To Dakar and Back

[1badMKIrocco]

Nice Truck! Best thing I've seen on this site in a LOOOONG time.

[California Jay]

Thanks for the comments! I really enjoy doing the build, design, fabrication and welding. Lawrence is loving it too. He's got plenty of off-road experience to aid me decisions for such a rigorous environment.

As far as the engine goes, from memory, the engine you can order as a part # right from the dealer. There are also a few companies out west that also sell eurospec and crate engines too.

[ElliottG]

Sick. Thanks for the info!

[California Jay]

np...

In recent news revolving the truck, some of the representatives from Royal Purple, when last visiting our facility at JRP, were very interested in the progress of the build. Lawrence has been communicating with them frequently and we may see some positive support from them for the Dakar. I'll keep my ears peeled for further info. They have already provided free fluids for the engine, trans and diff.

Getting this thing running asap will help generate more interest everywhere I'm sure.

[Angel@forgemotorsport.com]

I've seen this in person on a visit to JRP ( our canadian distributer ) and it's nothing short of amazing. It's not the only cool and unique vehicle they had in their shop either.

[2k4BlackMagicGLI]

Quote, originally posted by Angel@forgemotorsport.com »

I've seen this in person on a visit to JRP ( our canadian distributer ) and it's nothing short of amazing. It's not the only cool and unique vehicle they had in their shop either.

I can second that! The Fabrication department they have is quite nice! This truck as well as the other on-going projects they have are very impressive!

[California Jay]

thanks! maybe we'll run into you guys at WF...

We've recently run into some tensioner issues. Looks like we are back to a manual tensioner for the new longer belt... Unfortunately contrary to some people's thinking you cannot reverse the tensioner, as the bolt pattern is not symmetrical to the tensioner shaft and it will hit the diesel pump. So off to the drawing board. I'll post up some pics of the new design and finished exhaust later today.

[California Jay]

I thought I'd mention that if any parties reading this thread or passiing it along wish to have their company name on the truck for the rally, prices start at $1000. Lawrence is working more on the publicity side for the rally now as organizingfor the event is approaching.

I got to the exhaust last night, some fine adjustments to be made but will clear the rear suspension very well. Two flex sections are used to compensate for the muffler being hard mounted to the chassis. I also started on the small tensioner arm adjustment, more to come.

Modified by California Jay at 10:51 AM 6-19-2009

[ElliottG]

Nice work, Jay!

[California Jay]

The catch can was finished up tonight.. It has a dividing wall/baffle on the interior to prevent oil scavenge to the turbo inlet. I'd run it vented, but incase of an overload of water its not the best idea. It will sit next to the air box shown earlier.

Modified by California Jay at 8:53 PM 6-19-2009

[mAdD INDIAN]

Quote, originally posted by Angel@forgemotorsport.com »

I've seen this in person on a visit to JRP ( our canadian distributer ) and it's nothing short of amazing. It's not the only cool and unique vehicle they had in their shop either.

Do you guys have this located in the store off the QEW in Mississauga? I'll be going there tomorrow to buy some stuff, I'd love to check it out.

By the way, the welds on the above pic looks perfect. It's art.


Modified by mAdD INDIAN at 9:10 PM 6-19-2009

[California Jay]

Yeah just ask one of the guys at the sales counter to let you have a peek.

Thanks for the compliments, welding aluminum is fun after you get the rhythm to it.

[pedrosan]

Dizzel Powah

[California Jay]

Lawrence recently has picked up a few more sponsors.... heres a small list of locals that have jumped on board for him so far...
JRP Online
Rigo-Tec
Royal Purple
Pat's Driveline
Truck Lite
Kinedyne
Kleen Flo
Wilson Auto Electric
Arai Helmets
Scott Reinhart Trailers

One major one up in the air still is Total (a fuel company), who is in talks with Lawrence off and on, you may have seen their sponsor below the Dakar logo on Speedvision. They have a Canadian office. Hopefully this develops further.

[ElliottG]

Hmmmm nice list of sponsors. Always good to have Arai on board!

[California Jay]

Everybody loves more pics!!

I thought I would go more into the explaination of the tensioner, and the problem behind it.

The first pic notes the new belt route... opposite of the stock tensioner "pull". (This was also a perfect belt legth...155cm) Normally it pushes to the ground.. now it has to push towards the head.. Lawrence and I played around with the tensioner arm to make sure we couldn't flip either over, and each time it was impossible to grip and twist b/c a pulley was in the way or some sort of clearance issue with the belt arm or clearance to the upper timing belt cover.

So to utilize this route I made a model for two brackets to mount on the back of the tensioner shaft. You will notice the key way for the lower arm to grab on the tensioner shaft. Everything will be held apart by a heim joint/tie rod. I put in muliple holes just incase my angle of relaxed fittment was off or my tie rod measurement was off. Theres plenty of room. Its all just .25" thick steel

More of the exhaust welded up... took some close-ups. A total of three v-band assemblies are in the exhaust incase of repairs to other areas needs to be accessed, or to the exhaust itself.

Lawrence also got started on the switch panel and some wiring... Barely any harness to the Diesel, which is good. We had some Arming swtiches that did the job perfectly. So far they consist of two for fans, one glow, fuel, and start power.

Some pieces were added to the back cargo area for oil and fuilds.. One more large tray/box right behind the fuel cell for tools and parts will still be added.

Modified by California Jay at 5:33 AM 6-23-2009

[jerk]

[Elbows]

Is it weird that I'm impressed even though I know next to nothing about motor builds...like I have NO clue what 95% of these pictures are/mean - but they look incredible?

[Sporin]

those welds are flippin' sweet

[XrightcoastdriverX]

Beautiful Jay!

Absolutely Beautiful!

[California Jay]

Thanks man, its killer hot here off and on this week. Makes for sweaty welding, and lots of water consumption.

[Issam Abed]

Kind of late now but what block was used in this build?

[California Jay]

Block is AHU...

Nothing much to update tonight.. but I did get the exhaust positioned throught the side body panel... turns out I couldn't make it stick out too much incase of panel removal... pics up tomorrow maybe.

[Straz85]

Wow, this is an amazing build. I will be watching this thread closely!

[California Jay]

Felt like tossing in the towel early today... but pushed on. It was 93 deg in the shop, not too comfy for working away. Some more pics of progress below. The exhaust is complete now except for more supports along the muffler to the dowels holding it in place. From here this area will need heat protection and some exhaust wrap near the turbo down to the trans.

Lawrence got into doing the seat adaptation before I started the inner bracing. The bracing prevents side to side flex while seated and being thrown around, gussets will be used here along the inner brackets.

The catch can mounted up... had to keep it low profile as the fiberglass dash comes right overtop to mount the Terratrip. Seems to be a good spot.

Hopefully tomorrow/fri I'll have the tensioner in place and we can get some fluids in... and a running truck


Modified by California Jay at 6:51 PM 6-24-2009

[CarlitosVW]

Excellent builup.
Can't wait to see it in a couple of months on the road.

[ElliottG]

Awesome! Please do some video of the first startup!!!

[California Jay]

Links for video are a for sure thing. This next week or so will be a lot of fun.

[Holden McNeil]

Welding Geek Question: Did you back purge the exhaust tubing?

Your SS welds and the heat control are fantastic! I envy your skills and your job!! Great work!

[California Jay]

Thanks, had lots of practice...

Heres a sample of my backpurge proceedure/setup...any stainless I get my hands on I backpurge. Doing flex sections are a PITA, Vibrant ones anyway. Most of my thin gauge stuff is non pulse... until getting into exotic metals or .5mm thicknesses. This is all .9mm or 16ga.

[California Jay]

Things are getting closer and closer to being all together. I was hoping we would get to turn it over today but the lack of the of the tensioner arm was an issue.. so maybe over the w/e or monday it will roll. Today though it really started to look like it was something serious. Both seats are in and more little details are filling in space. I forgot to grab pics of the side body panels on, the seats in, and nets up... It was screaming awesome.

Modified by California Jay at 6:09 PM 6-26-2009

[iTech]

Geez and I was gonna do a build thread on my GTI,,,,no way I can compete with this LOL Looks amazing !! keep up the great work.

[ElliottG]

Awesome! Remember what I said: take video of the first startup if you can please!!!

[California Jay]

Will do for sure... the truck is up at Lawrence's this w/e for some home time and to let him do a bit of wiring, lights etc etc.. He's also got some help closer to home to make some duct work for the IC. Aside from the mesh that covers behind the front bulkhead area, it will have the duct work for more protection from the stones/debris. 14ga aluminum paneling should do fine. Much of the inner body panels are made with the same material.

[Beitz DUB]

Awesome work here