2insane’s Random 6.2/6.5 Diesel Projects

[campfire]

It is an incomplete tach sending unit. I think I have a complete one if you are in the market for one?

Not now. Perhaps not ever (I'm happy enough with my TinyTach unit). But I'm daily driving an engine with 2 cracked webs. Every once in a while I get the urge to build a good 6.5 block just to have some extra peace of mind. I may have the famed red block, but I'm still reluctant to run much boost in a stock high-compression engine with multiple cracks. So my turbocharger isn't netting me much benefit (I rarely get over 3psi). And, while the ATS kit may fit the squarebody better than a 6.5 setup does, the exhaust routing is terrible.


Long story short, I may wind up pulling the engine at some point, and I'll be interested in upgrades when that happens.

 

[2INSANE]

Not now. Perhaps not ever (I'm happy enough with my TinyTach unit). But I'm daily driving an engine with 2 cracked webs. Every once in a while I get the urge to build a good 6.5 block just to have some extra peace of mind. I may have the famed red block, but I'm still reluctant to run much boost in a stock high-compression engine with multiple cracks. So my turbocharger isn't netting me much benefit (I rarely get over 3psi). And, while the ATS kit may fit the squarebody better than a 6.5 setup does, the exhaust routing is terrible.


Long story short, I may wind up pulling the engine at some point, and I'll be interested in upgrades when that happens.

Cracked webs can be fixed! As long as they don’t exceed the length of the Lock N Stitch Kit.

I don’t hold on to extra spare parts long. Usually sell them or trash them for scrap after a rebuild.

That’s cool you are still rolling the Redblock!

 

[campfire]

That’s cool you are still rolling the Redblock!

Yep, I'm still rolling in the Redblock. Last week I used it for a 400 mile trip with my matching trailer:



I still feel like I should replace the block, just as insurance. But, thus far, it continues running right along without missing a beat.

 

[2INSANE]

There are not many pictures on Google of this 6.5/6.2 ESS Oil Pump Gear Drive with Tach Signal that comes out of a Military Humvee, so I thought I’ll share. It is different than the Civilian model as you can tell. I have a fella interested in buying it, so sharing its rare existence and information on it seems like a great idea.

 

[2INSANE]

Time for an update!

It’s been a crappy winter with record snow fall. Not much got done.

Currently Customer 43’s 6.5 Optimizer is at the machine shop getting honed, cam polished and crank balance done. After the (Budget) rebuild, the new rings did not like all the scratches on the bores, cam and crank. There was too much resistance I did not feel good about it so I took the whole motor apart again. This time it is going to be more costly for the customer but hopefully it works out for him. You can still see some of the deep groves in the cylinders after the power hone. Every bearing is getting replaced, every spec is getting measured to precision.

This last weekend, the snow kinda melted enough to pull his 700r4 Transmission which will be swapped over to a Th400 that was freshly rebuilt locally. I’ll have this done in about 2 weeks or so pending on part arrival.

 

[2INSANE]

Th400 is in and looking great! I picked up the rebuilt Np208 with the 32 spline input shaft and will hopefully get it in and running this weekend if the weather allows. I am using gaskets and Optimum Black to seal the adapter. 1” drop for better driveline angles and put on new poly bushings.

 

[2INSANE]

Transfer case is in. Everything bolted up great! It was a pita doing the wiring on the Kickdown switch and vacuum regulating valve, but those are in as well. Just need to hunt down a Th400 dipstick and fill her up with atf and she should be rolling!

I liked the polyurethane bushings soooo much that I ordered some for my ride as well.

 

[2INSANE]

Customer 43’s transmission swap is all done and working great! No more leaks and now has a good strong reverse! He wanted an additional cooler for the transmission to keep the th400 temperatures in order since they tend to overheat on long uphill pulls. Luckily I had an old new stock one sitting on my shelf and got it installed in about 45 minutes with fresh new hose. I used a pipe cutter to cut the cooler hardline, shop vac any debris that could have got in the line and then I flared the ends of the hardline to prevent leaks. To reduce the chance of the cooler cracking and flexing from road vibrations and body flex, I used rubber washers on both sides of the cooler to mount it. Here is a diagram of how his new transmission cooling system works.

 

[2INSANE]

Meanwhile, A bird told me where a 92 6.5 turbo block was hiding in the back of some guys field. I got ahold of the guy and we made a deal. $150 for all of it. I looked at the parts it had to offer and added up all the numbers. Sold! Easy pickings! The crank turned.

 

[Truckman4life]

Meanwhile, A bird told me where a 92 6.5 turbo block was hiding in the back of some guys field. I got ahold of the guy and we made a deal. $150 for all of it. I looked at the parts it had to offer and added up all the numbers. Sold! Easy pickings! The crank turned.

View attachment 445649

I've got a complete '92 turbo 6.5 I picked up like 15 yrs ago for my blazer. Probably needs a rebuild and it's been outside the whole time. Lugged it around with me on like 7 or 8 moves to different houses.

 

[2INSANE]

I've got a complete '92 turbo 6.5 I picked up like 15 yrs ago for my blazer. Probably needs a rebuild and it's been outside the whole time. Lugged it around with me on like 7 or 8 moves to different houses.

Nice! What ya gonna do with it?

 

[Truckman4life]

Nice! What ya gonna do with it?

The plan was to eventually build it and swap it into my 6.2L powered K5.

 

[2INSANE]

The plan was to eventually build it and swap it into my 6.2L powered K5.

Giterdun! The hard part and most expensive would be the exhaust!

 

[2INSANE]

After doing all this awesome work on customer 43’s ride, I had to mention how dangerous his hollow aluminum 4” blocks in the front were. I was able to convince him to buy my neighbors 4” Sky Jacker leaf springs for only $150!

Here you can see how warped the blocks got… It was a major ticking time bomb waiting to claim someone’s life.

Starting with the anti sway bar removal, It needs new bushings that I just ordered.

The 4” Skyjacker bushings were not that great either. Ordered some new ones and some new U-Joints from Amazon.

The front shocks are still good but ugly. I’ll clean them up and re use them.

Mocking up the spring, I am going to add grease able bolts to the new bushings when they arrive to preserve the life of the bushings and reduce binding.

The rear has 4” blocks which looks like the shocks are over extended. I have collected many things over the years and offered to sell a set of good used Bilstines to the Customer, which he gladly accepted. Lesson of the day… If an old and ugly part can be used again, never throw it away!

Now we wait again for the Parts to arrive…

 

[campfire]

Those blocks are scary!

 

[2INSANE]

Those blocks are scary!

For sure! I’ve heard about people putting blocks in the front but never experienced them in person until now. I think I just saved someone’s life or one heck of a accident waiting to happen.

 

[2INSANE]

Alright alright alright! Lol!

So I installed new spring bushings on the Skyjacker Springs, Installed the gently used Bilstine Shocks in the front and convinced the customer to get an ORD anti sway bar disconnect kit.

The front suspension was 1 1/2” higher than it use to be so I removed the old rear blocks and replaced them with 5 1/2” Sky Jacker angled blocks, new Bilstines, ORD extended brake lines and I did a PM on the Rear and front Differentials.

 

[2INSANE]

We used a local shop to extend, balance and install u joints on the front and rear drivelines.

I went to a junkyard and found some good front marker light pigtails to replace the jerry rigged LED marker lights from the PO, ordered LMC truck markers, modified the grill, sanded and chromed the grill and headlight trim.

 

[2INSANE]

Got some new license plate lights from Carquest. And scored a set of Oem rear mudflaps, ashtray and mirrors at the junkyard. I installed my favorite convex mirrors as well from Carquest and wired up a new lighter.

Customer also wanted all new super bright white leds in the dash and wanted new cab lights installed. I used an older 60’s model spacing on the cab lights to make it look more narrow and different.

 

[Blue85]

I went to a junkyard and found some good front marker light pigtails to replace the jerry rigged LED marker lights from the PO


View attachment 454428

So crimp-on butt connectors are the un jerry-rigged solution? Will you be able to go back and replace those?

5 1/2” Sky Jacker angled blocks

Holy Moly!