My mufflers showed
up last week. I went with a pair of round Magnaflow mufflers
mostly because their form factor fit well where I wanted them to go.
Once I positioned the mufflers I could finalize the angle for the
lower shock clearance hoops.
I was worried about the coolant line
routing on the drivers side it looked like the initial routing would
not work as the shock would hit the coolant line on articulation.
I had to order some new parts to route the line differently, mostly
due to the fact that the lower port on my radiator is 1.75" diameter
and other than the stainless flex hose I had no other hoses in that
The solution involved cutting down a
1.75" Dia 90 degree silicone elbow I purchased from Speedway Motors.
The elbow was the tightest one I could find and allowed me to route
the line inward and away from the shock. Next I modified a
1.50" dia 90 degree steel elbow by cutting it down and welding it
the 1.50" dia tubing that used to be under my seat. I sleeved
the end that attaches to the 1.75" dia. elbow with some 1.75" DOM
tubing so the diameters match. This solution adds several more hose
clamps to the system but I didn't see any way around it while
keeping everything removable for service.
Next I tied the two shock clearance
hoops together with some 1.25" ERW tubing. Despite the tubing being
as far forward as possible I had a few clearance issues with it and
the fuel cell fittings. I ended up tweaking the fuel cell
mounting a bit (moved it up in front) to gain fitting clearance.
The other huge chore I have been
tackling is identifying all the fittings and hose ends required for
the fuel, oil and transmission cooler circuits. The goal is to
have zero hose clamps in the system for better reliability and ease
of maintenance. I will be using socketless hose with AN hose
ends for all the connections, -6 for the fuel and transmission
circuits and -8 for the engine oil circuit. I'll go more in depth
with each system as I install them. As a side benefit I
wouldn't be surprised if these aluminum fittings dropped a few
pounds from the buggy compared to the same thing in brass. All of
the brass fittings I used to have in my transmission cooler circuit
had a considerable heft when thy were all placed in my hand vs. the
aluminum replacements which felt like nothing.
Before finalizing the position of the
fuel pump and filters I decided it would be best to finish up some
of the rear chassis bracing. This led me off onto another
tangent as I decided I did not like the way the initial radiator
mounting created a complex multi-level floor. The old setup is on
the left and the new on the right. I found I could run a pair
of cross braces from the cab area back to the shock hoop clearance
tubes (avoiding the heater lines on the drivers side.
This made for a single plane floor
surface and the forward portion of the cross braces will tie into my
upper link mount tabs nicely.
The fuel filter bracket for the
second filter which utilizes a single hose clamp to hold the filter
The fuel pump bracket is similar to the
filter bracket. I was after ease of removal if needed. I cut
the bracket from a piece of exhaust tubing allowing for a layer of
rubber to isolate the pump. A pair of hose clamps will secure
the pump to the chassis.
The lower cross member behind the
radiator has some extra bracing as it will be the mounting point for
the rear axle limit strap.
To supplement the engine cooling I am
adding a passive oil cooler which will be mounted where a
traditional radiator would go. Brackets were made to tie the
lower portion into the winch mount plate and the upper portion ties
into the non-removable section of the engine cage. I am hoping this
extra cooling will work well at speed, I have no doubt the dual SPAL
fans on the radiator can keep the engine cool when crawling.
The oil filter is being relocated to
provide more upper link clearance. I had to use a 180 degree
fitting for the return and a 120 degree fitting for the outlet side
to get the line pointed in the correct directions. The oil
filter ended up being mounted on the passenger side motor mount.
would have liked it up higher but needed the room for the power
Some overall chassis shots. At
this point I think I am going to flesh out the rear cross bracing
and then find a spot for the transmission cooler, ARB compressor and
the radiator overflow can.