blast if only for a couple of days of wheeling.

**Now for my lengthy review of the overall driving experience of the new powertrain.

As for the overall performance, despite the couple of minor interference issues, I couldn't be more happy with how the Jeep performed. My wife was getting a bit frustrated with me last week prior to leaving. She said "why are you so anxious? This is far from our first trip to Moab and we know the area like the back of our hands so why are you so stressed and anxious?" I had to inform her that the Jeep doesn't even resemble the same Jeep we have been wheeling for the past nearly 8 years and nearly 100k miles now. I told her it felt as though my first time going to Moab with a new Jeep. The Jeep has changed so dramatically even if it looks the same. Different gearing, different size tires, different suspension, different transfer case ratio and different engine & transmission. All of which I had calculated well out in my head but what worried me is the things that maybe I didn't think of or that slipped through the seams in the planning phases. After 3000 miles I now know what it handles like on the pavement in all weather and driving conditions and had an "image" in my mind of what it would wheel like and I wasn't going to be happy unless it meshed up with what was in my head.

Now that being said, it performed PERFECTLY. The power is so smooth and the seamless driving off-road I told my wife I feel as though I am cheating, if there is such a thing as cheating off-road.:lol_hitti It is just as docile and mild mannered off-road as it is on the pavement. What really pleased me is the fact that just like I have hoped is that I hardly had to use 4WD except on the actual obstacles. Being in 2WD most of the time kept my RPM's low and most of the time just idling along or well under about 1500 RPM unless I wanted to kick my speed up a bit which was a huge difference from before when I was in 4-LO and having to be up closer to 2500-3000 RPM as a normal RPM range. Fuel economy off-road didn't really seem to change because I was running so low of RPM and it was working so effortlessly the entire time. I noticed absolutely no difference in range based on this non-scientific gut feeling.

One trail in particular is called Gemini Bridges road. Those of you who have been to Moab will be very familiar with this road as it leads up to Metal Masher, Bull Canyon and of course, Gemini Bridges. The main trail is not difficult at all as it is just a narrow and winding dirt road but it climbs almost immediately as soon as you pull off of Highway 191. The road is steep and there are a couple of rough sections where the rocks are exposed but for the most part not technical at all. In the past this section had to be driven in 4-LO due to the fact of the grade and the lack of power of the 3.8 (and even the 3.6's in our group that had mild lifts and oversize tires) just wasn't sufficient to climb this in 2WD. Even the 3.6 Pentastars with about 80HP more than the earlier 3.8's would struggle but if they were run in 2WD for very long the transmissions would get hot and many times I have been on that section with novice Jeepers who would have their dash light up with overheating issues from the transmission or the engine if they didn't shift the transfer case down into 4-LO.

I was in the "testing" phase so out of curiosity I ran this trail in 2WD keeping an eye on both engine and transmission temps. and it never missed a beat. It motored up the grade without hesitation or even any sense of struggling. The engine temperature stayed in the 204-210 degree range and the fan would come on at idle speed (approx. 20%) and the transmission was around 150-degrees. Actually for the entire day the transmission temperature never raised above 165-degrees. I could toggle easily between first, second and even into third gear at a couple of times on that first section of trail on the grade. Much of it I went slower than normal due to the amount of bicycles on the trail that day but also because I just wanted to see if it would climb it at low speed vs. pushing the speed and cruising up it which it passed the test easily.

Once on top and cruising along the trail it was easily noticed that 4WD was going to something that I wasn't going to be using much in the future when not on the obstacles. I usually had to be in 4-LO because the sandy washes would just **** the power out of the engine as does any slight grade and 2WD just couldn't cut it, not so any longer. We took the turnoff down into Bull Canyon which is only rated as a moderate but just due to about 2 obstacles that require crawling over and tire placement. I did them both easily in 2WD and never slipped a tire. Speaking of tires, I love these Nitto Ridge Grapplers. Obviously it's Moab so traction is good but even in the sand and dirt they performed fantastic. I did air down a bit further than I usually did with my 35's and possibly a little too low on day number one. With my 35" KO2's I had my deflators set to 14 PSI and that is pretty much where I ran all the time off-road. I wanted to try a bit lower on these 37" Nittos but I think I set the deflators a bit too low on the first day. They dropped them to around 10.5-11 PSI and on a couple of occasions I hit a little hard and could feel the tire hit the wheel so once back at camp I played around with my deflators and adjusted the pressure up just a little. On day #2 on the trail they landed me at around 12.5-13 PSI which I found to be perfect for this setup. The ride was nice and smooth yet I had the traction I needed when I needed it. Along one long section of Debinky Well Road north of town I could easily cruise along at around 45-60 MPH and it just floated along with the engine sitting right on the thermostat and the transmission temperature around 125-130 degrees.

Once at the end of the trail the Powertank setup worked flawlessly when airing up. I couldn't be more happy with how the entire package worked off-road. Everything performed even better than expected and I am certain once I get those couple of interference issues addressed it will provide many years and miles of enjoyment.

I have two minor changes coming in the near future as soon as I get some time. I purchased a new CB for the Jeep during the holidays as I had several people mention that they had a hard time hearing me when we were in South Dakota at the FMCA 4-Wheelers gathering last September so I will be installing a new Cobra model 29 as soon as I fabricate a mounting solution for it. I also sold my Bestop Trektop NX soft top a few weeks back and purchased the Bestop Sunrider which will replace my two front panels of the Freedom top with a fold back setup. One thing the wife and I do miss is having the area over the driver/passenger open on nice days so this will provide that open feel yet I won't miss the hassle of the soft top. I will run this setup during the warmer months and put my Freedom tops back on during the winter.

I hope all of that makes sense Cam and I wasn't just rambling but I think I nailed the overall Jeep package right on the head.:bounce:
 
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LXCam

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I hope all of that makes sense Cam and I wasn't just rambling but I think I nailed the overall Jeep package right on the head.:bounce:

Ya I followed right along. The wife let the wind out of your sails and you got tired of being 2lo. :headscrat


hahaha

It made perfect sense Mike and I'm happy for you that everything worked to your expectations and then some. :thumbup: :beer:

So now that I'm out here in off road country I'm gonna have to get me a toy to go play on too.
 
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zmotorsports

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It is great that all the changes worked out that way. Good trip.

Dwight

Thank you Dwight and thanks for staying tuned to my thread.


Ya I followed right along. The wife let the wind out of your sails and you got tired of being 2lo. :headscrat


hahaha

It made perfect sense Mike and I'm happy for you that everything worked to your expectations and then some. :thumbup: :beer:

So now that I'm out here in off road country I'm gonna have to get me a toy to go play on too.

Hell yeah you will Cam, you're right in the middle of it. Just off the top of my head I would say find a nice clean 2007-2011 JKU and drop an LS in it and go have fun. But hey, that's just me.:beer:
 
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LXCam

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Hell yeah you will Cam, you're right in the middle of it. Just off the top of my head I would say find a nice clean 2007-2011 JKU and drop an LS in it and go have fun. But hey, that's just me.:beer:

I like that idea. What's your address and I'll get all that sent up and be over on memorial weekend to do the swap. :beer: :spit:


Looks like my shop activities have ended for quite a while. I'm just gonna have to fab vicariously thru you and a couple others here. :headscrat
 
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zmotorsports

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I like that idea. What's your address and I'll get all that sent up and be over on memorial weekend to do the swap. :beer: :spit:





Looks like my shop activities have ended for quite a while. I'm just gonna have to fab vicariously thru you and a couple others here. :headscrat



Let me get caught up on my son’s Duramax and Jeep and you can send me your Jeep for the swap Cam.

I’ll try not to disappoint while your without your shop. I feel for ya as I know what it’s like not having a shop for a while, it about did me in.
 

JasonJ

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So happy to hear everything worked better than anticipated... or worried about. Awesome setup I am so Jelly.

I love my power tank setup as well, just came back from the annual Death Valley trip and my first year running the power tank was great. Everyone with their hoods up, compressors yelling..... mine was just a Pffffffffffft and done. :)

Every year I go through my past notes to see what upgrade on the jeep rises to the top for the next year. This year I think it will be an intercom system. Though I have a hard top, I always 4WD with the freedom panels removed and doors off. The common complaint is that my buddy that rides with me and I can't hear each other between wind noise, road noise, etc... so I think a nice Rugged Radios Intercom system is quickly rising to the top for the next upgrade... and a 60w Dual Band radio as everyone I run with has moved away from CB's and into the HAM World.
 
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zmotorsports

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So happy to hear everything worked better than anticipated... or worried about. Awesome setup I am so Jelly.

I love my power tank setup as well, just came back from the annual Death Valley trip and my first year running the power tank was great. Everyone with their hoods up, compressors yelling..... mine was just a Pffffffffffft and done. :)

Every year I go through my past notes to see what upgrade on the jeep rises to the top for the next year. This year I think it will be an intercom system. Though I have a hard top, I always 4WD with the freedom panels removed and doors off. The common complaint is that my buddy that rides with me and I can't hear each other between wind noise, road noise, etc... so I think a nice Rugged Radios Intercom system is quickly rising to the top for the next upgrade... and a 60w Dual Band radio as everyone I run with has moved away from CB's and into the HAM World.

Thanks for the comments and for following along.

Like you I am very happy with my CO2 filling system. One of the things I hated before was I was usually the last one filled up and everyone either left without me or I was holding everyone up. I would rather be able to wander around and visit for a bit before hitting the blacktop back to camp.

As for the communication, many of our local club are starting to steer towards the HAM world because they say not everyone has a CB. This doesn't really make any sense to me because we have in our bylaws a list of required equipment in order to run with the club and one of the items is a CB. My thoughts are, if people aren't going to get a CB that is cheap and easy to setup and use, what makes them think people will go get a HAM license and radio?:headscrat

The national club that I run with have quite a few that have migrated to the HAM radios BUT they still have CB's which are the club requirement there as well. No one in that club goes on a run without a CB.

I'm stuck in the middle because I like the thought of the HAM and the range but don't want any more "stuff" in the cab of my Jeep and would just like to see everyone follow the guidelines and come with the required equipment which a CB would be completely adequate.

Thanks again for following along. I hope my Jeep mods are nearing completion, at least for this year.:bounce:
 

LXCam

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Let me get caught up on my son’s Duramax and Jeep and you can send me your Jeep for the swap Cam.

I’ll try not to disappoint while your without your shop. I feel for ya as I know what it’s like not having a shop for a while, it about did me in.

Mike you have no idea how much I appreciate the offer. Nor how much I'd really enjoy doing a project with you. But I got a feeling it'll be a year or two before I get any time to do much of anything hobby related. I just finished reading thru the state contract requirements that resulted in my new job................I'm gonna be one very busy boy for a while. :wtf:
 
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zmotorsports

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Mike you have no idea how much I appreciate the offer. Nor how much I'd really enjoy doing a project with you. But I got a feeling it'll be a year or two before I get any time to do much of anything hobby related. I just finished reading thru the state contract requirements that resulted in my new job................I'm gonna be one very busy boy for a while. :wtf:

Glad to hear you got what you were asking for, but sorry to hear you're going to be so busy.

After 2-1/2 years now of damn near killing myself working I am finally to a point where I am glad I dissolved my business and just focusing on my own stuff. Work is busy but on cruise control and I feel like there is at least a light at the end of the tunnel on my personal projects.

Prior to the move in 2016 I was finally to a point where my yard was in pristine condition and I could just mow it and enjoy it and my personal vehicles were all in perfect condition and I would go home each afternoon looking for something to work on and welcomed the clients vehicles coming into the shop to provide me with opportunities.

The last 2-1/2 years I have not been able to get my feet under me and feel like ALL I am doing is working and killing myself which is not good and I feel for ya having to go through that. I want to get back to that point in my new home/shop that I was at clear back in 2016 where I can go home and relax or work on anything or nothing that I wanted. I long for that feeling again as I don't seem to function well when I have this many items on my white board and not feeling like I have time to enjoy life. My goal right now is to get my son's vehicles up to par so he can get married, move out and start his life as stress free from vehicle issues as possible. THEN I can breathe a little, relax a little and hopefully enjoy the last half of the year doing some playing.

I hope you can get back to that point of doing some playing soon Cam because life without that is too taxing and not good for a person. I watched my dad work his life away and not able to slow down and smell the roses and I don't want that for others.

Good luck my friend.
 

PhantomEB

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I hear you on all that. Just spent a month out of town working, and I was dedicated to making minimum payments on credit cards, paying off all my personal creditors, speeding tickets, etc. Made the final payment to my better half ( we live a live of you got this obligation, I got mine, personal wants and needs are our own) and made a huge hit to one credit card. Now I letting the remainder of the paychecks to getting out of overdraft.

Life is great when you don’t owe everyone else and their monkey!

Now I can go wrench on my bronco with the eye on the ball of the next time I get to hit Moab....ten years later!
 

LXCam

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Glad to hear you got what you were asking for, but sorry to hear you're going

I hope you can get back to that point of doing some playing soon Cam because life without that is too taxing and not good for a person. I watched my dad work his life away and not able to slow down and smell the roses and I don't want that for others.

Good luck my friend.

It's all good Mike. Ya there's a down side but we're excited about this jump and all thought I'll be shopless for a bit, I'll be too busy anyhow I think. But once the dust settles and we find or build our last home things should go back to normal.

Ya know we've discussed this working your life away in this very thread before. Originally it wasn't my life plan to keep this kind of pace up. But this new gig is plum full of challenges and opportunities which I'm looking forwards too. We'll have to talk in a couple weeks or so when my schedule settles down. Unfortunately I won't nor can't discuss any details online.
 
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zmotorsports

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It's all good Mike. Ya there's a down side but we're excited about this jump and all thought I'll be shopless for a bit, I'll be too busy anyhow I think. But once the dust settles and we find or build our last home things should go back to normal.

Ya know we've discussed this working your life away in this very thread before. Originally it wasn't my life plan to keep this kind of pace up. But this new gig is plum full of challenges and opportunities which I'm looking forwards too. We'll have to talk in a couple weeks or so when my schedule settles down. Unfortunately I won't nor can't discuss any details online.

I completely understand Cam. Best of luck in your new adventure my friend.
 
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zmotorsports

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I only had about an hour and a half tonight after completing my yard work so I decided to at least start on my son’s Duramax injector project and see how far I could get.

While the coolant was draining I began disassembly of the driver’s side.

My trusty OTC fuel line disconnect tools work great. I love using these things as they just feel like a quality tool.
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That’s where I’m at when I closed up the shop for the evening.
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Thanks for looking.
 

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GRN96WS6

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Wait you're not standing back and supervising and making him do all the work! [emoji57]
 
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zmotorsports

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Wait you're not standing back and supervising and making him do all the work! [emoji57]

He did quite a bit of the top end removal while I was mowing the lawn but when it got the wiring and removing things like the glow plug module and fuel lines he said he would feel better if I did it so I stepped in. It's a team effort at this point.:bounce: I'm just glad he is out in the shop with me.
 
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zmotorsports

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One more picture from last night before I turned the lights off.
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zmotorsports

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My son and I made little more progress tonight on his Duramax.

Used a 19mm tubing crows foot to remove the high pressure lines.
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Everything ready to remove the upper rocker covers.
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Old high pressure lines. I dropped one of the retainers which found its way into the black hole that vehicles seem to have. I need to dig in and locate it once I get the front end up off of the jack stands.
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New parts at the ready.
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Thanks for looking.
 

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TTMotorsports

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There is a nice u shaped crossmember below front diff that likes to catch everything you drop on gm trucks. I've found spark plugs. Sockets and once a 10mm end wrench in that thing once on a truck I parted out.
 

fnieto

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Tucson,Arizona
Holy cow Mike! you must have three clones with the same awesome skillset. You have accomplished much in the last couple of months while still working full-time. I've spent a couple of hours catching up and let me tell you I'm just in awe. I like a variety of work and feel somewhat proficient but you take it to a much higher level. Remarkable work my friend.
 

protegeV

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DFW
Mike, how many miles on your son's LB7 and what issues is he having that is driving the injector change out?

Probably high fuel return rates or leaking externally into the crankcase. Pretty common with duramax injectors, especially the lb7.
 

rmack898

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Location
Honu Grove NE Florida
I can understand LO dilution but how do you determine high fuel return rates? Is there a drivability symptom?

I've got about 225K on my LLY and plan on keeping it forever so I'd like to know what to look out for and expect.
 
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zmotorsports

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There is a nice u shaped crossmember below front diff that likes to catch everything you drop on gm trucks. I've found spark plugs. Sockets and once a 10mm end wrench in that thing once on a truck I parted out.

I know that crossmember well as I have found many items in there on trucks that I have worked on. Can't seem to locate the retention tab in there though. I'll just have to keep looking.

Thanks for following along and commenting.
 
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