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This weekend was all about freshening up the paint on the RH side of the engine. Before I always thought my engine had OD Green and Cummins industrial tan parts added to a charcoal gray engine, but after degreasing and pressure washing it I'm convinced that the entire engine is still gray...

The M809 series TMs call for 130-167 lb-ft

My neighbor said he put 2 million miles on his small cam but he said you have to be smart with your foot to keep from burning a piston.

To change the direction of the tank's outlet pipe i sourced a 1 1/4" mandrel bent 90° stainless elbow with rolled beads from a fuel filler neck company and then shortened one leg to allow it to fit between the tank pipe and the engine block. The TIG guy said that "walking the cup" was...

The relocation of the surge/reservoir tank to the firewall has been an ongoing, slow but painful sort of project. Originally it mounted to the exhaust manifold bolts so I wanted to keep its install height close to that in case it affects its function. I clamped a corner square to the manifold...

Thanks! I don't know what the torque will be, but from what I've read the horsepower will be in the 300 - 315 range? I can only add so much fuel before the EGTs get too hot for the pistons.

Thank you! It will be fun to have jakes and a turbo on my truck - it will be making all sorts of fun noises 😁

I like your idea & I think that would look great, but the way they mount under the bracket I would lose the ability to bolt them to the bracket. If I make a pair as a floating intermediate hose separator w/o a bracket I will do that.

Due to drill bit wander some of the sides were not perfectly flush so they got ground to match and then polished up a bit. The holes were intentionally undersized so that I could drill them to the final diameter after the two halves were mated together; 31/64" for the small hose and 5/8" for...

Today i finished the support brackets for the surge / reservoir tank hoses and the jake brake wiring. I looked and couldn't find clam shell type hose clamps that i liked and that had both a 5/8" hole and a 1/2" hole so I made my own out of 3/8" 1018 carbon steel. These started out very messy...

OK, here's a sneak peek of my surge tank hose and oil feed hose mockup. Here I'm just measuring the hoses to cut to length and most of the parts are still in the white but the intention is there. My engine (manufactured in 4-81) only has the oil sample drain port as a source of supply oil for...

Thanks! One of the most detailed parts is almost done but not quite there yet...more to come.

Thank you! Much more pics and details to come. I've made some real good progress this week and I'm getting very close to painting my hot components.

I finished assembling the turbo oil supply hose using Fragola -06 PTFE braided stainless hose and matching 90° swivels; 9/16" male straight thread ORB on turbo end and 1/4" NPT male on the other. I also got a lot of metal massaging finished on the muffler mount. I got the top saddle...

I ended up finding the fittings at PSCpartsstore.com

I spent a ridiculous amount of time searching out fittings and hoses that looked factory for the radiator surge tank. I was trying to find that magic fitting that would give me a 90° swivel with an 3/8" NPT male or 1/4" NPT male and fit a 3/16" or 5/16" hose. I couldn't find such a fitting...

With this configuration and with the limited amount of space available to use on these 5-tons you definitely end up prioritizing form over function. For awhile I was contemplating a straight pipe exhaust where a flex pipe or true bellows would have easily fit in place of my muffler, but now the...

Today I'm disassembling all the exhaust components so I can degrease them and rough them up with maroon scotchbright pads before painting them with OD Green high-temp machine gun suppressor paint. While it’s apart I took some more measurements as promised. The 180° u-bend got whittled down...

Thanks Lonnie. Yes, I'm following your lead on this type of pipe routing. It looks so simple, but there are dozens of steps involved...

I drilled the exhaust port for the pyrometer probe and mine is a little too long as I suspected so I added a 1/4" NPT female to male adapter to take up some space. This is a special "interrupted thread" tap where the teeth on each flute cut a different thread. It makes tapping cast...