Good afternoon all, my conversion has been underway since mid September. I am making progress. I wanted to get the accessories all sorted out on the Kubota before I started the bellhousing adapter. I still don't have a Aiconditioning compressor mount, but the rest of the accessories are hung on the Kubota.
So I think it is time to start pulling the jeep engine. This 1994 jeep with ax15 5 speed 2wd, is probably not going to be the final home for this Kubota. But this is where I wanted to start. If it all works out, the final destination will be either a 1998 Dodge Dakota extra-cab 2wd with an AX15, or a 1998 Cherokee that has a bad automatic transmission.
Here are some pics of the Turbo.
FTE if you are out there this should be an exact copy of your Turbo. So what do you think? I had to take the brand new Turbo apart, and pull out one little indexing dowel in the exh side, and the one in the compressor side would not pull out so I had to cut it down.

More pics of the accessories in a bit.

 

here a pic of the alternator and PS pump. For the Aircon, I am thinking to mount the jeep crank pulley to the Kubota, and run the OE aircon compressor and pulley. I spent a few days trying to cut my own internal spline sleeve for this added pulley. I GIVE UP ON THAT. I think I can get a internal spline sleeve, but a 1.5" splined coupler is $100. the other choice is to just make a smooth walled sleeve that is interference fit on the crankshaft, and then held on with set screws.
I don't want to put this in a truck with out Aircon. That is why I did not drive the Mercedes Cherokee more. The Aircon compressor mount is in process, I need to do some more fitting and fab work on that.

 

Good Going.

I guess you did not get my PM on the Pulley?

I have been thinking about a Pulley for awhile for this application. As I have made a pulley or two when I was messing with a ground up UAV project a few years ago for a power plant I set up for the air craft.



What I have in mind with my limited tooling is to use a piece of flat aluminum as thick as needed for the belt. Then I will simply use a hole saw on a drill press to make a center hole probably around 3" this is not set in stone as you can do as you wish and what best will fit your lathe head.

For the Groove you can purchase some Tool Steel for the cutter the size you need then simply grind the shape of the v belt into the tool steel to set into your tool head to make the groove. I will also probably face off one side of the pulley to index onto the stock Kubota front pulley so I will not have to remove it from the engine. Then simply drill three or four mounting holes through the new aluminum pulley set it against the factory pulley of the Kubota mark the holes and then drill them out and tap them and walla you can then attach the pulley to the Kubota. Also by doing it this way you can stack more pulleys onto the new pulley you made as you wish.

Sorry I guess I should add this. If you think you may attach more pulleys to the one you made then I would face off both sides with a indexing face so on the pulleys you may make you can match this and they will self index on the previous made pulley and simply bolt them on.

So in the end you can make a pulley as thick as you like and have 1,2 or 3 extra grooves in one pulley plate. If you are going to make it then you can make whatever you wish.

 

HI Jester, I did get your message about the pulley, That was my first thought for a pulley as well. I even tried to make an aluminum pulley about a week ago. it did not come out satisfactory, then I thought I would rather use the stock jeep pulley, so I don't have to change the pulley on the aircon compressor. Both of the good vehicles have working AC. The POS starter jeep does not.
My lathe is only 13" swing. I will not have enough swing to turn down the flywheel cover. Most all the rest of the machine work I should be able to do in house. I could probably get it done on the mill, but it will be better to take that to someone with a bigger lathe and have it done correct.
Now I need a stud puller to get the 2 studs out of the exhaust manifold. I am going to use some countersunk screws in place of the studs to mount my turbo adapter. I tried to get the studs out with 2 nuts backed up to each other, and it just pulled the threads out of the nuts straight away, the nuts were expensive Chinese crap I guess. So that is going to be a delay.
What are you other guys using for exhaust gaskets on the high pressure side??? I got a stock Kubota exhaust pipe gasket, but I need something for the turbo inlet flange.

I guess that is it for tonight

 

DieselXJ I sent you a pm On the Pulley.

As for the Studs they sell a stud remover that looks like a socket that you can use.

But I would first soak them with some PB Blaster before trying to remove them. If they do not come out all that easy I would use a torch to apply heat and then try and remove them.

Or instead of the Stud removal tool if a sears is not close by you can get a couple of GOOD nuts and put them on there and then weld them to the stud. Heat the exhaust metal around the studs and then remove the offending studs.

But as you know if all this fails well then all you can do is cut off the stud and file it semi flush with the exhaust manifold center punch them and drill them and try an easy out again with heat and even further if that does not work and you are careful then drill them out and re-tap the threads.

Also as a long shot if you have nothing to loose you can make a new plate for the Turbo to mount to and then weld it to the exhaust flange using a low-hydrogen rod.

Or you can bite the bullet and get a Turbo Exhaust Manifold here https://parts-barn.com/index.php/kub...-manifold.html

Sorry if this is a bit much in one post.

 

I was originally planning on making my own turbo header out of stainless steel just for a fun project. But maybe next time. here is a pic of my turbo adapter plate. I can notch out the turbo exh flange and use the existing Kubota studs. Or my choice at least today is too pull the Kubota studs, and countersink my turbo adapter plate for flush grade 8 metric internal wrench screws. I don't think there is enough meat on the turbo to notch the housing for bolt clearance.
Also on the turbo now that it has been clocked , I need to re-do the wastegate actuator mount. I thought I could just re-index the wastegate actuator on the compressor housing, but for some reason it is not that simple. So I will have to make a little wastegate actuator bracket to re-mount the actuator.
Another thing that is scaring me a little is I might have jumped the gun with the accessories, because I might need to share the accessory mounts with engine mounts
and from talking to Rangmar, it looks like I will need to go ahead and get a bobcat oil pan.
It is never over even when it is over its not over.

 

Yes that is the same turbo as mine, when I clocked it I was able to mount the wastegate on the other side of the compressor. Mine has more bolt holes. I also have mine mounted @ 45deg to the motor, your pic shows you will be 90deg to the motor, that will make the plumbing easier. Mine couldn't do that due to the master cyl.

 

thanks FTE, nothing is set in stone on that turbo yet. I need to get the studs out and find some countersunk screws to fit in that plate. I hope I don't get an exhaust leak at the bolt holes. All the orientations seem to have pluses and minuses. This one will shoot the comp outlet the correct direction to hit a intercooler up front, but it puts the Airfilter going the wrong direction . Where did you get your high pressure turbo gaskets?

I have a spline coupler coming to sleeve the jeep pulley. And the heep engine should be out this evening

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Well I got the engine 3/4 of the way out of the jeep and the dam forklift quit. I hope it is just out of diesel. If I have to switch to manual it is going to be a pain in the ***.

 

It's best to have the the least amount of bends in the charge lines, so your setup sounds good. I made my gaskets out of bulk Fel Pro material. Mind posting the link for the coupler?

 

DieselXJ,
If you don't mind me asking, where did you buy your turbo? I've seen a few on EBAY but was concerned about the quality.

Thanks!