ZMotorsports Shop Projects 2.0

[zmotorsports]

POR15 is great stuff, but agree on the messy part! Nice work guys.

Thanks Marc. We have had excellent results with POR15 but I dread using it. Kind of a love/hate relationship.

My shop is absolutely filthy and will need a deep cleaning after this job.

The best part was being able to spend the last several nights and all day Saturday with my son in the shop. The weather was so nice we also were able to work with the shop doors open for the first time of the year. Doesn't get much better than that.

 

[PugetDude]

Mike, did you brush or roll the POR15?
I’m getting close to having the 32 frame ready for paint; trying to decide if I’m going to use POR or chassis paint.
(Took your suspension suggestion btw)

 

[lilscorpion]

Neat idea with the mirror Mike. I frequently wish I had a mirror in the shop, may do something similar.

 

[zmotorsports]

Mike, did you brush or roll the POR15?
I’m getting close to having the 32 frame ready for paint; trying to decide if I’m going to use POR or chassis paint.
(Took your suspension suggestion btw)

Scott, I just brushed the POR15 on because I didn't want overspray all over the shop. The nice thing about POR15 is that it flows out so well, even brushing it on the brush stroked disappear as it flows out and cures.

Personally, where you have it down to a bare chassis I would spray it. I sprayed my old 1971 Chevelle when I did the frame-off build. It had absolutely nothing bolted to it, had it sandblasted and then prepped and sprayed it and turned out awesome.

 

[zmotorsports]

Neat idea with the mirror Mike. I frequently wish I had a mirror in the shop, may do something similar.

Thanks Matt. Just a silly mirror mounted in the last shop but I guess it was something that my son remembers from all those years. I was glad he thought enough to grab it when we were packing everything up in the old shop and moving. It's a small detail but I'm glad to have it mounted in the new shop now.

 

[Jarhead0408]

You know Mike, I’m sure somewhere along the lines someone has mentioned it…

But if you ever launched a YouTube channel I think you’d find a decent audience to tune in.
Your attention to detail is fantastic and somehow even the most mundane things are made fascinating.

 

[lilscorpion]

You know Mike, I’m sure somewhere along the lines someone has mentioned it…

But if you ever launched a YouTube channel I think you’d find a decent audience to tune in.
Your attention to detail is fantastic and somehow even the most mundane things are made fascinating.

See if this link works: https://www.youtube.com/channel/UC6CvyvC1OkmsR1ZtyhdOk3w

if not, his channel is zmotorsports

 

[Jarhead0408]

See if this link works: https://www.youtube.com/channel/UC6CvyvC1OkmsR1ZtyhdOk3w

if not, his channel is zmotorsports

Buddy, I appreciate it.

I have to admit…it wasn’t until you posted that link that I realized I am already subscribed to his channel. Life has been busy lately and I completely forget about it.

(My apologies to you Mike!)

 

[zmotorsports]

Buddy, I appreciate it.

I have to admit…it wasn’t until you posted that link that I realized I am already subscribed to his channel. Life has been busy lately and I completely forget about it.

(My apologies to you Mike!)

Thanks John.

Matt beat me to it. There is also a link to my YouTube channel in my signature here as well.

I don't have a lot of subscribers, but that' ok. I realize my channel is more of a niche type of channel and I don't do it because I want to rack up subscribers. I actually enjoy making the videos and showcasing my work plus showing some of the unique jobs I work on. The average run of the mill jobs aren't that interesting so I don't video everything that I work on in my shop.

I seem to get a lot of negative comments on my channel for talking too much when explaining things but then there are others that comment about how much they appreciate the deep detail in which I provide on how I go about things. I can't win for losing it seems. I generally don't respond to the negative comments and just continue on but it gets old.

The good part of the YouTube aspect is that I have met some amazing people in mine and my wife's travels. It seems that the coach videos, the Aqua-Hot service and work videos in particular have gotten a lot of attention over the years and I have met some people in both Colorado and South Dakota when wheeling that recognized my Jeep and stopped my wife and I to say hello and introduce themselves. I have enjoyed meeting people and talking RV's and Jeeps.

* Funny story. My wife and I along with 3 other couples were in a Mexican restaurant in Spearfish, South Dakota last September enjoying dinner after one of our Happy Hours. As we were preparing to leave we asked the waitress for the check and she told us it had already been taken care of. I immediately looked at one of our friends from Texas because I had helped him with an issue on his Jeep the day before and I was certain he paid for our dinner. He said it wasn't him and went to investigate. He was gone from the table for quite some time and when he returned I asked him who he knows clear up here in God's country, because this guy seems to run into someone he knows about everywhere we go and if not he will meet someone and it will be as though they've known each other since grade school.

He smirked and said "it's not me". Not knowing what he was talking about the waitress pointed to who paid for our dinner and when my wife and I approached their table this gentleman and his wife were having dinner and he was so grateful for my Aqua-Hot videos as they had helped him to find a problem with his Monaco coach's heating system and then it turns out I had helped him through texts to diagnose his Jeep problems after having an LS engine installed. He and his wife were from Las Vegas and we ran into them in South Dakota, how odd is that? He for sure didn't need to buy our dinner but it was awesome to meet him and his wife and put a face with a name. Meeting great people like that is what makes all of the negative comments seem pretty insignificant.

I appreciate you following along John.

 

[OutlawDrifter]

Mike, I've found that when they project negativity towards someone, it's generally to overcome their own insecurities. Most of the keyboard know-it-alls and tough guys need to get out of their mom's basement and get some life experience.

While I enjoy the few forums I post to, there is always an ******* somewhere. Most of them don't have the guts to say such things in real life, knowing they'd probably eat a knuckle sandwich!


Keep doing your thing, I/we appreciate it around here!

 

[zmotorsports]

Mike, I've found that when they project negativity towards someone, it's generally to overcome their own insecurities. Most of the keyboard know-it-alls and tough guys need to get out of their mom's basement and get some life experience.

While I enjoy the few forums I post to, there is always an ******* somewhere. Most of them don't have the guts to say such things in real life, knowing they'd probably eat a knuckle sandwich!


Keep doing your thing, I/we appreciate it around here!

Thanks Marc. One thing I have noticed than nearly every negative comment has in common is that the person(s) has/have NO videos of their own posted. So that tells me that they don't want to make themselves vulnerable to criticism but sure as hell don't have a problem casting comments to others. That's why I generally don't respond as I feel many of them just like to stir the **** and don't have anything valuable to add anyways.

I appreciate the comments Marc. Thank you.

 

[lilscorpion]

I’m not a fan of social media haters. I don’t get why it’s in anyones interest to just pooh on someone else especially when they don’t know you and likely will never even meet you. To me it’s a reminder that hiding alone in my garage totally lost in my projects may be healthier than anyone realizes.

 

[zmotorsports]

I’m not a fan of social media haters. I don’t get why it’s in anyones interest to just pooh on someone else especially when they don’t know you and likely will never even meet you. To me it’s a reminder that hiding alone in my garage totally lost in my projects may be healthier than anyone realizes.

I don't understand that either Matt. In fact there have been several time when I almost said "screw it" and closed out my channel and figured I'd do the same thing, hide in my shop and do the work I enjoy and keep it to myself.

I guess it may be like Marc said, people make negative comments and makes them feel better about themselves and their own insecurities. While I've seen quite a few videos that were showing erroneous information and/or poor procedures I won't even give them a thumbs down. If I don't have anything good to say, I won't say anything. However, on the flip side, when I see someone post something that really catches my attention I am sure to always post a comment in addition to a thumbs up.

 

[zmotorsports]

I had a fun little project last night from a fellow Garage Journal member.

He contacted me a little over a week ago and asked if I would be willing to take on a small machining job. Not having done the job before I found it intriguing so we arranged a date and time for him to come by the shop and drop it off. With the POR15 still curing on my son's Duramax last night I figured I would take some time and knock this project out for him.

The gentleman is converting a Snap-on long handle 1/4" drive ratchet to a 3/8" drive but doing it the correct way and not merely swapping the head. The difference is in the face plates and how they attach to the head as the heads are rated for different torque ratings. The head with the higher torque spec's has the face plate attached with the screws coming in from the top of the ratchet near the direction lever. The lower torque ratchets have a recess machined into them where the screw heads come in from the back side and screw up into the head. There is quite a material thickness difference between the two.

Here on the left is the thicker face plate that is threaded to accept 4-40 screws. Face plate on the right is recessed with through hole for the screws.


Face plates stood up on end to see the material thickness differences.


High torque 1/4" face plate is approx. .182" full thickness.


The lower torque 3/8" drive face plate is recessed which only retains about .036" material thickness at the screw head recess.


Some quick measurements scribbled down and a small piece of aluminum in which to make a mounting fixture.


Mounting fixture drilled and now reaming the screw holes for a very tight fitment so the face plate will not move at all once drilling and milling begin.


Face plate screwed to the mounting fixture.


Locating center of the hole, drilling a through hole and then the boring can begin.


Using my Criterion 2" boring head to bore the minor diameter out to approx. .521"-.522" diameter.


Taking a rough measurement before I go to the pin gauges for more accurate measurements.



Stay tuned for the final pictures.....

 

[zmotorsports]

Continuing on with the Snap-on ratchet mods.

Once the minor diameter was bored to size, I machined the recess in the face plate for the sealing ring to reside. This was approx. .040" deep and .595" in diameter according to the size of the original 3/8" drive face plate.


Removed for final measuring.


Minor diameter is the same as the original at .522" diameter.


Gauge pin in original 3/8" drive face plate.


Gauge pin slides into the newly machined face plate.


Major diameter of .595" barely slips into the recess in the newly machined face plate.


Gauge pin barely fits into the original 3/8" face plate for a similar fitment.


Newly machined compared to the original with the thinner recess screw holes.


Completed and ready for the owner to pick up at his convenience.

Thanks for looking.

 

[lilscorpion]

I don't understand that either Matt. In fact there have been several time when I almost said "screw it" and closed out my channel and figured I'd do the same thing, hide in my shop and do the work I enjoy and keep it to myself.

I guess it may be like Marc said, people make negative comments and makes them feel better about themselves and their own insecurities. While I've seen quite a few videos that were showing erroneous information and/or poor procedures I won't even give them a thumbs down. If I don't have anything good to say, I won't say anything. However, on the flip side, when I see someone post something that really catches my attention I am sure to always post a comment in addition to a thumbs up.

You're bolder than I am. I really want to have a channel and have for years. Couldn't even tell you why but I suspect it's for similar reasons for sharing here - because I hide away in my shop where no one could ever see what I do unless I take a camera with me. Video is a different level of time commitment though. About the only way I'd do it is if I could get good at getting things right on the first shot OR if I could figure out the pure voice-over style where I just take mountains of video and then after the fact layer in words. For the most part what I really don't want to do is spend time video editing. I mean I could...I just don't see it as enjoyable. I'd rather spend that time building.

Another truth about why I don't YouTube is that I'm not sure anyone would be able to follow my thought process. My ideas don't just come to me, then to paper, then to existence. There's sometimes months or years between the initial idea and what I show as the end product in pictures and I have no idea how I could translate that process into video nor would people be able to follow some of it. It's a lot less glorious than simply modeling it and then making it. Also, I tend to have "moments" during the build process and not having them on video is probably a really good thing. I actually like being able to hide the failures in the trash can. One of the benefits of being the only one in my garage.

 

[zmotorsports]

You're bolder than I am. I really want to have a channel and have for years. Couldn't even tell you why but I suspect it's for similar reasons for sharing here - because I hide away in my shop where no one could ever see what I do unless I take a camera with me. Video is a different level of time commitment though. About the only way I'd do it is if I could get good at getting things right on the first shot OR if I could figure out the pure voice-over style where I just take mountains of video and then after the fact layer in words. For the most part what I really don't want to do is spend time video editing. I mean I could...I just don't see it as enjoyable. I'd rather spend that time building.

Another truth about why I don't YouTube is that I'm not sure anyone would be able to follow my thought process. My ideas don't just come to me, then to paper, then to existence. There's sometimes months or years between the initial idea and what I show as the end product in pictures and I have no idea how I could translate that process into video nor would people be able to follow some of it. It's a lot less glorious than simply modeling it and then making it. Also, I tend to have "moments" during the build process and not having them on video is probably a really good thing. I actually like being able to hide the failures in the trash can. One of the benefits of being the only one in my garage.

Matt, that is probably why my channel is not well known nor many subscribers. The video is not professional at all. I'm a mechanic not a videographer. I don't do trial runs, I don't do a lot of editing and I don't do voice-overs. My work is shot in real time and I talk through my process on the video as I'm filming. Like you however, I have given many of my projects a lot of thought long before I turn the camera on. I try to explain in detail that thought process in my videos which is probably where the "talk too much" comments come from. There are people who like the thought process being revealed which is why I continue to do it despite the negative comments, to help those who want to know the process behind the scenes.

I have had my fair share of screw up or as I call them "project alterations" but they are captured in real time. The good part is that they are few and far between, probably because of the amount of time I've thought about them prior to beginning.

My FASS installation on my coach and the LS swap in my Jeep are two that come to mind. By the time I turned the camera on I had probably already completed each project a dozen times in my head and then when the camera was turned on I ran through the process quite rapidly because I had been thinking about them for months or even years and knew the information forwards and backwards.

I think you should give a YouTube channel some serious thought. I love seeing your projects here and I'm certain your work would be even more informative on video.

 

[lilscorpion]

Continuing on with the Snap-on ratchet mods.

Once the minor diameter was bored to size, I machined the recess in the face plate for the sealing ring to reside. This was approx. .040" deep and .595" in diameter according to the size of the original 3/8" drive face plate.


Removed for final measuring.


Minor diameter is the same as the original at .522" diameter.


Gauge pin in original 3/8" drive face plate.


Gauge pin slides into the newly machined face plate.


Major diameter of .595" barely slips into the recess in the newly machined face plate.


Gauge pin barely fits into the original 3/8" face plate for a similar fitment.


Newly machined compared to the original with the thinner recess screw holes.


Completed and ready for the owner to pick up at his convenience.

Thanks for looking.

Sweet project. Like little quickies like this a lot. I had no idea that the face plate was actually different. For whatever reason I thought they were interchangeable which also meant they were the same(ish). This is the perfect example why everyone needs a mill in their shop!

 

[zmotorsports]

Sweet project. Like little quickies like this a lot. I had no idea that the face plate was actually different. For whatever reason I thought they were interchangeable which also meant they were the same(ish). This is the perfect example why everyone needs a mill in their shop!

Agreed Matt. These little shop jobs are AWESOME! I would love to do more of these and not have to crawl around under cars, trucks or RV's any longer to make money. I was not familiar with the spec's on the Snap-on ratchets until this gentleman contacted me and ran through the process.

 

[strokinhorns]

Hi Mike,
I am a long time follower your thought today compelled me to comment. I would guess there are many people like me who read GJ every day and don't comment. I find that I even follow a lot of the same people on here that you do. i just wanted to thank you for your positive posts and reassure you that there are people out there that you impact.

 

[PugetDude]

You're bolder than I am. I really want to have a channel and have for years. Couldn't even tell you why but I suspect it's for similar reasons for sharing here - because I hide away in my shop where no one could ever see what I do unless I take a camera with me. Video is a different level of time commitment though. About the only way I'd do it is if I could get good at getting things right on the first shot OR if I could figure out the pure voice-over style where I just take mountains of video and then after the fact layer in words. For the most part what I really don't want to do is spend time video editing. I mean I could...I just don't see it as enjoyable. I'd rather spend that time building.

Another truth about why I don't YouTube is that I'm not sure anyone would be able to follow my thought process. My ideas don't just come to me, then to paper, then to existence. There's sometimes months or years between the initial idea and what I show as the end product in pictures and I have no idea how I could translate that process into video nor would people be able to follow some of it. It's a lot less glorious than simply modeling it and then making it. Also, I tend to have "moments" during the build process and not having them on video is probably a really good thing. I actually like being able to hide the failures in the trash can. One of the benefits of being the only one in my garage.

That’s why I am posting a few of the ‘32,build pics here instead of on the H.A.M.B- those guys are brutal as soon as they realize you’re a heretic using a fiberglass body instead of a rusted out POS you pulled out of a manure pile with a backhoe…and basically zero tolerance for newbies. I get a lot of information there but rarely post.

 

[zmotorsports]

Hi Mike,
I am a long time follower your thought today compelled me to comment. I would guess there are many people like me who read GJ every day and don't comment. I find that I even follow a lot of the same people on here that you do. i just wanted to thank you for your positive posts and reassure you that there are people out there that you impact.

Thank you very much for following. I am flattered and greatly appreciate the comments.

 

[zmotorsports]

That’s why I am posting a few of the ‘32,build pics here instead of on the H.A.M.B- those guys are brutal as soon as they realize you’re a heretic using a fiberglass body instead of a rusted out POS you pulled out of a manure pile with a backhoe…and basically zero tolerance for newbies. I get a lot of information there but rarely post.

That's sad actually because there are a lot of talented builders over there and some people seem to forget that they were all newbies at some point in time. I guess I look at things differently and want to give back and help others as well as learn from others.

Either way Scott, I'm glad you're posting pictures of your '32 here.

 

[steves_001]

I second strokinhorns comments and I think I've said it before, please keep posting! I learn a lot from your projects and they are just fun to see as its something I don't get to do much of. My days of wrenching have slowed seriously as age increases (hard on the old bod).

 

[Mr.zippy]

I have followed your work for some time, and have watched your YouTube works! I like your style Mike and you keep doing you, it’s way good! Thanks for your efforts, it is much appreciated!

 

[Jarhead0408]

Mike,

I read your latest response and wanted to say two things.

One, I am thrilled to follow along. It continues to pay dividends in my own shop processes and workflow, as well as other areas of my life where your philosophy tends to transfer over. I am 35, a father of three, and try to pursue wisdom wherever I find it. I’ve found a good bit of that just in your projects and posts, and that’s without including anything from your YouTube channel.

Two, I’ve got a pre-employment drug test and physical exam tomorrow morning. So I’ll hold off on an in-depth response to your last response and write out something a little more in depth tomorrow.

Thanks again.

 

[zmotorsports]

I second strokinhorns comments and I think I've said it before, please keep posting! I learn a lot from your projects and they are just fun to see as its something I don't get to do much of. My days of wrenching have slowed seriously as age increases (hard on the old bod).

I have followed your work for some time, and have watched your YouTube works! I like your style Mike and you keep doing you, it’s way good! Thanks for your efforts, it is much appreciated!

Mike,

I read your latest response and wanted to say two things.

One, I am thrilled to follow along. It continues to pay dividends in my own shop processes and workflow, as well as other areas of my life where your philosophy tends to transfer over to. I am 35, a father of three, and try to pursue wisdom wherever I find it. I’ve found a good bit of that just in your projects and posts, and that’s without including anything from your YouTube channel.

Two, I’ve got a pre-employment drug test and physical exam tomorrow morning. So I’ll hold off on an in-depth response to your last response and write out something a little more in depth tomorrow.

Thanks again.

Thanks guys, I appreciate all of the positive comments. I didn't expect this outpouring of comments actually, I was just making a few remarks about why I do what I do but I'm flattered by all of the supportive comments. I know this community here is made up of quite a wide range of professions, upbringings, philosophies and wisdom and I appreciate all of the diversity this forum has to offer yet the commonality of garages, shops, tools and all that goes on inside of our shops keeps us here and interacting.

John, I wish you the very best and hope the morning goes well for you.

 

[zmotorsports]

Last night my son came over and we worked on his 2002 2500HD Duramax. We started by doing a quick clean up of the shop then proceeded to reattach the e-brake cables, wiring loom and shocks that we had removed prior to prepping and painting his chassis.

We reinstalled his hitch after he painted it as well, and yes, I used anti-seize so hopefully it won't fall off and kill someone.


We then clamped the new FASS Titanium Signature series pump and manifold assembly in the vise so we could install the fittings and prep it for installation. I don't like trying to install these fittings with the pump/manifold assembly lying on the bench because there is a long stainless steel draw tube that protrudes from the bottom of the manifold that resides inside 2-micron filter/water separator and by placing these on their sides and trying to install fittings, this tube can get damaged as well as scratches and blemishes can be created by having parts moving around on a workbench. I prefer to hold things securely and hate wrestling with components on the bench when I don't need to. My vise is mounted solidly to my workbench and my workbenches are of solid and sturdy construction. Even in my last shop my workbenches were mounted to the floor and walls to insure a solid mounted work surface. I hate chasing a workbench around when using a vise. I use my vise very frequently and would encourage others to do the same as this can be an invaluable tool in the shop. I see quite a few YouTube videos and I have noticed an odd trend of people using vises that are in either poor repair or are not securely fastened to a work surface and therefore can actually have the opposite affect and cause damage to components when using. Several years ago I swapped my vise jaws around to have the smooth side of the jaws facing inward and I have found I prefer this jaw orientation as I don't need to use my aluminum soft jaws nearly as much and I don't get any marring on the surfaces. In the event I have something that I really need to bite down on to and am less concerned about the finish, swapping the jaws around is quick enough.

In this instance with the black anodizing of the manifold I threw a couple of shop towels in the vise to protect the nice finish.


We loosely mocked the pump assembly into position under the left side of the bed, just behind the cab so we could measure for hose lengths. Next we placed some abrasion resistance covering over the hoses as we were installing the fittings that came in the FASS kit. I realize this is not necessary and way overkill but I did the same thing on my coach FASS installation and I feel it aids in preventing chafing of the hoses as these do vibrate a small amount and seeing as how they are in contact with various parts of the vehicle's chassis and body and should prolong the life of the hoses. I will also state that the quality of hose that FASS provides in their kits is of the highest quality. They do not just throw in cheap hose, fittings or electrical connectors. In the FASS installations I have seen online I have not seen anyone else running abrasion resistance and none are having any issues and have been installed for many years so I'm sure this is overkill and not necessary.


Access to the OEM lines is relatively easy once you drop the fuel cooler down out of the way. It's only a couple of fasteners and the fuel cooler is out of the way and disconnected from the crossmember. For the pressure line we were able to use the OEM style quick connection for the pressure line coming out of the FASS pump and heading up towards the engine bay. For the supply from the tank to the supply port on the FASS pump assembly, the PO somewhere had cut the OEM quick disconnect off so we just used a union and joined the two hoses together.


Here is the FASS pump assembly permanently mounted to the included brackets and to the front left bed bolt. This is a solid mount even with the rubber isolators that FASS provides. The hoses are routed to keep them away from sharp edges and I kept the radius of the bends relatively large to prevent any kinking of the hoses. FASS provides plenty of hose so don't skimp and use a generous amount to keep the bends large and away from sharp edges. In this picture you can also see the return line cut into the fuel fill hose (hose is not installed on this fitting yet). Ensure the Y-fitting is out towards the bedside and leading inward directing the flow to merge seamlessly with the fuel filler hose. This will see a LOT of fuel as this is the polishing effect of the FASS system so make certain the hose clamps are tight and secured away from sharp edges as this pump is the standard Duramax pump assembly rated at 100 GPH and in the event of a rupture it can empty a tank in a hurry. I actually used two clamps on this fitting to ensure a positive connection.


Next step will be to run the electrical side of the system so we have not installed the filters yet. The installation instructions actually start with the electrical but we chose to do the fuel side of the installation first while the truck was on the lift and provide easier access to the fuel lines.

Thanks for looking.

 

[Bob Heine]

I'm sure this is overkill and not necessary.

Mike, I'm the old guy who remembers an ounce of prevention is worth a pound of cure. I'm also a close friend of Mr. Murphy who reminded me things will go wrong at the worst possible moment. Chafing that sleeve is a whole lot better than chafing the hose and would likely be noticed long before fuel starts spraying everywhere.

the PO somewhere had cut the OEM quick disconnect off

Maybe the PO decided the quick disconnect tool was too expensive. Harbor Freight sells a crappy set for $5.99 and Amazon sells a master set for $28.99.

 

[zmotorsports]

Mike, I'm the old guy who remembers an ounce of prevention is worth a pound of cure. I'm also a close friend of Mr. Murphy who reminded me things will go wrong at the worst possible moment. Chafing that sleeve is a whole lot better than chafing the hose and would likely be noticed long before fuel starts spraying everywhere.

Maybe the PO decided the quick disconnect tool was too expensive. Harbor Freight sells a crappy set for $5.99 and Amazon sells a master set for $28.99.

Thanks Bob.

It could have been the cost of the tool or the PO could have had air intrusion at that fitting and rather than purchasing a tool and new quick disconnect just eliminated the quick disconnect. This seems to be a common issue in these fuel systems as well as a common means of taking a possible air leak out of the equation. It's not that big of a deal and I've seen this same thing done on quite a few Duramax's that I've worked on over the years. I think the O-rings inside quick disconnect get old and brittle over time (and miles) and begin to allow air into the fuel system which is death to a diesel fuel injection system so I don't blame them for taking steps to eliminate that possibility. I've seen this on Duramax trucks with much less miles on them than my son's that now has 285k miles.

 

[bugnut]

Mike, saw this today and thought of you! I think their exists special folks who truly believe only they are correct, and they have a case full of participation trophies, to prove it!

 

[mpro323]

Continuing on with the Snap-on ratchet mods.

Once the minor diameter was bored to size, I machined the recess in the face plate for the sealing ring to reside. This was approx. .040" deep and .595" in diameter according to the size of the original 3/8" drive face plate.


Removed for final measuring.


Minor diameter is the same as the original at .522" diameter.


Gauge pin in original 3/8" drive face plate.


Gauge pin slides into the newly machined face plate.


Major diameter of .595" barely slips into the recess in the newly machined face plate.


Gauge pin barely fits into the original 3/8" face plate for a similar fitment.


Newly machined compared to the original with the thinner recess screw holes.


Completed and ready for the owner to pick up at his convenience.

Thanks for looking.

Continuing on with the Snap-on ratchet mods.

Once the minor diameter was bored to size, I machined the recess in the face plate for the sealing ring to reside. This was approx. .040" deep and .595" in diameter according to the size of the original 3/8" drive face plate.


Removed for final measuring.


Minor diameter is the same as the original at .522" diameter.


Gauge pin in original 3/8" drive face plate.


Gauge pin slides into the newly machined face plate.


Major diameter of .595" barely slips into the recess in the newly machined face plate.


Gauge pin barely fits into the original 3/8" face plate for a similar fitment.


Newly machined compared to the original with the thinner recess screw holes.


Completed and ready for the owner to pick up at his convenience.

Thanks for looking.

Hopefully, Mike will be okay with me adding this here. Here is the faceplate installed on the THLLF72 that has been converted to 3/8” drive. A+++ on the machining Mike. It was a perfect fit.

For comparison from left to right FCF72, F80, and the THLLF72 conversion.

 

[mpro323]

Hopefully, Mike will be okay with me adding this here. Here is the faceplate installed on the THLLF72 that has been converted to 3/8” drive. A+++ on the machining Mike. It was a perfect fit.

For comparison from left to right FCF72, F80, and the THLLF72 conversion.

 

[zmotorsports]

Hopefully, Mike will be okay with me adding this here. Here is the faceplate installed on the THLLF72 that has been converted to 3/8” drive. A+++ on the machining Mike. It was a perfect fit.

For comparison from left to right FCF72, F80, and the THLLF72 conversion.

That looks like a very useful small bodied ratchet Calvin. Thanks for posting and glad to have helped you out on this project. I appreciate the comments and it was a pleasure to meet you. Let me know if I can help you out with anything else down the road.

 

[zmotorsports]

Finished up the FASS pump install on my son's 2002 LB7 Duramax last night.

Only part remaining was running the wires and making the electrical connections.

I prefer to securely mount relays vs. having them loose or zip-tied to things so I knocked out a quick mounting bracket in which to secure the relay to. I just dug through the drops and found a piece of .125" aluminum. However, it was 6061 so when I bent it in the pan brake it actually broke at the bend. I thought it was 5052 for some reason but most of what I have is 6061 so I should have known that is what I would inadvertently grab. I had already drilled both holes and tapped the relay hole to 10-32 so rather than duplicate my error on another piece I just fired up the TIG welder and welded the two pieces at a 90-degree angle.


There was more than enough wire loom provided in the kit so rather than have it all coiled up under the cowl, I routed it around behind the underhood fuse box, along the battery tray and main engine loom to the positive junction box where I made my connection. I also grounded the circuit where the bracket fastens to the engine near the main engine ground rather than make the connections at the battery where FASS suggests. This way the wiring looks more OE than tapping directly onto the battery terminals.


Then secured the relay to the aluminum bracket made earlier.


Lastly, rather than tap into the underhood fuse box using a fuse tap provided with the FASS kit, we chose to run the ignition hot wire through the firewall and tapped into a circuit in the dash fuse panel. This way we can keep it hidden and use an existing fuse that is already in the dash fuse box. The circuit we tied in to was the "SEO IGN" fuse but removed the 10-amp fuse and replaced it with the 3-amp that FASS provides. The SEO circuits are not used in this truck as it is for Special Equipment Options such as for law enforcement or emergency vehicles and the circuits just dead end behind the fuse panel. This provides a very clean installation and OEM appearance when opening the fuse panel. Much nicer than seeing a single wire running out of the underhood fuse box and trying to make it look nice and clean.

After starting it and going for a test drive we noticed a very small drip hanging off the fitting providing positive fuel pressure to the engine and seeing as it was getting late we closed up the shop and we'll address the leaky fitting tonight. Other than that it starts great, runs great and seems to be noticeably smoother at idle and tip-in, although it wasn't bad before.

Thanks for looking.

 

[zanyad]

You're bolder than I am. I really want to have a channel and have for years.

Matt, ... I think you should give a YouTube channel some serious thought. I love seeing your projects here and I'm certain your work would be even more informative on video.

Second this!

Hi Mike,
I am a long time follower your thought today compelled me to comment. I would guess there are many people like me who read GJ every day and don't comment. I find that I even follow a lot of the same people on here that you do. i just wanted to thank you for your positive posts and reassure you that there are people out there that you impact.

I'm also a long-time lurker who rarely posts but has learned a lot. Keep the good stuff coming!

 

[zmotorsports]

Last night I was able to fix the small fuel leak at the pressure fitting on my son's FASS pump. It was merely a small burr on the seat of the 37-degree AN male fitting preventing the female fitting from sealing properly. I didn't notice it while the assembly was on the workbench so I removed the fitting, ran a piece of emery paper over the burr, reinstalled and test drove. Leak abated and then cleaned up the shop which was filthy.

The truck looks pretty good with the chassis painted and his summer tires/wheels installed. We kept the FASS pump assembly tucked up as tight as possible so it isn't as noticeable from under the front of the bedside. If you look they are barely detected from a distance but if we moved it up any further we would be contacting the fill hose and I didn't want the pump assembly coming in contact with the fill hose.


Going to get the Jeep in the shop over the weekend and do a LOF service and with the weather changing I will be installing my Sunrider flip back top. It's supposed to be a beautiful weekend here so I'm looking forward to just opening the shop doors, cranking up the tunes and doing some preventive maintenance on the Jeep.

Thanks for looking.

 

[PhantomEB]

I like the idea of the mirror. I am sure my better half would appreciate me coming in the house a little cleaner! LMAO!

 

[zmotorsports]

I like the idea of the mirror. I am sure my better half would appreciate me coming in the house a little cleaner! LMAO!

I actually already forgot I had it. Last night I was working on my son's LB7 and while removing the fitting I had something drip on my glasses and my cheek. I pulled the mirror on my son's truck out to check and see if there was anything on my face and my son asked if I had already forgotten we had a mirror over the workbench. I simply said "yep, I forgot."

It was a permanent fixture in our last shop for nearly 25 years but I haven't gotten used to having it in this shop yet.

 

[Snapped-off]

I like the relay holder for the Fass. What would it cost to make one of those to hold 2 relays side by side in that same spot?