Storms a 'comin! Project Thunderbolt returns (with pics)

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Re: Storms a 'comin! Project Thunderbolt returns (with pics)

Postby giusedtobe » Wed Feb 17, 2021 8:14 am

As for the O-ring, I went to NAPA and they just tried a few random ones from their kit until we found one that fit. Couple bucks.

On the head, a lot of the new manufactured heads do not have the holes for the smog pump. I deleted mine since we do not have emissions tests here but if you have to have it you will need a new head or have a machine shop drill and tap the holes.

My head came from Clearwater and frankly I never asked about that so was just lucky as I planned to eliminate the smog stuff anyway.
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Re: Storms a 'comin! Project Thunderbolt returns (with pics)

Postby BoiseTrooper » Wed Feb 17, 2021 12:53 pm

Thank you gentlemen. I figured it was something like that.

Not sure if this is a california car. The only sticker on the ECM box says "FED"

Regardless, I think I will follow what you guys have done and just eliminate the smog pump and metal rail and get a new catalytic converter. Where I live, there is no dyno or inspection. The only emissions tests are the sniffer probes in the tail pipe.

I really appreciate the help.
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Re: Storms a 'comin! Project Thunderbolt returns (with pics)

Postby BoiseTrooper » Thu Feb 18, 2021 1:49 pm

Quick question. I found these two in the gasket engine set. Not sure what they are for.

I would hate to leave out something necessary.

Anyone recognize these?

Thanks much.

635295161.jpg

635295191.jpg

IMG_8383.jpg

4zExploded View.png
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Re: Storms a 'comin! Project Thunderbolt returns (with pics)

Postby hessmess » Thu Feb 18, 2021 5:28 pm

The first one is an oil seal, probably front or rear crank, maybe front cam. Your engine builder already put those in. The last one was an exhaust for I think a Honda. I have thrown several of those away
86 Trooper (sold to brother) wrecked and recycled
88 Trooper (recycled)
91 Trooper, 3.1, bored .40, Cam, 4.3 TBI, roller rockers, Fiero valve covers, remote oil filter, LSD, 2.25 Cat back exhaust, BJ flip, 5 speed conversion, Round eye conversion-retired and parts donated to the new 91
91 LS Trooper, 5 speed, 3.4, bored intake, LSD, rebuilt using parts donated from the first 91
https://forum.planetisuzoo.com/viewtopi ... 15&t=81567
89 Pup LS Space Cab, 4X4, 2.25 cat back exhaust system, LSD, Jerry Cam, otherwise stock, painted Oct 2018.
https://forum.planetisuzoo.com/viewtopic.php?t=55081

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Re: Storms a 'comin! Project Thunderbolt returns (with pics)

Postby BoiseTrooper » Thu Feb 18, 2021 5:56 pm

hessmess wrote:The first one is an oil seal, probably front or rear crank, maybe front cam. Your engine builder already put those in. The last one was an exhaust for I think a Honda. I have thrown several of those away


Thanks Dick. You have an uncanny ability to put someone's mind at ease with just a few sentences.
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Re: Storms a 'comin! Project Thunderbolt returns (with pics)

Postby BoiseTrooper » Thu Feb 18, 2021 7:13 pm

So the Haynes manual says to use sealant with the rocker cover on the cover-to-head surface, especially in the bolt holes. Posts from long timers on here range from none to just using it under the half moon rubber piece at the back.

IMG_8384.jpg


IMG_8385.jpg



On the large aluminum crank cover shell, a previous repair had used orange rtv and no gasket.

IMG_8386.jpg


IMG_8387.jpg


Any opinions or experiences? Yea or nay?

Just thought I would check.

Thanks in advance.
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Re: Storms a 'comin! Project Thunderbolt returns (with pics)

Postby aidan7777 » Thu Feb 18, 2021 9:54 pm

I've heard JLEMOND say those gaskets are for the 2wd oilpans and will leak if you put them on a trooper pan. He reckons RTV is the way to go with these things, and that's what i did with mine.

No leaks so far, only had trouble with the stupid gasket on my lower pan not sealing up right. probably because it's warped a bit or something.

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Re: Storms a 'comin! Project Thunderbolt returns (with pics)

Postby hessmess » Fri Feb 19, 2021 4:54 am

On the valve cover, I used RTV in the rubber plug and just a dab on the front in the corners where it goes over the cam seal. On the oil pan my kit didn’t have a gasket. Used a RTV instead, never leaked.
86 Trooper (sold to brother) wrecked and recycled
88 Trooper (recycled)
91 Trooper, 3.1, bored .40, Cam, 4.3 TBI, roller rockers, Fiero valve covers, remote oil filter, LSD, 2.25 Cat back exhaust, BJ flip, 5 speed conversion, Round eye conversion-retired and parts donated to the new 91
91 LS Trooper, 5 speed, 3.4, bored intake, LSD, rebuilt using parts donated from the first 91
https://forum.planetisuzoo.com/viewtopi ... 15&t=81567
89 Pup LS Space Cab, 4X4, 2.25 cat back exhaust system, LSD, Jerry Cam, otherwise stock, painted Oct 2018.
https://forum.planetisuzoo.com/viewtopic.php?t=55081

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Re: Storms a 'comin! Project Thunderbolt returns (with pics)

Postby BoiseTrooper » Sat Feb 20, 2021 1:45 am

You fellas want to see something crazy? The viewpoint is the block laying on it's side looking at the crankshaft.

I noticed these two bolts when I took the crank cover off. The crazy part is I never touched them. They were that loose on their own. :shock:

Yikes. But it ran great. I know that doesn't make sense, but it did. And the new crate motor doesn't have them. Any idea what they are for?

IMG_8392.jpg


IMG_8393.jpg


IMG_8395.jpg
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Re: Storms a 'comin! Project Thunderbolt returns (with pics)

Postby giusedtobe » Sat Feb 20, 2021 2:54 pm

Never noticed that odd bolt on mine but maybe it was there.

The green seal thing I had the same question. Like Dick said it doesn't apply to your motor.

For the valve cover I put RTV under the little half moon and between the half moon and valve cover and then over the hump where the camshaft connects to the sprocket. I've had no leaks so far.

Oil pan I had a gasket like yours which was a one piece rubber and it did not fit at all. I also had two little rubber half moons that fit in the groove where the crankshaft lies. I used a liberal amount of RTV on both sides of this little half moon and also a liberal amount on the oil pan itself.

Another problem I had was my gasket for the little top hat oil pan was not the right shape so I had to cut part off and reposition it. I used liberal RTV here as well.

Good Luck
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Re: Storms a 'comin! Project Thunderbolt returns (with pics)

Postby BoiseTrooper » Sat Feb 20, 2021 3:36 pm

Oof. I gotta stop working so late. I came out this morning and realized those bolts hold on the oil pickup tube. Sheesh.

IMG_8400.jpg


Thanks for rolling with me fellas.
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Re: Storms a 'comin! Project Thunderbolt returns (with pics)

Postby hessmess » Sat Feb 20, 2021 6:04 pm

Oh man, that is funny. At least it didn’t keep you up all night! Or did it?
86 Trooper (sold to brother) wrecked and recycled
88 Trooper (recycled)
91 Trooper, 3.1, bored .40, Cam, 4.3 TBI, roller rockers, Fiero valve covers, remote oil filter, LSD, 2.25 Cat back exhaust, BJ flip, 5 speed conversion, Round eye conversion-retired and parts donated to the new 91
91 LS Trooper, 5 speed, 3.4, bored intake, LSD, rebuilt using parts donated from the first 91
https://forum.planetisuzoo.com/viewtopi ... 15&t=81567
89 Pup LS Space Cab, 4X4, 2.25 cat back exhaust system, LSD, Jerry Cam, otherwise stock, painted Oct 2018.
https://forum.planetisuzoo.com/viewtopic.php?t=55081
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Re: Storms a 'comin! Project Thunderbolt returns (with pics)

Postby BoiseTrooper » Mon Feb 22, 2021 5:05 am

Well, this is frustrating.

I had a socket wrench on the oil pickup tube bolt and caught my foot on an air hose. Stumbled, grabbed the wrench and twisted the bolt for the pickup tube right off into the crank. And it broke on the tightening in, not the loosening out. I am worried about getting it out of there. Holy crap.

Anyone have any suggestions or amazing broken bolt removal ideas? I guess I will try a fluted extractor tomorrow.

Oof.

IMG_8414.jpg
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Re: Storms a 'comin! Project Thunderbolt returns (with pics)

Postby giusedtobe » Mon Feb 22, 2021 3:14 pm

Wow that looks like something I would do! Not much experience with removing sheared off bolts.

Good Luck
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Re: Storms a 'comin! Project Thunderbolt returns (with pics)

Postby BoiseTrooper » Mon Feb 22, 2021 6:14 pm

No worse feeling.
IMG_8414.jpg



No better feeling.
635722681.jpg


I took it over to my Dad's workbench. He has a much nicer drill press and I wanted to be able to clamp the cap to drill a good hole in the bolt. Seeing it starting to turn out is a giant exhale. Whew.
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Re: Storms a 'comin! Project Thunderbolt returns (with pics)

Postby hessmess » Tue Feb 23, 2021 5:06 am

I had missed this, glad it worked out. I have twisted a few off myself, last one was the bolt holding the vibration dampener on. It’s still there, the engine isn’t. Yes the one in the crank.
86 Trooper (sold to brother) wrecked and recycled
88 Trooper (recycled)
91 Trooper, 3.1, bored .40, Cam, 4.3 TBI, roller rockers, Fiero valve covers, remote oil filter, LSD, 2.25 Cat back exhaust, BJ flip, 5 speed conversion, Round eye conversion-retired and parts donated to the new 91
91 LS Trooper, 5 speed, 3.4, bored intake, LSD, rebuilt using parts donated from the first 91
https://forum.planetisuzoo.com/viewtopi ... 15&t=81567
89 Pup LS Space Cab, 4X4, 2.25 cat back exhaust system, LSD, Jerry Cam, otherwise stock, painted Oct 2018.
https://forum.planetisuzoo.com/viewtopic.php?t=55081
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