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Copper nickel alloy gets my approval too. Stainless requires premium tooling to properly form the double flare. Copper nickel is easier than steel to form.

Careful with stainless threaded fasteners. They are quite sensitive to galling. Most important would be thread repair inserts and coils. A2 is 304 stainless equivalent, A4 is 316..matching nuts are often of slightly different alloy to prevent galling as adding small amounts of sulfur aids...

Grinding stainless is a pain. Especially 3/8" thick flanges..got half of them, that is 4, outside ground from the ugly plasma torch action. The inside grinding is a bit easier with 1/2" diameter carbide burr but makes a bunch of needle sharp mess. Now to match drill the bolt holes. 1 down...

Fuel lift pump. The stock unit has two vents on the dry side of the diaphragm. The lever and spring are on the crankcase side, the lever pulls on the diaphragm through a rod, this rod runs through a bushing which reduces the chance of a ruptured diaphragm leaking into the crankcase. Now, the...

My welding skills with one and one-half hands plus OCD to achieve full penetration welds makes for ugly stuff. So these will not have beautiful welds. Also, dimensions are being held with zero root gap process, a tricky option on 0.109" wall. All low carbon 304 so it doesn't really matter...

Getting somewhere.. turbos will live somewhere in the middle, another tee will be cut and inset at an undetermined yet angle. The ends pointing up in this picture will be squeezed oval vefore welding to flanges.

Check out the download section as there is a pdf of the dealer info book, vintage complete with errant stains.

Oh yes. There was a time I was going to use an Arduino but an innovative chap in Scotland has a good kit for this application.

Stock 6.2 diesel. 36k miles, 27k with me behind the wheel since 2012. Yes, it only had 9k at liberation time from Ft. McCoy.

Ran the 1031 SECM for compressed air duty. Seasonal check on the motor pool plus did some plasma cutting for the 1031 twin VNT project. Why twins? Because these were a steal due to economy of scale. Each turbo is good for 120 HP or 20+ pounds mass of air per minute. Bear in mind, a stock...

I did the rest of the plasma torch cutting today..some ugly, got three flanges in need of weld repair. Still have over 2 pounds of 309L in various diameters. Going to go fast now I have a pattern. The 1/2" carbide burr is still perfectly sharp, removes metal fast and doesn't heat the parts...

Back to thermodynamics, with mass flow of air at 26 pounds per minute and injection volume of 48 mm^3, the air/fuel ratio is 20:1. Boosted with mass flow of air at 36 pounds per minute, matching the a/f ratio means injection volume of 67mm^3. The IP plungers are 0.290 inches in diameter...

If only one of the battery terminals are hot, that indicates a poor connection. If all terminals and wires are warm, this points to starter. Terminals are hardened lead, a poor conductor compared to copper. Clean all terminals, including negative to ground as rusted steel is another poor...

Not many circuits are live when the key switch is off. But key switches fail. Other parasitic paths are alternators so identify which battery is being drawn down. You could link two booster packs in series and then use the NATO receptacle but if the front battery is weak, there will be no...

Have a plan..and a backup. I made plasma templates out of 1/4" MDF for cutting manifold flanges, thinking 3/8" stainless would cut fast on 50 amp plasma torch and the 7/16" torch offset would prevent charring. Well, extension cord voltage loss p!aged the plasma torch and patterns began to...

Top tube to transmission. The reason for the vacuum is this transmission was designed for use behind gasoline engines where manifold pressure is a good indicator of engine load. The modulator adjusts hydraulic pressure to the clutches and adjusting shift points. Adjustment of the VRV is...

Last time I checked, the vacuum regulating valve is no longer made..New old stock is all that is left and only found on eBay. 14057219 is the GM part number.

8 welds done, only one needs rework..not too shabby for having a bum hand. 26 parts became 12 so cutting the parts count feels great. Stock manifolds turn down, these will turn up. Since this is Schedule 10S pipe and fittings, it is much stiffer than any single piece flange. Which is why...

The ones that burned out were in it since liberated from Ft. McCoy in 2012. AC 13Gs. I had purchased Duratherms that year from Rockauto as they were on sale for under 6 dollars each. Zero defects so far.

Got some pipe cut tonight..stainless is tough to cut with an old fashioned pipe cutter. But no kerf loss, minimal mess and square cuts are a benefit. Need 8 pieces, 0.75" long. That is a inch saved over cold sawing. Tack welding in the morning. Then gentle squeeze of the port ends to match...