Laid everything out saturday to remove more unnecessary circuits. The harness in the foreground is the 3800 harness. The only component I am reusing is the C3I spark control module under the coils. The Megasquirt controller I am building will run all spark and fuel functions. It is going to run timing events off the dual 18X/3X crankshaft position sensor and a digital 3X crank position the spark control module will send it. The Megasquirt I'm building will not support SFI, so the camshaft position sensor won't be used.

Still working out if I can download to code to run EVAP and EGR systems, or if I should just do away with them all together and hope I pass emissions without them.



here's what I cut out:


almost finished engine harness. Still need to add a few senders for additional guages on my dash.

This harness will be split between one of the plugs on the left side of the engine bay, and the Megasquirt relay board mounted on the firewall. All fuel and spark management will run directly to the fuel/spark controller while all power/charging supply and warning guage senders will reconnect to the isuzu engine bay harness.



Started breaking down two Toy t-cases for the dual setup and kit I ordered from Marlin Crawler. Here is the "bad" cae of the two. It was definetly left outside in the elements for many years. The hear oil is mixed with dirt and water like chocolate pudding.





Here is a side by side of the bad case that was mistreated to the good case that must have been looked after. the good case looks brand new inside. I was shocked at how shiny everything was. (both are from 1988)




I am using the "good" case as my transfer and the "bad" one as the 2.28 reduction box. Here they are both broken down: you can see the difference in color. This is after I put the cases through the dishwasher. (don't try this by the way)
[img]http://berisford.net/uploads/cpom/projectpup/4/11.jpg[/img]

Those that aren't familiar with these marlin adapters, the top row's parts will makeup my reduction box and only that box on the far end is used. the other two parts of the case in previous pictures are not used. I have to press the gear off that big output shaft (top left) to be reinstalled on the Marlin crawlbox output shaft.

Both t-case input shafts will be swapped for stronger 23 spline versions, so I'll reuse the middle piece's bearing but the little shafts will not be used. The right low range gears will be reused exactly as is but can be swapped out for lower gearsets in the future.
[img]http://berisford.net/uploads/cpom/projectpup/4/12.jpg[/img]

Here is a closeup of my 6308 output shaft bearing, "bad" case on the right. When I got this case this shaft would barely turn as this bearing was siezed with rust. I sprayed carb cleaner to clean it out then used a combination of PB and 80W to work it back into motion. It spins OK now with little noise but I think I should replace it. Compared to the good condition one on the left, there is more noise and less resistance. There is a tiny but of axial play but not much really. Anyone know where I can get one of these bearings for cheap?
[img]http://berisford.net/uploads/cpom/projectpup/4/13.jpg[/img]

I just realilzed now typing this that I may not need a 6308 bearing for the crawl box. I will have to see what comes in the kit when it arrives.