Dodge Diesel Cummins Vegetable Conversion

315/75/16 TOYO M/T tires are rubbing in the front a leveling kit on top of the coil springs should eliminate the annoying rub.

Here are some pictures:

Davco 384 fuel filter from a Semi U-pull-it
12 volt and coolant heat no big deal
Picking it up this Saturday


Took the truck to get wood yesterday.


Wired in tank selector switch to three way hydraforce valves




Anthony Working on the switch


Check back for progress.

Write a comment if you need a particular image.

Veggie Updates

Scout:
Fabricated alternator mount
Installed alternator
-Freeing up 3 parasitic pulley's
Routed coolant block heater

Cummins:
Ordered service manual-
Should help out with the conversion and general maintenance
Called a couple of dealerships and they are more than happy to let you read any section that you want, but you can't beat having a personal copy. It will set you back about $100.
To order the service manual call Chrysler publications 1-800-890-4038.
Ordered Tranny filter and gasket plan on using the service manual to adjust the bands.

Marked the Google calender for all routine maintenance in the owners manual to include:
- Clean Fuel Strainer
- Inspect Water Pump Weep hole, Fan Hub, Dampner
- Flush and fill
-Tranny, Diffs, T-case
- Lube
-Zerk fittings, wheel bearings, seat adjustments, aka all moving parts.

Ram Update

Did some preventative maintenance on the Ram today
- Oil Change
- Diesel Filter
- Serpentine Belt

The L tank is crap found one little rust hole in the bottom decided that since the thing is pitted inside and out it has to go.

Normally I would shop around and buy one of Craigslist but time is of the essence.
The New tank will be had from Coastal Farm and Ranch and be exact same as the rusty one sitting in the scrape pile. Only I will take care of the new tank.

Ordered Hydra force valves, Hot Fox, Isspro Sender, and ON-Off-ON switch from Vegpower.com today.

Pictures coming soon.

Veggie Ram

Bought a 4x4 dodge diesel today because it was a good deal.

I plan on making the cross country trip to Georgia in this dodge with a conversion.

I have ten working days to complete this conversion.

Got the guy to throw in an L tank that was sitting on the side of the house that will be the base of the conversion.

Copper doesn't react well with vegetable oil, and the copper in tank heating element takes a lot of valuable time. An Arctic Fox heated fuel pickup will save time and last forever.

Would like to use the same VW oil cooler idea but I've heard of a large DAVCO filter housing that is coolant heated, lasts forever, can be had for cheap, and filters are $10.

This Davco filter is rumored to be found at big rig parts yard in Idaho. A Soldier at my unit knows more, and of course I will post the specifics later.

Stay tuned it is about to get exciting.

Veggie scout voyage adds a member

Booked Rebbecca's flight today so she will be joining the trip:

No time for a body swap on the scout

Found a set of four studded tires in the backyard mounted on Nissan Wheels

Need to find 2 more 16 inch rims with a 5 on 5.5 bolt patter to cover the snow tires.

Need to buy a Yakima rack system or try a stock scout traveler rack

Planning on buying storing gear in over sized bins laying plywood on top laying down a mat for a sleep area.

Leaving on election day and giving the trip 6 days at just under 7 hours a day should be easy.

Cross Country Venture

Going to Georgia for a month and a half of training. Need a vehicle while I'm there so why not drive from Oregon to Georgia?

The Scout is going to need some work to make the trip comfortable so there may be a body swap in the future.

15 availible days to work on the vehicle. Planning to ski on the way home.

Needs:
Deaden the roar of the SD33 (Carpet)
Acquire Snow tires
Remove parasitic second alternator
Install Cold Air Intake
Fix Stereo
Load Fuel
Stock Filters

My Georgia girlfriend has already acquired a vegetable oil account for travel during and after training.

I will be documenting as much of the trip as possible with pictures and video.

Heated Fuel Filter

This author chose to use the inexpensive yet very effective Volkswagen oil cooler as the Flat Plate Heat Exchanger (FPHE). This setup costs about $30.00 and gets the job done. You will have to resource the oil cooler from an early four cylinder Jetta found at any U-pull-it / junkyard. Make sure you grab the piece of threaded pipe going from the oil filter to the housing. Then go to Jegs.com and purchase the PermaCool part# 1719. Go to Napa and get fuel filter #1275 $18.19



VW oil cooler


A similar setup


Mount your new filter head in a convenient location close to the injection pump as it will be after the hose in hose setup coming from the tank. Splice into the heater hose before it enters the heater and route it to the (oil cooler/FPHE fuel heater) the hose exiting your FPHE will T into the hose in hose coming from the veg tank.

If you are confused read the above a couple more times and create a diagram. Contact me if you have questions by commenting on the post.

DIY Homemade Heated Fuel Pickup

This tank leaked If you do cut a whole in a tank put a cork gasket down upon reassembly.

Paying for a hotfox or other heated fuel pickup is worth it in my humble opinion.

It's corny and cliche but had to paint the veg tank green.





Making your tank should be straight forward.


Chose to use the stock fuel tank location for the vegetable oil tank. International offered the 33 gallon tank as an option. after acquiring the tank note the size of your fuel pickup lid. The Scouts was small and impossible to use with copper tubing so I cut a big whole and an even bigger piece of steal to cover the whole for a lid.

This is the tubing bender to use:


Drill holes that are 1/3ish larger than the outside diameter of the 3/8 copper tube. After the final test fit build a lip of epoxy around the copper tubing:



Another picture with the epoxy in place.


My setup leaks because I only used RTV. Get yourself a thick cork gasket and put RTV on one side.

Test that your sending unit works with the gauge.

Oil Collection Methods

Getting oil should be relatively easy and inexpensive.
The method for collection is situationally dependent. Some Restaurants store their oil inside. Some put oil back in 5 gallon containers (easy), but if they are not used to this it will be difficult to persuade them to change habits. Rather than changing habits one should make the best of what situation they are dealt.

Ideally you can pick up the container and if need be provide an empty container of the same size.
If you have a pick up or a hitchable vehicle this image below is an easier option for transporting heavy 55 gallon barrels.


If you have to suck the goop out of the barrels either because the barrel is behind fence or fill in your reason here________ then the image below is the tool that you need. This pump is a tuthill. Do a google search and pick your favorite vendor.



These are the best for starting with quality oil, and keeping water out of the fuel.

Google Ez strainer, and or go to Fryer to fuel

They are reasonably priced but get you on shipping costs.


These are the best thing since sliced bread. The best method for filtering vegetable oil and the restaurant does it for you.

Wiring Vegetable Oil Fuel System

Wiring the system is fairly straight forward. The Switch I use is an on-off-on model meaning that when the rocker switch is up it sends power to one set of accessories. In my case the up position sends power to the vegtherm, and hydroforce supply valve. Hydraforce three way valves are numbered 1,2, 3. When not energized the valve flows from port 3 to port 1. This is the default / diesel position. When the valve has power (is energized) it shuts port 3, and flows from port 2 to 1 supplying oil from the vegetable oil tank to the injection pump into the engine.



The vegetable oil and diesel fuel filters come before the supply valve.

The beauty of creating your own vegetable oil fuel system is that there are numerous ways to accomplish the same goal. This is simply what made sense for me at the time. The system is modular and easily changeable. Click on the wiring schematic in the top right picture for a better view of my setup. I've debated using an ON-ON-ON rocker switch wired to ignition power so I can power the fuel pump at the diesel tank, and send the fuel return to the diesel tank as well.

Going to Annual Training until August 24th hopefully there will be internet out there. If there isn't I'll try and get one more post before leaving.

Hydroboost!!

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Diesel engines don't produce their own vacuum and need a pump to accomplish vacuum power. The stock SD-33 diesel engine has a vacuum pump mounted on the back of the Hitachi alternator that is not very powerful, and isn't operable. The previous owner (PO) installed a GM Alternator in another location and the engine is running both. With a Hydro boost conversion the power brakes tie into the power steering pump, are more effective and allow you to free up engine power.

Parts can be had at any u pull it, and an early 90's Astro Van is the preferred donor vehicle.
-Note if your scout/ vehicles power steering pump & steering gear has flared fittings you will have to change out hose ends or buy adapters to fit the O-ring type hydraulic fittings that GM used on all of there vehicles from the early 80's on up.

If your scout is circa 1980 you will have O-ring fittings and an easier install.

Parts list:
Astro Van
-Hydro boost
-Master cylinder
-Proportioning valve
-hydraulic lines connected to booster
-brake lines extending from the Master cylinder to the ABS

Decided to tackle this project as the examples from binderbulletin.org
made the project appear easy. This project has proved to be relatively
complicated. Learned how to flare brake lines which is a must for this project.
The other time consuming aspect was dealing with the longer shaft of the hydro booster.
some people section the rod that connects to the pedal while others build a plate to mount the booster farther back from the firewall. I chose to create a plate, and adjust the brake light switche. Other conversions used some sort of spacer that backs the booster 1 inch from the firewall. Cutting the stock booster bracket and welding it to the Astro van donor booster is the best option IMHO (in my humble opinion).

I didn't want to use a welder and it has ended up costing me more time and money.
Had a great idea of fabricating an aluminum spacer, but made it to thin and didn't complete the install before the weekend climbing trip to Smith Rock and had to give gas money to buddies.

After working past 4am plumbing and installing the brakes waited till the next morning to bleed the system and wouldn't you know it the rear master cylinder plug cross threaded and refused to seal letting air in the system.

Longest Trek Yet!

What a great day yesterday was. Got up early (4am) and headed on up to FT. Lewis for a flight physical. Pretty cold in the Scout with the top off.

Flew through the physical and was done by 1030am. Drove on up to visit John Fleck at Back Country Binders in Port Orchard. Crossing the sound was epic. The enormity of the scenery was intimidating with the gigantic masts thrusting from the vast waters, and the high wind warning I felt as if I'd be sucked out of the Scout. Not on this day just the big beautiful sun.

Purchased a roll bar from Jon because that long of a drive in the hot sun deserves a bikini top. There is a stock roll bar inside the fiberglass traveler tops. John learned this after rolling a couple scouts.

Projects to come will are:
Hydroboost Brakes
Cold Air Intake
Alternator Relocation
Bikini Top
and on and on

Making the Scout Perform as a Capable Ski Rig

This diesel scout set out life with this author to cruize up Mt. Hood 40+ times a winter on an economical fuel. While going up a decent hill the scout tops out at 45 mph if you drive according to the Pyrometer. The Pyrometer measures EGT exhaust gas temperatures. Diesels especially turbo diesels should be driven according to the pyrometer. Unlike a typical gas engine which are driven to a tachometer. Diesel drivers need to be aware of the RPM's just as gassers, but this is done mostly by sound.

High EGT's are a sign of over fueling and injectors are usually the culprit. Today the injectors where inspected for free by Diesel Fuel Injection Services based in Portland Oregon. They reported that the spray pattern on all injectors was sub standard, and serviced them to the tune of $216.

The Scout is very quick on acceleration and after gear shifts, but the EGT's don't seem to be any lower. A positive unsuspected side effect is that the Scout will idle perfectly well on vegetable oil and before it would not. This is a problem that has plagued many that have converted a Nissan diesel, but that’s another posting all together.

Hose in Hose explained

The idea is simple enough although many hose and fitting establishments will have no idea what you are talking about when you speak with them. In the great NW we are lucky to be in close proximity to SwageLock the fitting experts.

The SwageLock Part number you need is B 810-1-12. The B stands for brass and cost under $8 each. When you get your fittings you will notice that your 3/8'' ID Pex fuel line doesn't slide all of the way through the fittings. You will need to bore out the fitting with a 1/2'' drill bit. If you have access use a drill press. I used a cheap vise and an electric drill. You will have to drill through a good amount of fitting, but it is brass and should go quickly. The drill method did produce some unsavory kickbacks.

It's rumored that the best deal on other fittings can be found at www.plumbing.com. You will need 4ea: 3/4 NPT (Pipe Thread) x 3/4 hose barb, 3/4 NPT x 5/8 hose barb.

Vegetable oil conversion parts list

Double click on the receipts and you should be able to read them. If not then let me know.

In an attempt to quantify the time and money involved in this particular project I've decided to scan all receipts and post them here.

The receipts include all of the needed data and then some and are a heck of a lot easier then entering data into excel etc.

Edit 01 NOV 2010
Obviously this list isn't all inclusive. Ive been enjoying my other projects and need to do a better job of documenting the older projects.
excel is a tool that is time intensive. i will be spending some time in the near future and list out a complete parts list.

Vegetable Oil Plans

Purchased this 1980 International Scout Diesel that features a naturally aspirated Nissan SD-33 compression engine.

Converted it to run on used cooking oil and am now using it as the daily driver. This blog is going to describe in detail how the conversion was done so that you may be able to do a similar conversion with fewer headaches. Future posts will include an in depth parts list, wiring, and plumbing diagrams.


The fallowing topics will be covered:
- In Tank heat
- Hose in Hose heat
- Valve Selection
- Sourcing and filtering fuel etc
- Recommended Vendors /Parts
-PB Blaster
-SwageLock
-Hydraforce
-Plantdrive.com
-Vegtherm
-Harbor Freight
-Parkrose Hardware (Fancy ACE)
-ETC.

Feel free to ask questions about your conversion.