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  1. US6x4

    Need help with my exhaust cross heads!

    Ok, good to know - thanks for the response. Guess my install will get delayed a bit.
  2. US6x4

    Need help with my exhaust cross heads!

    I do have a set of 013294 jake gaskets which may be the same as rocker box gaskets so I could do the cross head swap, rocker adjuster swap and stud swap while I wait for another set of gaskets...
  3. US6x4

    Trick, functional jake brake grenade shifter

    I completed the wiring from the clutch switch to the throttle switch and back to the dash this morning. The dimmer switch screw is doing triple duty now since I added a p-clamp to it to hold the wires. The dimmer wiring p-clamp had enough extra room to add my two new wires to its bundle. I...
  4. US6x4

    Need help with my exhaust cross heads!

    I'm trying to swap in my Jacobs exhaust cross heads but they interfere with the rocker box no matter which way I twist them. Should I force them on with a hammer or do the rocker boxes have to come off? I don't have rocker box gaskets. @WillWagner
  5. US6x4

    Trick, functional jake brake grenade shifter

    The clutch switch bracket turned out better than expected - no grinding or tweaking required at all! It fit just right. I replaced the factory high beam light switch screws with 1" long button heads which provided enough extra screw threads on the backside to attach the bracket with nylocks...
  6. US6x4

    Rubberized paint spray - select interior places

    I really like the 3M brand rubberized undercoating and the stuff I got at the automotive paint store was way better than the 3M stuff I got at NAPA or box stores. This stuff hardened a lot more and would resist a thumb nail imprint unlike the other stuff where the thumb imprint never went away.
  7. US6x4

    Service manual for NHC-250

    Cummins part no. 3379076 There are -0_ releases of the manual as well. My 1978 manual is 3379076-03.
  8. US6x4

    Trick, functional jake brake grenade shifter

    yes, I have access to laser cutters, CNC press brakes, full machine shop, saw shop, tube benders, welders, hydraulic hose crimp machine, powder coating & wet paint shop, blasting booth...etc. Basically, everything you need to do this stuff the right way. All one needs is some imagination...
  9. US6x4

    Trick, functional jake brake grenade shifter

    The switch brackets were laser cut out of 14 ga. stainless steel and formed up to the shapes you see. The welded 1/4" nut that's been drilled out on that Z bracket will index the bracket to the throttle lever just like the original throttle lever bolt so it should always stay straight. The...
  10. US6x4

    M920 - Passenger tank install, battery and air tank relocation

    Here is a walk around of the truck Soni built - might catch a peak of a useful detail or two...
  11. US6x4

    3 Jake heads under a stock M809 hood!!!

    All washed, painted, lightly oiled inside, and continuity checked in the wire connections. Just waiting to get installed :) *for whatever reason my engine has a charcoal gray block, OD heads, gray rocker boxes and valve covers, gray intake, OD thermostat housing & water pump. Can't guess...
  12. US6x4

    3 Jake heads under a stock M809 hood!!!

    The first order of business was taking an inventory, then washing/ degreasing everything, and wire wheeling any rusty threads. Second step was getting the front head milled to clear the radiator support bracket. The machinist at work took off .188" in the CNC mill to get the bracket just a...
  13. US6x4

    3 Jake heads under a stock M809 hood!!!

    I looked high and low for 425A jake brakes purely for the benefit of running a divided entry turbo with pulse manifold and the closest I found was one set of heads only (no installation hardware or crossheads) for $1000. That's a better price than new but still pretty steep. I checked in with...
  14. US6x4

    3 Jake heads under a stock M809 hood!!!

    Well, since I modified a spare valve cover I still have my original that I will have to do something with. I'll think about that and see if my welder is up to it. If I did another one I would experiment with cutting out the triangle sliver but leaving the short side without any relief cuts or...
  15. US6x4

    3 Jake heads under a stock M809 hood!!!

    Thanks, lonnie! Hopefully there is little enough variation in these trucks that yours might also have a similar clearance.
  16. US6x4

    3 Jake heads under a stock M809 hood!!!

    With the new low-profile valve cover now finished with its surgery I mounted it onto a jake head to see if it would clear the internal parts that sit proud of the upper gasket surface. My plan was to dimple the valve cover in places that needed more clearance if there was a crash. The socket...
  17. US6x4

    3 Jake heads under a stock M809 hood!!!

    I can't take credit for the welding as I had a coworker who does that for a living stitch the valve cover back together again. His TIG welds turned out pretty nice but my cutoff wheel action left almost 3/16" gaps to fill and that was a challenge. And now with the welds ground down and...
  18. US6x4

    3 Jake heads under a stock M809 hood!!!

    I did not completely sever the top lid on the short side of the valve cover - I left the straight parts connected but I did cut through the indentation areas of the short side with a dremel tool cutoff wheel since the metal would have to go somewhere when bending the top down flat. Now it's...
  19. US6x4

    3 Jake heads under a stock M809 hood!!!

    Today I had my first trial fit with a front jake head installed under a stock hood and it was a success! Woohoo! ...Okay, i had to trim the middle hood support channel, but other than that no cutting, spacing, clearancing, denting or hood scoop done to the hood. I've been poking away on my...
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