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Here the center section of the new transmission mounting crossmember is being drilled. | On the left is David S., my nephew, who is an electrical engineer. He is going to be designing and building the control module for the pusher fan. The fan has a viscous clutch and will have its degree of engagement based on engine temperature. The fan will start engaging at 190 degrees and be fully engaged at 220 degress. By only engaging the fan as needed, fuel economy will be improved. | Back outside, this is the rear crossmember that has been cut into three pieces. The center section, which contained the motor mounts for the 440, is going to be replaced. | Another view showing the lower bracket and pedal position. |
Meanwhile, back inside the bracket for the fuel pedal was completed and the pedal installed. The pedal has the curve in it as in the donor, it needed this curve because of the mounting options combined with the transmission tunnel. | Meanwhile at the top of the engine, the air intake was replaced on the engine so that proper engine height can be determined. Two things were determeined. The first is that the engine can go up another inch or so. The second is that the engine compartment wall will not interfere with the air intake system. The air goes in here and down into the turbo then out the other side and on to the intercooler. | Here is the driver side bracket. This one presented a more challenging situation to design a means of supporting this side of the engine as the bracket was in midair with nothing closeby. To provide proper support to the engine and not get involved in esoteric solutions, we went with strong iron! A 1&1/8" plate will be inserted in the gap that you see. It will be anchored by the same four bolts that will be securing the crossmember that was removed and attaches to the verticle plate on the left. The plate will then extend back to where the engine support bracket is which will then be welded to the plate. The crossmember has been redesigned to allow for the plate and to go under instead of in front of the engine. That will keep the area at the face of the engine open and free for radiator mounting designs. | Here is a closeup of the bracket that was on the driver's side in the donor, but is now on the passenger side. The engine is now where it will be from a left to right perspective. That gap will be filled by a 1/2" plate that will be welded to the frame and then the bracket will be welded to the plate. The engine will be raised about 1" from what you see. |
If you look at the left and right side of the picture, you will see the engine support brackets that were in the previous picture. They have been cleaned up and attached to the motor mounts on the engine. They will need to be attached to the frame of the coach. | These are the two engine support brackets that were welded to the frame of the donor. They have been removed from the donor and will be welded into place in the FMC. The engine mounting brackets attach to these brackets with four long bolts that go through the tubes that you can see. Yes, they are side specific: facing the engine, the left one is on the left and the other one on the right. Due to the proximity of the steering column in the donor, they had to be different. | (3 Comments) No, they are not weird lawn darts! This is the tool that will be used to align the differential yoke with the transmission yoke. One will be attached to each yoke and the points will need to be touching to ensure vibration free and long life for the driveshaft. | For those not familiar with FMC's and their independent suspension, because of that the driveshaft can be very short. This is the driveshaft! If the differential is not moving, that is all you need. |
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