Town Wagon 4BT conversion, getting closer....

[JimmieD]

Well, September 4, 2006 was a very big day for old JimmieD, boys and girls! I was finally able to step back and take a look at my Cummins 3.9L 4BT sitting in my Town Wagon, all bolted in place!!! No pics yet, that all comes later.....

This has been far more of a challenge than I anticipated at first. The donor truck used GM drivetrain which cants the engine to a tilt of about 10 degrees. Correcting for that was surprisingly difficult. Fabrication of motor mounts was real tricky as I wanted engine to sit flat on horizontal mounts, instead of traditional angled mounts found in early Dodges. Also the layout of the TW required fabrication of a completely different transmission mount for the NV4500, using Dodge 360 motor mounts and a custom built crossmember.
It ended up sitting straight, level and upright and is stout to say the least. One 360 mount ended up cocked a bit sideways but it won't ever show and I really don't care! Driveline angles look good, and I'll have a nearly flat floor with only about 3"-4" trans hump.

All of this project is being accomplished in a backyard, with dry grass turned to dirt. A nice slope in the yard says throw away the level and plumbbob, and makes it pretty tough to roll around heavy parts on hoists or jacks. The prior extensive body damage adds to the task, plus little info is available out there for step-by-step instructions. Regardless of all that the engine's in, and trans is in, and now I'm waiting on some part$. More part$. Lots more part$.

Pictures eventually.....

JimmieD

[CGarbee]

Congratulations...!!
From now on, all you have to do is just plug away at the "small" stuff...

I can appreciate your working out in the yard and my hat goes off to you, I did my first install of a 4BT into a M37 out in the backyard as well... Wore a path between the door and the truck that still won't grow grass...

Take lots of photos even if you don't get them all posted anytime soon, one day you will want them, and it's hard to get some shots when the sheetmetal is back in place and everything is buttoned up...

Looking forward to reports of your first drive,
CGarbee

[JimmieD]

Thanks, Cabell, and thanks for your assistance with the project! Yea, I've taken tons of pictures and will get them all assembled in a later day. Who knows, Gordon may want an article contribution on 4BT swaps for the Power Wagon Advertiser magazine. If it wasn't for guys like you, and Paul in NY, I never could have done it! Can't wait to hear that baby run again......

[Kevin Mienke]

Congratulations Jimmie. I thought I had it bad working out of a domestic, attached garage. I suddenly feel blessed. Can't wait to see the photos.

[JimmieD]

Congratulations Jimmie. I thought I had it bad working out of a domestic, attached garage. I suddenly feel blessed. Can't wait to see the photos.

Thanks, Kevin, I think you inadvertently hit the nail on the head! It has been proven numerous times after the most astounding attempts that I cannot be domesticated. Therefore there's never anything to attach a garage to.....

[Kevin Mienke]

Thanks, Kevin, I think you inadvertently hit the nail on the head! It has been proven numerous times after the most astounding attempts that I cannot be domesticated. Therefore there's never anything to attach a garage to.....
I understand completely. When I got the cancer, we moved to town after 12 years on an acreage in the country. At the old place I was free to be myself. At the new place, called Venbury, we have covenants that govern what I can own and park in my driveway (ie..duckboats and project trucks) I have all neighbors eyes on me all the time. The Venbury Hillbilly wishes he could go back home. This photo shows my house and garage in the background.

[BobbyMike]

Good news indeed, JimmieD!

Like you, all my work on my truck gets done outside. At least I have a gravel driveway....

Currently in Austerlitz we don't even have zoning, and I can even park scrap vehicles in my front yard (although the local Democratic party has recently come into power and is working very hard to put zoning into effect). It's a classic case of 2nd home owners and retirees from NYC moving into a pristine country enviroment and wanting "to keep it that way". It's been causing quite a bit of bad blood. It's gotten so bad that some of the locals have asked if I'd like to run for the town board (I'm registered as an Independent). For some reason we're well like by most everybody in town and even though I've publically stated my opposition to zoning they think that I'll get votes from people who voted for the pro-zoning candidate last time. The only problem is if I ran and won, I'd lose whatever free time I have to work on 'Old Yeller".

[JimmieD]

Well, boys, it's a pity and a darned shame that some of these folks don't find something better to do with their ever precious time than complicating other people's lives! I've just come to the end of a 2 1/2 year ordeal of having a bonafide psycho for a next door neighbor. Space doesn't permit telling the story. That's one reason I'll be moving out of here soon as the rig is done. Can't wait..... :~ )

[MoparNorm]

Good news indeed, JimmieD!

Like you, all my work on my truck gets done outside. At least I have a gravel driveway....

Currently in Austerlitz we don't even have zoning, and I can even park scrap vehicles in my front yard (although the local Democratic party has recently come into power and is working very hard to put zoning into effect). It's a classic case of 2nd home owners and retirees from NYC moving into a pristine country enviroment and wanting "to keep it that way". It's been causing quite a bit of bad blood. It's gotten so bad that some of the locals have asked if I'd like to run for the town board (I'm registered as an Independent). For some reason we're well like by most everybody in town and even though I've publically stated my opposition to zoning they think that I'll get votes from people who voted for the pro-zoning candidate last time. The only problem is if I ran and won, I'd lose whatever free time I have to work on 'Old Yeller".
Run, win, and declare all zoning null and void for all eternity, outlaw ALL future government and then resign....ha!ha!
MN

[Gordon Maney]

I understand completely. When I got the cancer, we moved to town after 12 years on an acreage in the country. At the old place I was free to be myself. At the new place, called Venbury, we have covenants that govern what I can own and park in my driveway (ie..duckboats and project trucks) I have all neighbors eyes on me all the time. The Venbury Hillbilly wishes he could go back home. This photo shows my house and garage in the background.
A nice Cummins powered Frito-Lay van would enhance your neighborhood. You could drive it to work, and park it on the street in front of the house. It would, of course, need to retain the Frito-Lay markings, and you might want to further spruce it up with some large jumping bass decals, and maybe a camouflage canoe on the roof.

[Kevin Mienke]

A nice Cummins powered Frito-Lay van would enhance your neighborhood. You could drive it to work, and park it on the street in front of the house. It would, of course, need to retain the Frito-Lay markings, and you might want to further spruce it up with some large jumping bass decals, and maybe a camouflage canoe on the roof.
I like it. When I get tired of driving it I can pull the 4bt for a Fenway repower. The Frito Lay van could remain in the street permanently with a camouflage net over it. It would make an awesome duck blind and perfect for hunting the geese that water on the neighborhood pond. Oddly enough, there is nothing mentioned in the covenants about Frito Lay vans or permanent duck blinds. The lawyers who wrote them obviously didn't plan for people like us.

[BobbyMike]

I like it. When I get tired of driving it I can pull the 4bt for a Fenway repower. The Frito Lay van could remain in the street permanently with a camouflage net over it. It would make an awesome duck blind and perfect for hunting the geese that water on the neighborhood pond. Oddly enough, there is nothing mentioned in the covenants about Frito Lay vans or permanent duck blinds. The lawyers who wrote them obviously didn't plan for people like us.
Or your son could use it for practicing drums with his garage band.... Also don't forget the NRA and "Rush baby onboard" stickers.

[BobbyMike]

Run, win, and declare all zoning null and void for all eternity, outlaw ALL future government and then resign....ha!ha!
MN
That has entered my mind.

[Doc Dave]

Diane and I also live "out in the sticks" zoning-wise on 25 acres of land. We like it as we have no covenents at all, but only a mile or so as the crow flies is a housing development with many convenents, and if I lived there I would be "stifled".
I too would like to see pics of Jimmy D's project.

[Sickcall]

When I get that Corn Chip van in one of these future auctions the chasis is going to sit on pier blocks up in the trees. I'll spray it a little camo and use it as a storage container with only the rear doors showing, maybe a little concrete out front and a light/power. I think it beats having to build a shed or buy an ocean shipping container. Nobody will ever see it!

[BobbyMike]

When I get that Corn Chip van in one of these future auctions the chasis is going to sit on pier blocks up in the trees. I'll spray it a little camo and use it as a storage container with only the rear doors showing, maybe a little concrete out front and a light/power. I think it beats having to build a shed or buy an ocean shipping container. Nobody will ever see it!

Put it up high enough and it can do duty as a deerstand too.

[JimmieD]

You guys are cracking me up. Genuine 'Laughing out Loud'! thanks, I needed that.... :~ )

[yosemitesamiam]

You guys are cracking me up. Genuine 'Laughing out Loud'! thanks, I needed that.... :~ )

Maybe I missed it. Did you ever get a chance to post pix??? How is the project coming?

[JimmieD]

Hi Sam! No you didn't miss it, I did. Just haven't had time for pics as the conversion takes every spare instant and then some. I'll get some pics up some day soon.

I'm in the home stretch. Check clutch slave pushrod length, finish rewiring and a few other things and it'll be running in a couple of days, God willing. Serious snowstorm blowing right now so that may hamper things as it's not unusual to get 3-4 feet overnight around here. Sure hope not this time: gotta work outside! Thanks for asking.....

[JimmieD]

Well, twisting up the last few wires, fill her up with dino and let the games begin, maybe a day or two?

Just wanted to suggest a modification to consider for those using the NV4500 and Dodge bellhousing. I did a custom installed Poly slave cylinder as mentioned previously. That required a home-made slave cylinder pushrod turned down from a Grade 8 bolt. Had to guesstimate the correct length and no reference points because I didn't purchase the stock hydraulic slave unit to compare to. Filled and bled the system yesterday but don't have any idea if the clutch will work or not??

The '00 Dodge/Cummins bellhousing has no inspection cover of any kind, just some vent holes up on top [CTD clutches can get pretty warm] with a plate covering them. Seems a good idea to cut an inspection hole in the bottom of the bell, at least 3/4" to 1" and with a cover, to allow a guy to take a peek and see what's going on with clutch etc. !?! I won't know if the pushrod length is correct until it's running the first time and I try to cram it in gear....

[rcts]

I too have a huge box of brass fittings, photos to follow, its super handy as you say! Don't know where I read this post but I thought I would mention it. Did you get the 4 banger fired up yet? Send me pictures.

I have been swamped at work but my 75 Dodge Cummins project is coming alowg, I have wire drawing for the swap built and my other drawings up on the web site under a new link, tech stuff!

More pictures all around, I'm looking at the next open spot in the shop to pull the 92 in and pull out the drivetrain. I have my new parts for the project in the shop.

Stock 75 frame, 92 rad support, new lift pump, alt & starter brushes, water pump, belts, tensioners, brand new from dodge 1992 CTD front springs.

Anyway, I Hope you have yours together or close to. If you were closer to Calgary canada we could have a beer drinking brass fitting sorting night, hee hee.

Reg

[JimmieD]

Well, getting VERY close Reg! Brass fittings post was over at Norm's place, the '61-'71 Dodge Sweptline Forums.

My swap is 3.9L Cummins into '67 D-100 Town Wagon. That involves fab custom frame supports boxes and engine mounts, fab custom exhaust, new D-200 front axle w/ steering and brakes, new Eaton Detroit Springs 1,500 lbs front spring packs, rebuilt steering box from Firm Feel, build custom extended steering column, install NV4500 trans [build 2 crosmembers], Dana 1410 U-joints, Tom Woods Custom Driveshaft, 4.1 Dana 60HD rear, coil-over rear shocks, D-200++ rear springs, install 25 gal aluminum fuel tank between rear frame rails, new fuel lines, rewire ALL wiring to custom circuit breaker panel eliminating all bulkhead connectors but lights [change that later to another breaker panel], rebuild cab mounts, fab custom steel tube support structure for floors and seat mounts, replace firewall pieces, front floors, seat area floors with 1/8" plate, repair body damage from 1/2 rolling it and getting rear ended HARD, TWICE [couldn't believe it...], and a whole lot more!

Pics will come later, and hoping to have it running/driving in a couple of days, again: God willing! Snow slowed me down, working outside..... Next comes one l-o-n-g vacation and who knows, I might drive north with my can of brass fittings and a whole bunch of fresh roasted coffee ha haha!

[JimmieD]

Side note:

Many guys are running 1st Gen 5.9L CTD's in a 7,600 lbs 4x4 trucks with great results. My truck tips the scales at about 4,800 with the 3.9L installed. The 5.9L trucks come out to about 1,280 lbs per liter, mine comes out at 1,230 lbs per liter! Already have 3" exhaust, equal to a 4.5" in the big engine, plus a 3200 rpm governor spring and HTT turbo upgrade [they're not yet installed] and looking at water/meth injection and Bosch VE fuel pump tweaks. 2WD has less parasitic drag so it might come out pretty nice....?