Ferm
 

I promise I will NEVER referred to my outboard work as a "Project" again after reading this post.
You are doing one heck of a job here , not in my wildest dreams will ever manage a project like this.
Good Luck and keep us posted

There all projects, I sort of turned this one into an adventure though.

Today's update.

Well I started the day by removing the fuel lines from the donor and putting them in the shop to put on tommorrow. Then I decided to tackle the wiring and get started there. Managed to get most all of the old engine wiring out and most of it laid out as to how to put the new back in. I also pulled the cluster out and redid the glow plug circuit as my 95 powered it but the DMAX grounds it.

The cluster is out and wiring getting sorted out.
http://i162.photobucket.com/albums/t...n/HPIM0972.jpg

The cluster before.
http://i162.photobucket.com/albums/t...n/HPIM0973.jpg

And after. You can see the jumper I installed to the power that would have been for the DRL(my 95 doesn't have daytime running lights) to where it used to be grounded. Picking the copper off the plastic is alot more work than you would think to boot.
http://i162.photobucket.com/albums/t...n/HPIM0975.jpg

Midway through cutting out the engine and uneeded connectors.
http://i162.photobucket.com/albums/t...n/HPIM0976.jpg

End of the day. Got almost all of it out and can start taping it back up tommorrow after I fix some of GM's SH!TTY splices. No wonder these trucks have developed so many grounding issues, GM did some HORRIBLE splices inside of the wiring harness's.
http://i162.photobucket.com/albums/t...n/HPIM0978.jpg
http://i162.photobucket.com/albums/t...n/HPIM0977.jpg

I always end up with a few extra pieces after a project like thishttp://www.dieseltowingresource.com/...ilies/hihi.gif.
http://i162.photobucket.com/albums/t...n/HPIM0979.jpg

Ferm I think you have forgotten more than most of us will ever even know.
Hope it goes smooth from here for ya

I sort of got an early start on teething myself with wrenches.

http://i162.photobucket.com/albums/t...RMANATOR/1.jpg

Don't have any pics, but I have been busting my tail on this thing all week. My pins for the fuse block just came in today so I can get back to wiring again soon. While I was waiting on my terminals for the fuse panel, I decided to hook up the transfer case shift linkage and I also got a shift linkage mount bracket fabbed up. the DURAMAX shift cable will not hook up to the early cloumn, so I had to buy a new shift cable(mine wouldn't stay on the shift arm as the nylon in the end that locks it on was worn) and custom fab my bracket as the 95 cable is 2 inches longer than the DMAX cable from the mount point to the shift arm. It is pretty tight under there as the 2" setback put the cable mount RIGHT next to the U-joint for the front shaft. I was able to get a 1/4" of clearance on the crossmember and a 1/2" on the shaft(may ned up bringing it in closer to the shaft if it hits the crossmember). So I can now shift it through it's gears in the trans and transfer case.

I pulled the tank out and removed my 5/16" return line and opened it up and installed a 1/2" feed line and will use my old 3/8" feed for my return and I have the fuel cooler off and am about ready to mount it under the truck as well as my KENNEDY lift pump. I discovered that the DMAX metal lines will not clear the steering linkage on my SUB, so I hooked up my nylon covered diesel line right to the quick connects and was able to get them over the lock portion so I could double clamp em on there. And I will just use nylon covered diesel flexible line for the bulk of the fuel system. The tranny cooler metal lines didn't clear my front axle mount with enough room for mmy liking even after some tweaking, so I got some AN hose and AN fittings and will just plumb the cooler system that way. This really sucks as I had already had the original lines done up with hydraulic line in place of the old rubber line.

While the fuel tank was out I did the rear gears today since that BIG opening made getting to the diff EASY as piehttp://www.dieseltowingresource.com/...es/biggrin.gif. The GM 14 bolt 10.5" rear axle is actually pretty easy to build compared to the DANAS and CHRYSLER corporates I am used to building up. The tough part was torquing the pinion nut. This required a 4' 3/4" breaker bar and socket to match and locking the pinion yoke down in my vise. This allowed me to stand on the bar as my impact with 600 foot pounds could BARELY budge it(I had it in the press to install the front bearing and bring up the slack to the crush sleeve, even at 6 tons of pressure the crush sleeve didn't compress). It looks like I lucked out as my G80 looked BRAND NEW inside. I went ahead and pulled it apart and inspected the governor, and all the clutches were good and tight and all of the governor teeth were intact. I'm going to pull the rear hubs tommorrow and replace the axle seals since I'm this far into it. And hopefully get the fuel system plumbed as well.

I got my shipment from ALLIGATOR today, and will hopefully get my TCM tommorrow. That CORSA muffler is one BIG SOB now, espescially compared to the diamond eye that came in my exhaust kit. So I will have a 6.5 3" downpipe and a 4" straight through muffler for sale soon. Little by little I'm getting this thing tackled, but it's the little details that will KILL you in a project like this. I spent almost 2 hours trying to bend and fit the fuel lines in only to find they wouldn't clear the steering linkage after doing ALOT of bending and cutting on em. And you don't realize how much time you can spend bending and fitting a 1/2" feee tube and soldering and epoxying it in. The best way to describe it is an old saying we used in drag racing, "OEM = A complete list of all items that MUST be replaced or modified when building a performance vehicle."

Time for my next update, I'll try and get a few pics tommorrow for my my next update. The fuel tank is back in and my 1/2" feed and 3/8" return are plumbed and my fuel cooler is hung right behind the frame support crossmember. Got my KENNEDY pump in and wired and primed it to the CP3 and found no leaks in the system. The rear end is finished up and new wheel cylinders installed. My TCM is supposed to be in MONDAY according to UPS tracking(the TCM was overnighted on FRIDAY, but UPS decided mine was important enough I guess), and hopefully my driveshaft is done as well. The majority of the wiring is done except for hooking up my relays in the PDC and wiring in my toggles and cruise switch inside the truck. I'm running into TAMPA tommorrow and hopefully my driveshaft is ready and I'll pick up some more hose and cushion clamps to finish up my plumbing.

I took it easy today after putting in several 14 hour days and nights trying to start her up this weekend. Hopefully tommorrow I can fire it off so I can verify my wiring and new injectors, but I'm not going to rush it.

Good luck, don't rush it brother, now is when the mistakes can happen as I am sure you know

A small victory
 

I made a few tonight, but it didn't end that badly:party:.

Tonights update.

I don't have many pics tonight, but I did make some headway with it. I got impatient today so I got the harness mostly finished up and decided to do a test fire to make sure it was all working properly. Well the first 3 attempts it just wheeled over and wouldn't fire a lickhttp://www.dieseltowingresource.com/...ilies/mad2.gif. It was building rail pressure and such, and I had disabled the theft system with EFILIVE. So after about an hour of head scratching it dawned on mehttp://www.dieseltowingresource.com/...smilies/33.gif, I had disconnected the FICM because I was doing some welding on the downpipe hanger on the engine. Hooked up the FICM and after about 3 seconds of cranking she came to lifehttp://www.dieseltowingresource.com/...s/thumbsup.gifhttp://www.dieseltowingresource.com/...ies/banana.gif. After about 20 seconds of running it must have learned the new balance rates a bit and started smoothing out it's idle and sounded pretty good. SO hopefully this will give me a second wind and I can get this thing wrapped up soon and on the road.

Now for a few pics.
Heres the harness mostly together and ready for a test fire.
http://i162.photobucket.com/albums/t...n/HPIM0982.jpg
http://i162.photobucket.com/albums/t...n/HPIM0981.jpg

Heres the new location for the glow plug/intake heater fuse. It is right underneath and in front of the ABS pump and right behind where the drivers side battery will go. This also helped in the problem that the DMAX battery cables has too short of a lead to reach to my PDC for my 95, so I used the fuse block as a junction block and hooked on the 6 guage cable from the old harness on the battery side of the fuse block and this got me a good power cable to the PDC.
http://i162.photobucket.com/albums/t...n/HPIM0983.jpg

And heres the PDC almost finished up. I ran out of tape so I couldn't put the flex covering over it tonight. Didn't come out to bad for a spliced together mess.(And don't ask me how many solders and splices I had to make in that one little area, it's a good thing that I like electrical)
http://i162.photobucket.com/albums/t...n/HPIM0985.jpg

And a special treat, the audio sucks but you get the idea.
http://s162.photobucket.com/albums/t...t=HPIM0984.flv

Sounds like a road trip coming

I had a shorter day today as I have to go down tommorrow and get one of the new exhaust pipes expanded so it will fit onto my CORSA muffler. I got MOST all of the wiring in and done today as well as the driveshafts. Since I needed to have the pipe done I decided to take my time and make the wiring as neat as possible. After finishing up the wiring and putting the shafts in I started her up and put it in gear to see if it would go in and it dropped into forward and reverse right away. I also did 3 starts on it with no check engine light so I may be OK in the MIL department. The tachometer works fine since I am driving it off the alternator just like a 6.5 did. I still need to check my speed outputs as I decided to try and use the ECM's and bypas the VSSB(if they don't work I left the wires there so I can hook it back up).

Heres a shot of the engine with the harness's in place(ECM and TCM will be mounted last after everything is together).
http://i162.photobucket.com/albums/t...n/HPIM0986.jpg
http://i162.photobucket.com/albums/t...n/HPIM0987.jpg
http://i162.photobucket.com/albums/t...n/HPIM0998.jpg
http://i162.photobucket.com/albums/t...n/HPIM1000.jpg

Heres the PDC all finished up.
http://i162.photobucket.com/albums/t...n/HPIM0988.jpg

And I spent some time and made an updated insert to go in my PDC for correct fuses and relays.
http://i162.photobucket.com/albums/t...useblock-A.jpg

My toggle switches in and my QUDZILLA guage.
http://i162.photobucket.com/albums/t...n/HPIM0990.jpg

The fuel cooler and you can also see the driveshaft.
http://i162.photobucket.com/albums/t...n/HPIM0993.jpg

And a few underside shots to show how tight the fit is.
http://i162.photobucket.com/albums/t...n/HPIM0994.jpg
http://i162.photobucket.com/albums/t...n/HPIM0996.jpg
http://i162.photobucket.com/albums/t...n/HPIM0997.jpg