My Frankensuzu is ALIVE!!!!!

Updated the site tonight with all the details......

Looks great - you're making quick progress. Can you tell us more about your fan setup? It's on my to-do list so manufacturer/part numbers might help me out.

How loud is it without a muffler?

The fans I ordered from summitracing.com. They are made by Be Cool. They were about 75 dollars a piece and 9" in diameter. I used some of that universal angle you can buy at any hardware store with all the holes pre drilled in it. I cut them to length to run horizontally and bolt to the same bolts holding the radiator to the core support. The fans had to be rotated a bit and are only held by two bolts, one in each "corner", but they are plenty sturdy. They are nice and close to the radiator too.

Yesterday while it was idling, once it warmed up the fans would come on about every two minutes for 45 seconds or so. You can just watch the temp gauge go down when the fans come on. I am very happy with the way they work, plus it opens up a lot of room in the engine compartment with the mechanical on removed.

I can get some better pics if you want them.

I have a favor to ask of you to, but I'll send you an email this evening.

Thanks.

I thought I'd answer your question here, just 'cause it might help someone else. The alternator wiring looks to be this way:

Chassis/Alternator connector
Black-white/Black-white ... Ignition (might be black-yellow since it's very dirty)
White/White ... 12 V battery
White-Green/White-Red ... measures 86 ohms - charge relay

Hope that helps.
Is your relay and temperature switch a one-piece unit?

Great work - and fast, too. They do sound nice, don't they? Even without a muffler, mine isn't too loud. The turbo takes a lot of the energy out of the exhaust.

So, what did you decide to do with the glow plugs? A momentary switch to the relays?

Thanks Jon, that's what I needed.

The temp switch is an over the counter item and said to be capable of 20 amps without a relay. I put the relay in just cause I tend to overwire stuff and I don't care for the standard little plastic relays. It is part number ST85 at NAPA.

I forgot to answer the muffler question earlier. It's not very loud and it sounds pretty good. The turbo sounds really nice too.

I am not going to put a muffler on when I do the exhaust. I think with the bends it will have in it going back across to the drivers side and back it will be about right. If not, I can always put a muffler on later. I like my stuff a little loud as long as it's behind me and not too noisy in the cab.

I did a little more testing with the glow plugs and am almost certain that this engine has 12 volt plugs and that is what is causing the problem. I am going to pop the plugs out and see if the C223 style 6 volt plugs will interchange as I have a brand new set I could put in it. If not, a hidden momentary switch under the dash will do for just in case. I don't like cluttering up the dash with switches and with two cold starts in the mid 30's, it fired right off without them.

Hello F
I have been trying to hook up my alternator for a while now. The connector plug was missing coming out of the wiring harness, so I am not sure which wire goes where. If you get a chance check out my post under "still trying to hook up my alternator in 86 Trooper TD (more pics)". I have some good pics of the color of the wire. in your post you said

Chassis/Alternator connector
Black-white/Black-white ... Ignition (might be black-yellow since it's very dirty)
White/White ... 12 V battery
White-Green/White-Red ... measures 86 ohms - charge relay

but my alternator wires are all white. So I was thinking on my trooper it would be

Chassis/Alternator connector
Black-yellow/White-blue ... Ignition
White/White ... 12 V battery
White-red/White-Green... measures 86 ohms - charge relay

Any Ideas
Thanks
Billy

Hey Jon, I got my alternator hooked up and working today, thanks for looking at that for me.

I also took my exhaust flapper apart and cleaned it up so it will work. It was stuck. Does your's work? I know it closes along with the flapper on the intercooler during warm up to heat the engine faster. I seem to recall reading somewhere it is supposed to work like an engine brake in 4L only also. Does your's do that too? I have an exhaust brake on my Dodge, and that would be a nice feature to have on this one too, since it's already there I could wire it in easily enough.

Billy, Did you get your alternator hooked up? I forgot to check colors as I hooked mine up, but I think you're right in your assumption. Of the white wires on the chassis, one of the three is larger than the other two. That goes to the black-yellow. The solid white goes to the solid white on the alt. The other two, whatever colors they are I can't remember, hook together.

It's done.....D U N....done, lol

No time to update the site yet or really say much here, but it's done except for a front end alignment and the exhaust. It's in the shop getting that done this week.

I put about 30 miles on it yesterday, putting it through the paces. Everything from freeway at 70, to some steep grades at varying speeds, to a long straight stretch humming along at 90+, to in town, and a windy road that requires a lot of speeding up and slowing down.

First impression is just WOW. I can't explain it. Not only is it a power house, but it is FAST. It doesen't do much in first gear off the line until it starts to build boost, but from there on up to 90 mph in 5th gear, your head is against the headrest.

I haven't found a hill that will bog it down at any speed. It might not gain much (unless you downshift) on the really steep ones at slower speeds, but it doesn't bog down. This one hill is about a 8% grade. I went up most of it at 40 mph in 4th and almost at the top there is a sharp curve you have to slow down to about 30 mph for. I came out the other side still in 4th and it pulled right out of it from almost an idle. Once I found it would pull out of it, I grabbed 3rd and flew out of it <img src="/forums/images/graemlins/smile.gif" alt="" />

On another road (flat ground), I have an 1/8 mile marked out after you come out of a sharp curve at about 30 mph. I came out of it in 3rd and stood on it. By the 1/8 mile mark, I was doing over 70 and just barely into 4th.

Remember, this is with open manifold, no exhaust, and no scoop feeding nice cold air to the intercooler. Once that is fixed and I tweak the pump timing and wastegate a little, I expect a significant improvement.

Also, all the suspension and steering work I did was way worth it. It has a little body roll because of the lift, but it handles awesome, nice and tight.

Anyway, I am VERY impressed with this engine in all aspects. Startability, smoothness, streetability, raw power, and zippyness. I'm sold. I want another one.

I'll update the site with more of my mechanical progress when I get some time to sort thru the pics.

Excellent news! Good to hear the clutch hydraulics worked out well. How is the radiator so far? The real test will be July/Aug, but with the decent weather this weekend it seems like you'd get a good indication.

Paul