ok - been busy since the successful engine first-fire/break-in, mostly concerning the exhaust. Fire = bad, and things got pretty toasty underneath the cab, and even the driveshaft got hot, and I'm fairly certain if unaddressed the heat will melt the grease right outta the u-joints, and that's no bueno. So...the following is what I've been doing since to mitigate the heat.
First, sent the pipes to Jet Hot. Next, slapped on a LOT of DEI Floor and Tunnel Shield II reflective heat insulation to the underside of the cab and driveline, and put more on the tanks - it looks like a satellite under there now.
I also fabbed up three heat shields to go between the exhaust and the driveline and to protect the charcoal canisters/evap plumbing, shift cables, and above the rear muffler. To ensure the peel-n-stick insulation had the best chance of remaining put I had the heat shields powder coated for maximum paint adhesion.
This...I think...will do it, and I hope it does because I don't know how to do it any better. Bonus is I get to keep the second gas tank...which would have to come out if this doesn't work, and I reallyreallyreally want the second tank.
What else......oh, fuel: Cleaned all of the leaky aviation sealant and redesigned/reassembled everything with good ole Teflon tape. Redesigned the EFI tank head unit using steel NPT-AN fittings, and I'm waiting for my welder to get my fuel tank sending units done so I can reinstall them.
Also broke out the bender and fabbed up the basis for the rear winch mount/rock bumper; the front is next. Soon as I have the sending units back from my welder I'll have the fuel system back together, and we can fire it back up and resume testing.
The plan is to have the 'core' tested (all driveline/suspension/etc.), and when the go, steer, and stop are all good to go we'll take it to our local off-road park for trials, and if all of that goes well...7 weeks from now we're taking it to Moab.
Lots of DEI 'Floor and Tunnel Shield II' -
exhaust reinstalled without the driveline and shields -
these are the heat shields, with the insulation applied towards the 'hot' side -
main heat shield between the exhaust and intermediate shaft -
painted the bottom side gray to make things easier to 'see' -
and the additional bolt-on top shield to protect the fuel charcoal canisters and plumbing, and shift linkage -
...and then squeeeeeeze in the driveshafts... -
this is the upper 'fin' installed shielding the cable shifter and fuel plumbing...kinda hard to see tho -
Steel fuel fittings and 90* hose ends -
Core of the rear winch bumper -