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Old 02-02-2014, 10:36 AM   #61
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Hey thanks a lot. Yeah I have to disconnect the garage door and hold it up in order to get it out.

Yes im going to be running the turbo that was on it. Its the same one on the 12 valve dodge cummins. I believe it's the hs35.

Ive been doing a little side work on a trailer I picked up, making it into an off road trailer.

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Old 02-02-2014, 04:17 PM   #62
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This build is awesome and I agree with the post about getting it out of the garage.

Looks like it's time for a shop!

Good work

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Old 02-09-2014, 03:03 PM   #63
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How does is NV4500 expected to do with the 4bt on a tj. I know they're geared pretty low, especially in the first 3 gears, so would the stock ax15 be a better alternative? My goal is to do this to a tj this summer and while I'm at it at AEV's brute pickup kit, but I don't see myself doing too much offroading, and I'd still like it to be at least drivable on the highway.
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Old 02-10-2014, 01:47 PM   #64
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Well with stock tire size the nv4500 would be pretty bad. The Ax15 would not be the best choice if you were going to modify the cummins at all for more power of torque.

With 37's and 4:10 gears I'll be able to go around 65 or 70 and still be in the power band.

With 31's I would imagine it would be much less
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Old 02-10-2014, 01:49 PM   #65
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As for progress, the Cage is fully welded. School and work has been pretty busy and I haven't gotten much done.

I did just order 50hp injectors, fuel pin and spring, and ARP head studs though.
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Old 02-10-2014, 04:38 PM   #66
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Quote:
Originally Posted by wmeyer116 View Post
Well with stock tire size the nv4500 would be pretty bad. The Ax15 would not be the best choice if you were going to modify the cummins at all for more power of torque.

With 37's and 4:10 gears I'll be able to go around 65 or 70 and still be in the power band.

With 31's I would imagine it would be much less
What are you thinking your rpm's will be at 65-70 in 5th?
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Old 02-10-2014, 05:07 PM   #67
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Sub'd. Nice work so far.
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Old 02-10-2014, 05:18 PM   #68
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I'll be right around 1800 rpms going 65 in 5th. lol I have no desire for going much faster than that in a wrangler anyway. It suits my needs well.

Thanks ageless stranger.
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Old 02-11-2014, 12:36 AM   #69
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Old 02-11-2014, 11:00 AM   #70
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Old 02-11-2014, 04:18 PM   #71
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Late to the party, but sub'd.
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Old 02-21-2014, 05:27 PM   #72
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Small Update:


Hi everyone, yesterday evening I took my engine, and every component to my friend's father in law's shop. In the next few weeks they're going to hone the block, balance the crank and the cam, balance the pistons, and cook the whole block in an engine cleaner.

I found out the injectors I ordered are on back order, so I'm going to be ordering them from somewhere else. If I could I would rather have something a little less smokey than POD's, but for some reason most of the upgraded bosch injectors only fir 91.5 and up 4bts, and mine is a 90.

The ARP head studs came, as well as the fuel pin and 3200 rpm spring. Now I just have to wait...


In the mean time Ive gotten a new set of brakes to put on the 14 bolt. It had an old weld-on disc conversion, but it looked pretty crappy, so I ordered disc conversion brackets from Ballistic fab, and new rotors, calipers, pads, and caliper bolts from advanced auto.

Also, I've been working a little more on my off-road trailer. Here it is so far lol
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Old 02-25-2014, 08:24 PM   #73
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Did a little bit or work on the brakes and diff today.

I got one side done. It took a little longer than I anticipated, but thats what I get for anticipating lol.



I took the diff cover off, and man, it was disgusting. a lot of the fluid leaked out from the vent when I was transporting it home, so the inside had been low and caused some surface rust. There was some older rust on the outside of the gears as well, but no pitting on the the teeth or anything. I'm not sure if I need to gave it looked at by a professional or not. For I now I just sprayed it down with some oil and I'll put the diff cover on and fill her up tomorrow.



This was some of the gunk that was around the magnet...
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Old 03-13-2014, 11:24 PM   #74
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Sorry for the lack of pictures or updates, I'll be getting some pics soon.

As for progress, The block is done being re-machined, but the head was cracked. Its pretty common in 4bts. I've ordered a new head and it should be here next week. Also, the injectors are in as well.

In other news, I took a long look at the nv4500 I had got off of craigslist last summer and, as well as the bell housing for it and the bellhousing from the old sm465 that was in the breadvan, and decided that it is too mismatched to have it work how I want it to. The starter does not line up, the slave cylinder does not line up, and a few other things. Also, the the input shaft on the np205 is too long, and the output shaft on the nv4500 is dinged up a little.

So, I bought a ZF5 off a ford 7.3 diesel, and I'm going to be mating it to a Dana 300 with some beefed up internals, using an adapter from Advanced adapters.

So now I need to get the ford adapter plate for the 4bt, the Dana 300 and the adapter for it, and a flywheel and starter.

I'll be posting some pics of the transmission hopefully tomorrow
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Old 03-13-2014, 11:25 PM   #75
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I ended up cleaning out the differential, and had a a friend check out the gears and all and said they were okay. So I put on the new Ballistic Fab diff cover and filled it up with new fluid. I replaced the brakes on the other side as well, and also all the seals. The bearings were good on both hubs.
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Old 04-04-2014, 09:26 PM   #76
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Excellent build! Can't wait for more progress reports.
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Old 04-04-2014, 09:42 PM   #77
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Haha, Just cruising the site and saw your post.

I've not done much on the jeep other than just collecting a LOT of parts.

These are all the parts I have ready to go on:

-New head for the cummins
-Injectors
-intercooler out of an Audi TT
-New Radiator from Mopar
-Dana 60 3/4 ton front brake conversion brackets for my front axle from TMR
-New rotors, calipers and pads for the Dana 60, the same as the rear. ( I would normally want to keep the 1-ton's massive stopping power, but the calipers take a lot of fluid to fill and work properly. The 3/4 ton rears are plenty strong enough, guys even run them with 44's)
-JD Motor mounts
-Rhino pac clutch and slave cylinder assembly (pre-bled)
-Crossmember kit from ruffstuff
-LUK clutch for the ZF5
-4bt to ZF5 adapter for the zf5, with flywheel from dieseladapters that uses a 6.0 starter
-XDP diesel Sump kit to modify the stock gas tank for diesel
-Clutch fork for transmission

For the transmission, I steel need The following:
-top plate/ shifter
-inner/outer shifter boot
-clutch fork boot

I also found out that the wrangler uses the vacuum to run the brake booster. I don't have a vacuum pump on the 4bt, and I don't think that I would have peace of mind using an electric pump on something as important as brakes. So I'm going to be getting a hydroboost out of a chevy application. This will be plenty strong and does not use a vacuum.

To install the engine I still need to get the intercooler and radiator piping and fittings. I still have the wiring harness from the 4bt, but I will need to make something for the new gauges I will be running, most likely glow shift.

The engine was honed, the pistons are balanced, but I still need to take the flywheel and clutch to be balanced with the crank and cam. I also found out that there was an imperfection from the factory in the casting in the block, and its right where head sits. So, Either I have to shave off the imperfection from the top and run a thicker head gasket, or bore out the cylinder and sleeve that particular one to match the thickness of the other 3 cylinders. Cummins recommends sleeving instead of oversized pistons on their B-series engines.

I've been doing a bad job on pictures, I think I'll be installing my front brakes this weekend so...hopefully, I'll get some good ones for you guys.

If any of you have any questions about the swap or anything feel free to ask!
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Old 04-21-2014, 10:53 PM   #78
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Finally got around to do the brakes.

Here are some pics of the front and some more pics of the back. The front ones are using the k20 brakes and the brackets from TMR








And here is the front diff drained. It looks almost brand new. I need to get a new cover for it.

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Old 04-26-2014, 12:12 PM   #79
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I got a used windshield frame (not shown), as well as a hood and the grill i got a while ago.






I also ordered the front dana 60 cover, as well as some Blue Torch Fab tube fenders that came in the other day. I have to get some grill support rods that connect to the firewall in order to mock up the tube fenders, as they are a DIY kit.

Also I got the Dana 300 off of Ebay for $250, not too bad. I ordered a complete rebuild from Novak conversions, as well as the adapter from advanced adapters, and the twin stick kit from JB fabrication.
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Old 04-30-2014, 09:10 PM   #80
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I got the front end mostly straightened out as far as the grill and hood go. I'll have to take it apart again once the engine goes in but I needed to have it set up strait so that I could start on the tube fenders. I took some more crappy cell pics of the side I got tack welded up.







The engine is taking so much longer than I anticipated. I had to go up to the machine shop last night to part way assemble the block to the point of one of the pistons and rods installed. This way we could tell what the piston stick out was now that the block is a bit shorter. The stock cummins stick out is .0024" - .0028" and it was at .0056". They will be shaving off the remaining amount from the pistons.

Anyway, I got all the parts for the Dana 300 so I'll hopefully be able to tear that down as well.
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Old 04-30-2014, 09:12 PM   #81
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I have massive amounts of clearance... to say the least. I'm going to wait untill the engine is set in and see where the springs are and hopefully I'll be able to adjust the back to be the same height. There is just no reason for it to be this high lol
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Old 04-30-2014, 09:52 PM   #82
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Awesome job! Your are gonna have one beast of a Jeep
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Old 04-30-2014, 11:15 PM   #83
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Sometimes I wish I would have went cummins.. Less wiring. Hah
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Old 05-01-2014, 08:20 PM   #84
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Thanks SonofAmerica! Yeah I can't complain about the wiring. It'll be pretty easy to set up in there
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Old 05-08-2014, 01:36 AM   #85
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Finished up the tube fenders last week during my finals. I got the whole front assembled in order to get the fenders straight, but it will all have to come off again when the engine goes in.












Also I got the Dana 60 cover on



And I started on the Dana 300 rebuild. Here is the entire case disassembled as of tonight. I won't be working on it again until next week.


The engine is ready to be assembled. The pistons are cut, the internals balanced, the head is assembled. I may get to work on it sunday. If by some miracle It gets done next week then it will be going in either next week or the following!
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Old 05-16-2014, 07:57 PM   #86
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Got to the shop last night, and we got a good amount done. The guys in the picture are my friend and his father in law, the one that owns the shop.







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Old 05-16-2014, 07:59 PM   #87
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My photo bucket account is messing up right now or I would post some more
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Old 05-16-2014, 08:01 PM   #88
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Old 05-16-2014, 08:05 PM   #89
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The fuel pump needs to be timed, and the injectors need to be seated properly, as well as some dremeling off the under side of the valve covers to clear the ARP's, among other things. Hopefully I'll get up there Sunday to finish it, and then ill be bringing it home to set it all together and get it ready to mount in the jeep!
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Old 05-16-2014, 08:29 PM   #90
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sub'd this is a crazy out of ur mind build but I love it wish my phone would show more of the pictures

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