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///80 Series Monster Bus

Sabbath'

Redblock Jesus
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Soooo...progression on the radiator.



Well...i put the belts and hoses on...so should have filled it with coolant and put it back together and had it running by lunchtime.

But...then **** got retarded.

First, i noticed that there was a touch of water in the drivers side headlight (condensation buildup due to running HID's with no rubber)



So to get the headlight out you have to pull half the grille out and the parker lens. So it was looking like this



Logic then stated "hey, you've come this far, why dont you pull the grille out and try mocking up fitment of the heat exchanger. So i did that.



To get it to fit i had to remove the centre support for the grille. This bracket is going to need to be "massaged" out of the way

 

Sabbath'

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Why stop there! I said to myself....so i didnt.

Out came the airbox



So that i could re-do the fusebox that i put in a few months back. Working out locations for it, i decided to move the compressor for the Diff Locks.



Muchos room for activities!

Now with all the extra room i went back to mocking up brackets for the intercooler core itself.

Previously i was working on using this style of bar bent and bolted onto angle bar.



But since i now have access to a welder i decided to utilise it.

Measuring up


Welded


And in the car


(my welds suck but it's solid and will do the job.)

I had planned to move the air compressor to the opposite side, but i fear that location has been swallowed up



 

Sabbath'

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Proof i do all my own stunts. Appropriate PPE included!

 

Jonesy484

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Proof i do all my own stunts. Appropriate PPE included!

I assume the mrs is standing there with a fire extinguisher???

also nice while under the bonnet why not replace bonnet struts?
 

Sandman

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Nah she's taking the photo standing (hiding) behind that window/wall lol.
 

Sabbath'

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Had an RDO today, so had a whole day of learning experiences with welding and such.

Trip down to bunnings for more supplies. (then had to go out again later when i ran out of wire and destroyed the last tip. damn welding with a fresh tip is nicer than a chewed up one.)



Started making up the bracket for the other side of the intercooler. Decided to mount it off the exhaust manifold heat shield bolt holes. Can see one bottom left of pic



Cut some cross ties out, the angle will become clearer later.



Aaaand welded on



The original plan was to weld the 27.5 length onto the end of the crossbar. But decided against it. Mainly when my abilities let me down.

So instead put another piece of angle across from it. which i can also brace off the strut top for extra rigidity.



And this is approximatly how it will sit



Mocked up





And those 27.5 lengths i cut before will be welded onto the base for the upright

 
Last edited:

Sabbath'

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Finished up my intercooler bracket last weekend and gave it a trial fit. It subsequently went straight in the scrap metal bin.

The basic issue was, the only person i know to have put one of these on an 80 series had his motor on a stand while he built the bracket so he could check all his clearances without climbing in and out of the engine bay. Which is an absolute ####. So issues ranged from water and oil feed lines being in the way, to water inlet pipe being blocked, and finally turbo exit being too close to the bracket. So, enjoy my failings.









 

Sabbath'

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So roll around to this weekend and decided i should put the thing back together.

Got pissed off with the shitty job i did of the fusebox last time due to lack of space. So now, because i've removed the compressor for the diff locks i could move the fusebox to a more hidden location.

Previous shitfight




And now.







Also started on intercooler bracket 2.0

Couldnt find any angled steel at bunnings, so i made my own.





Slowly but surely my welds are getting less pathetic.
 

Sabbath'

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Update time sine i've started working on this again.

Firstly -

I have a shed now.



Swapped the intercooler that i had for another one, was having issues with the in/out locations. The new one:




Which has lead to this:








Because i've moved the location of the core, i've had to redo all the wiring i did previously. But on the up side, i've been able to plug the compressor for the diff locks straight back in without having to lengthen anything. Not sure where im going to put the reservoir, but thats next weekends problem.
 
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