The Polar Bear - NP241 Upgrade

[downtowncb]

Two steps forward and one step back. I got a ton of work done but ... the Corvette headers arrived and they won't work. So now I'm going to take everything back out tomorrow and cut up the frame to make the Camaro ones work...

I pulled out the front axle and painted it. Then put all the brake hardware back on. I haven’t put on the passenger side hardware yet because one of the studs on the Spider Tracks spacer has gnarled threads so I’m trying to find a replacement.



Close up of the brake line routing.





Test fitting the radiator and fan so I could measure for a filter and intake to order. I also started routing all the cable for the starter, power distribution center, alternator, etc…



Here is the box I welded that will house the iPhone controller, fuses and relays eventually.



Oh and Agitated, mine has crackle

[AgitatedPancake]

hahaha crackle huh...nice.

You need to hurry up and get this thing on the road, I wanna see and hear it!

[DaveJeep]

I ended up using the f-body manifolds as well. I ground down the hump on the passenger side manifold quite a bit without going through the casting. My frames is already hacked to shit though lol

[downtowncb]

hahaha crackle huh...nice.

You need to hurry up and get this thing on the road, I wanna see and hear it!

I figured you'd appreciate that haha. I think it did it because it's cold. Believe me I want to get this driving ASAP, all I have for transportation right now is my motorcycle, which really sucks when it's raining.

I ended up using the f-body manifolds as well. I ground down the hump on the passenger side manifold quite a bit without going through the casting. My frames is already hacked to shit though lol

Can you show me a photo of how far you ground down? Just to give me an idea of what's safe. I'm really not looking forward to chopping up the frame and fresh paint.

Have you started on the wiring yet?

[paulkeith]

what'd you paint the axle with? did i miss it?

[downtowncb]

what'd you paint the axle with? did i miss it?

POR 15

[DaveJeep]

Can you show me a photo of how far you ground down? Just to give me an idea of what's safe. I'm really not looking forward to chopping up the frame and fresh paint.

Have you started on the wiring yet?

I will get a pic tomorrow of the manifold.

I have not started the wiring yet, still have to finish the frame hopefully this weekend. But now I've gone over the wiring so much now I think I could do it with my eyes closed.

[paulkeith]

POR 15

Cool. That's what it looked like, but I didn't know. You were all about the industrial epoxy stuff earlier

I painted a whole trailer with POR15 one time using an air gun. Shit got Eeeeverywhere, including on my contact lenses. Stayed there for the rest of the time i wore those contacts, too. Crazy stuff.

[AgitatedPancake]

Yeah they say it takes weeks to get it off your skin haha. Never done it but I think applying it by air might be a bit rough =P

[paulkeith]

It got on my toenails too (was working in flops since it was 110 and we'd paint for 10 minutes and swim for 10 minutes), and it stayed on my toenails until they grew out.

[downtowncb]

The first time I used it about 6 months ago, I was using a paint brush and the bristles flicked some on my face... Yeah it stayed there for a while haha

[downtowncb]

Pulled the motor ... AGAIN. Cut the frame, made a scab plate and was about to weld it in when it started to rain. I'll finish it up tomorrow. Shit I'm tired, early to bed tonight.

[chadjans]

Pulled the motor ... AGAIN. Cut the frame, made a scab plate and was about to weld it in when it started to rain. I'll finish it up tomorrow. Shit I'm tired, early to bed tonight.

Right click, "Save As." Not sure I have ever seen the inside of a ZJ frame rail at this location. Seen a few XJ's never a ZJ though.

Chad

[downtowncb]

I almost finished plating the hole, I'll post photos tomorrow.

I also installed spacers in my air bumps today to reduce them from 4" of travel to 2.5". I'll see how I like this length once I get to drive it and adjust from there.

Here is a shot of the internals and the spacer that I turned on the lathe. It goes in place of the shorter spacer currently on the shaft.



Here is a comparison shot.



I had a little accident when I was reassembling the first one and shot shock oil ALL over the place, mostly on the ceiling haha.

[downtowncb]

I plated in the frame and painted it, don't have pictures of it painted yet.



The only thing keeping me from putting the motor in finally is there is an exhaust bolt broken off in the rear driver's side head. I tried using a Harbor Freight easy out to remove it that broke off in the bolt (stupid ass, I should have know). Anyways, it now has a hardened steel core and just rounds off all the drill bits I've thrown at it. I haven't figured out how I'm going to get it out yet. I wish I knew where to get tungsten carbide tipped drill bits but I haven't had any luck yet. I'm open to suggestions.

[NIK5.9]

Can't you just weld a bolt to the broken piece and pull it out?

[ATL ZJ]

The only thing keeping me from putting the motor in finally is there is an exhaust bolt broken off in the rear driver's side head. I tried using a Harbor Freight easy out to remove it that broke off in the bolt (stupid ass, I should have know). Anyways, it now has a hardened steel core and just rounds off all the drill bits I've thrown at it. I haven't figured out how I'm going to get it out yet. I wish I knew where to get tungsten carbide tipped drill bits but I haven't had any luck yet. I'm open to suggestions.

Mcmaster carries carbide drills in a variety of coatings, along with one of the finest tap selections you'll find.

[downtowncb]

Can't you just weld a bolt to the broken piece and pull it out?

Tried that, couldn't get a good enough weld penetration to unscrew it.

Mcmaster carries carbide drills in a variety of coatings, along with one of the finest tap selections you'll find.

Cam to the rescue, thanks a lot. I'll order it tonight; stuff gets here so fast from them I wouldn't be surprised if it's here on Saturday.

[bnboffroad]

I plated in the frame and painted it, don't have pictures of it painted yet.



The only thing keeping me from putting the motor in finally is there is an exhaust bolt broken off in the rear driver's side head. I tried using a Harbor Freight easy out to remove it that broke off in the bolt (stupid ass, I should have know). Anyways, it now has a hardened steel core and just rounds off all the drill bits I've thrown at it. I haven't figured out how I'm going to get it out yet. I wish I knew where to get tungsten carbide tipped drill bits but I haven't had any luck yet. I'm open to suggestions.

same thing happened to mine heard its common for the rear bolt to do this on these motors i had a friend come over and we had to drill till it was the bolt size and retap it

[DaveJeep]

Common GM problem. My 5.3l has the same issue, one broke bolt but it never broke off flush so I hope I can visegrip it out. Two guys at my work have 6.0l 2500s and they both have had exhaust manifold leaks because of broken bolts.

Frame plating looks really good Cody! I'll get back at mine once my eye heals from the piece of metal that decided to get past my safety goggles and plant itself into my eye.

What size metal did you use on the inside frame?

[Jeeptech01]

Thats odd I've never run into that before and I've worked on tons of these motors. Then again I am in Fl so maybe thats it. Or maybe its a higher mileage thing?

[DaveJeep]

One truck at my work had 35,000km and the other 95,000km. They are both company trucks and both bought at the same time. One guy drives way more than the other but they both had the problem within a month of each other.

[ATL ZJ]

One truck at my work had 35,000km and the other 95,000km. They are both company trucks and both bought at the same time. One guy drives way more than the other but they both had the problem within a month of each other.

did their problems happen in the winter?

[downtowncb]

Common GM problem. My 5.3l has the same issue, one broke bolt but it never broke off flush so I hope I can visegrip it out. Two guys at my work have 6.0l 2500s and they both have had exhaust manifold leaks because of broken bolts.

Frame plating looks really good Cody! I'll get back at mine once my eye heals from the piece of metal that decided to get past my safety goggles and plant itself into my eye.

What size metal did you use on the inside frame?

Thanks! It's all 1/8" (I have a big sheet laying around) but there is a lot of cross webbing and reinforcements on the inside that I unfortunately didn't get a picture of. Where the motor mount bolts are there is another piece of 1/8" behind that the bolts are welded to and is welded to all the factory motor mount reinforcements plates. I then placed the outer plate over it and used about 10 plugs welds to connect the two. I also cut a slit where that internal factory cross piece is and allowed it to poke trough; I then welded along the slit to join the two. Hope that makes sense.

Sorry to hear about the eye ball! I was wondering why you weren't done yet you seem to work very fast.

I have definitely heard of these breaking exhaust bolts before and it usually seems to be the one I broke. I bought some hi quality bolts so hopefully this won't be a problem in the future. I ordered a 3/16" carbide tipped bit from McMaster last night that will hopefully be the final solution to this 10 month problem.

[DaveJeep]

did their problems happen in the winter?

Yup, middle of winter.