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<blockquote data-quote="ChrisCo" data-source="post: 1559105" data-attributes="member: 18105"><p>Now to get it attached to the engine... There was a mounting bracket of some sort already in place (I'm guessing it was for the stock A/C compressor), so decided to I use it as the attachment point. I lopped of a couple of short pieces of angle iron, and drilled 3/8" holes in 'em... Test fit:</p><p></p><p><img src="http://chrisco.texas-222.com/20090315/MountingEarsStep1.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>After several more test fits, I ended up with:</p><p></p><p><img src="http://chrisco.texas-222.com/20090315/MoutingEarsStep2.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>There wasn't a whole lot of metal to connect the angle to the mount, so I added a gusset for a little extra strength:</p><p></p><p><img src="http://chrisco.texas-222.com/20090315/MoutingEarsStep3.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>----</p><p></p><p>I wanted to avoid getting a custom high pressure line made up, so my original plan was to relocate the alternator from the driver's side over to the passenger's side, then mount the PS pump in the alternator's stock location. After pulling the alternator, fenagling with it a little while, fenagling some more, having lunch, looking at it a bit more...you get the point... After an hour or two of dinking with it, I wasn't sold on the idea of relocating the alternator... I decided to see if I could reshape the contortion of tubing they call the stock power steering line:</p><p></p><p><img src="http://chrisco.texas-222.com/20090315/StockPSLine.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>If I break it in the process -- no big deal. At this point, I'm expecting to get a new one made up anyhow. After about 15 minutes of careful use of a hand held tube bender, I ended up with this:</p><p></p><p><img src="http://chrisco.texas-222.com/20090315/StockPSLineStraightened.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>That wasn't as bad as I'd expected. OK, the alternator can stay in it's current location...so, back in it goes... Next up was to spend some time figuring out the best routing. This is what I came up with:</p><p></p><p><img src="http://chrisco.texas-222.com/20090315/PSLineRouting1.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Now to figure out how the heck I'm going to mount the pump (which was the whole point to working out in the shop this weekend to begin with :lol: ) I had an idea of how I'd wanted to do it (clearly, up on top of the York), but I was a bit concerned about the clearance between pulley and the radiator hose. After a little more looking, fenagling, thinking, stoking the wood stove, etc, etc, etc... I had an idea of how I wanted to do it. Scooting the pump out away from the engine just a little would allow me so use the PS pump to tension the belt, and still allow for plenty of room for the hose.</p><p></p><p>Next, I moved on to the actual mount itself. The mouting holes on the front of the pump are on the same plane, but they're not on the back... I wasn't looking forward to trying to figure out how to bend a plate of steel to the perfect shape to fit the back of the pump...then it dawned on me -- Toyota has already done that for me! So, I grabbed the stock mouting bracketry, and chopped off the front and back sides of the mount.</p><p></p><p>The front side of the bracket had some bends in it to make the pulley align correctly. I didn't need these bends, so I used my 20 ton press to flatten out the plate. After some creative cutting, I ended up with an almost tear-drop shaped bracket for the front. Sorry, I didn't stop to grab any pics, but I'd be happy to snap some later, if anyone needs 'em.</p><p></p><p>For the back, I (again) used the stock bracketry, but I had to do a little more work in order to be able to use it... I had a problem in that the back of the bracket was (I'm guessing for alignment purposes) was shorter than the front side...so, it was about 1.5-2" too short to use. Still not wanting to figure out how to bend any steel to match the contours of the bracket and/or pump, I decided to not bend anything . Instead, I tacked a small piece of angle iron on the bottom, and gained all of the extra length I needed:</p><p></p><p><img src="http://chrisco.texas-222.com/20090315/PSPumpBackMount1.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>After a little welding, drilling, and cleanup, I ended up with:</p><p></p><p><img src="http://chrisco.texas-222.com/20090315/PSPumpBackMount2.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p></p><p><img src="http://chrisco.texas-222.com/20090315/PSPumpBackMount3.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>I made up some mounting ears that I then welded to the top plate of the York mount... I didn't get any pictures these either, as I was trying to get as much done as possible today... Again, I can get some later -- and I probably will when I take it all part for paint anyhow...</p><p></p><p><em>EDIT: Here's pics of the front and back plates for the power steering pump mount:</em></p><p><em></em></p><p><em><img src="http://chrisco.texas-222.com/20090321/PSPumpMounts.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></em></p><p><em></em></p><p><em>The piece on the right if the front plate, and the left is the back plate.</em></p><p>I then mounted up the power steering reservoir, and dry-fit everything in their proper places:</p><p></p><p><img src="http://chrisco.texas-222.com/20090315/PSPumpMockup.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>I'm still not 100% convinced that I like how the high pressure line ended up (it may get reworked). I also still need to figure out how I'm going to work the tentioning device... If I can find one, I'll pick up a turnbuckle, and just use that (makes life super-simple for tentioning <img src="data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7" class="smilie smilie--sprite smilie--sprite8" alt=":D" title="Big Grin :D" loading="lazy" data-shortname=":D" />). If not, I'll have to figure something out. </p><p></p><p>I'm hoping to have fully functioning power steering (and partially functioning OBA) by the end of next weekend. I still need to go measure for, and pick up a belt for the York and PS setup, too...</p><p></p><p>----</p><p></p><p>I'm not sure how, but I spent all day out in the shop (minus a somewhat quick trip to Monroe), and it seems like I got hardly anything done <img src="data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7" class="smilie smilie--sprite smilie--sprite3" alt=":(" title="Frown :(" loading="lazy" data-shortname=":(" /> I did manage to get a belt that fit, and got everything installed for the last time...for a while.</p><p></p><p><img src="http://chrisco.texas-222.com/20090321/PSPumpAndYorkInstalled.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>I didn't like the clearance between the PS pulley and the radiator, so I reworked the pivot point for the PS pump just a bit... Between the rework, and trading for a belt that was 2" longer, I've got plenty of room between the pulley and the hose now.</p><p></p><p>...but, I may have another problem... The new reworked pivot point was about an inch lower. Between that, and the longer belt, the pump swings way farther out than it did before...resulting in very little belt contact on the York <img src="data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7" class="smilie smilie--sprite smilie--sprite3" alt=":(" title="Frown :(" loading="lazy" data-shortname=":(" /></p><p></p><p><img src="http://chrisco.texas-222.com/20090321/YorkVeryLittleBelt.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>I'm hoping that it's not going to be a problem... I guess I'll find out when I get the York all plumbed in. If it's going to be a problem, I expect it'll be after it's built up a little pressure.</p><p></p><p>I forgot to grab a transmission cooler while I was in town today, so I'll probably run into town and grab one tomorrow... I'll get it plumbed in, and get the reservoir setup in it's new location (I didn't like where it was).</p><p></p><p></p><p>----</p><p></p><p>WOO-HOO! Power steering at last!</p><p></p><p>I looked all over the place for 3 1/2" exhaust tubing last week, but couldn't find any <img src="data:image/gif;base64,R0lGODlhAQABAIAAAAAAAP///yH5BAEAAAAALAAAAAABAAEAAAIBRAA7" class="smilie smilie--sprite smilie--sprite3" alt=":(" title="Frown :(" loading="lazy" data-shortname=":(" /> I ended up stopping by Homeless Depot, and picked up a sheet of metal (I forget what gauge -- it's about 1/16" thick).</p><p></p><p>First step: Figure out the dimensions... The PS reservior was 3 5/8" around (or something like that), and the R=Dxpi (or, in this case, length of cut = 3 3/8" x 3.14) worked out to just under 13". I wanted to extend the reservior by about 5 inches, so I marked a 13x5" block to cut out of the sheet metal:</p><p></p><p><img src="http://chrisco.texas-222.com/20090401/SheetMetalMarkedForCut.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>Next up, chop the stock reservior in half. I randomly chose a cut point. OK, not so randomly. I chose a point that'd leave me with plenty of overlap between the stock reservoir and extension... Here's the cut:</p><p></p><p><img src="http://chrisco.texas-222.com/20090401/PSResMarked.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p><img src="http://chrisco.texas-222.com/20090401/PSResCut.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>...and, in the interest of getting something done... fast forward an hour or so, and you end up with this:</p><p></p><p><img src="http://chrisco.texas-222.com/20090401/NewPSResMounted.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>...zoomed out...</p><p></p><p><img src="http://chrisco.texas-222.com/20090401/NewPSResMounted2.jpg" alt="" class="fr-fic fr-dii fr-draggable " style="" /></p><p></p><p>I also replaced the 52+" belt with a slightly shorter one (a shade over 51")...</p><p></p><p>I still need to bleed the system...but it's already better than before :rockon:</p></blockquote><p></p>
[QUOTE="ChrisCo, post: 1559105, member: 18105"] Now to get it attached to the engine... There was a mounting bracket of some sort already in place (I'm guessing it was for the stock A/C compressor), so decided to I use it as the attachment point. I lopped of a couple of short pieces of angle iron, and drilled 3/8" holes in 'em... Test fit: [IMG]http://chrisco.texas-222.com/20090315/MountingEarsStep1.jpg[/IMG] After several more test fits, I ended up with: [IMG]http://chrisco.texas-222.com/20090315/MoutingEarsStep2.jpg[/IMG] There wasn't a whole lot of metal to connect the angle to the mount, so I added a gusset for a little extra strength: [IMG]http://chrisco.texas-222.com/20090315/MoutingEarsStep3.jpg[/IMG] ---- I wanted to avoid getting a custom high pressure line made up, so my original plan was to relocate the alternator from the driver's side over to the passenger's side, then mount the PS pump in the alternator's stock location. After pulling the alternator, fenagling with it a little while, fenagling some more, having lunch, looking at it a bit more...you get the point... After an hour or two of dinking with it, I wasn't sold on the idea of relocating the alternator... I decided to see if I could reshape the contortion of tubing they call the stock power steering line: [IMG]http://chrisco.texas-222.com/20090315/StockPSLine.jpg[/IMG] If I break it in the process -- no big deal. At this point, I'm expecting to get a new one made up anyhow. After about 15 minutes of careful use of a hand held tube bender, I ended up with this: [IMG]http://chrisco.texas-222.com/20090315/StockPSLineStraightened.jpg[/IMG] That wasn't as bad as I'd expected. OK, the alternator can stay in it's current location...so, back in it goes... Next up was to spend some time figuring out the best routing. This is what I came up with: [IMG]http://chrisco.texas-222.com/20090315/PSLineRouting1.jpg[/IMG] Now to figure out how the heck I'm going to mount the pump (which was the whole point to working out in the shop this weekend to begin with :lol: ) I had an idea of how I'd wanted to do it (clearly, up on top of the York), but I was a bit concerned about the clearance between pulley and the radiator hose. After a little more looking, fenagling, thinking, stoking the wood stove, etc, etc, etc... I had an idea of how I wanted to do it. Scooting the pump out away from the engine just a little would allow me so use the PS pump to tension the belt, and still allow for plenty of room for the hose. Next, I moved on to the actual mount itself. The mouting holes on the front of the pump are on the same plane, but they're not on the back... I wasn't looking forward to trying to figure out how to bend a plate of steel to the perfect shape to fit the back of the pump...then it dawned on me -- Toyota has already done that for me! So, I grabbed the stock mouting bracketry, and chopped off the front and back sides of the mount. The front side of the bracket had some bends in it to make the pulley align correctly. I didn't need these bends, so I used my 20 ton press to flatten out the plate. After some creative cutting, I ended up with an almost tear-drop shaped bracket for the front. Sorry, I didn't stop to grab any pics, but I'd be happy to snap some later, if anyone needs 'em. For the back, I (again) used the stock bracketry, but I had to do a little more work in order to be able to use it... I had a problem in that the back of the bracket was (I'm guessing for alignment purposes) was shorter than the front side...so, it was about 1.5-2" too short to use. Still not wanting to figure out how to bend any steel to match the contours of the bracket and/or pump, I decided to not bend anything . Instead, I tacked a small piece of angle iron on the bottom, and gained all of the extra length I needed: [IMG]http://chrisco.texas-222.com/20090315/PSPumpBackMount1.jpg[/IMG] After a little welding, drilling, and cleanup, I ended up with: [IMG]http://chrisco.texas-222.com/20090315/PSPumpBackMount2.jpg[/IMG] [IMG]http://chrisco.texas-222.com/20090315/PSPumpBackMount3.jpg[/IMG] I made up some mounting ears that I then welded to the top plate of the York mount... I didn't get any pictures these either, as I was trying to get as much done as possible today... Again, I can get some later -- and I probably will when I take it all part for paint anyhow... [I]EDIT: Here's pics of the front and back plates for the power steering pump mount: [IMG]http://chrisco.texas-222.com/20090321/PSPumpMounts.jpg[/IMG] The piece on the right if the front plate, and the left is the back plate.[/I] I then mounted up the power steering reservoir, and dry-fit everything in their proper places: [IMG]http://chrisco.texas-222.com/20090315/PSPumpMockup.jpg[/IMG] I'm still not 100% convinced that I like how the high pressure line ended up (it may get reworked). I also still need to figure out how I'm going to work the tentioning device... If I can find one, I'll pick up a turnbuckle, and just use that (makes life super-simple for tentioning :D). If not, I'll have to figure something out. I'm hoping to have fully functioning power steering (and partially functioning OBA) by the end of next weekend. I still need to go measure for, and pick up a belt for the York and PS setup, too... ---- I'm not sure how, but I spent all day out in the shop (minus a somewhat quick trip to Monroe), and it seems like I got hardly anything done :( I did manage to get a belt that fit, and got everything installed for the last time...for a while. [IMG]http://chrisco.texas-222.com/20090321/PSPumpAndYorkInstalled.jpg[/IMG] I didn't like the clearance between the PS pulley and the radiator, so I reworked the pivot point for the PS pump just a bit... Between the rework, and trading for a belt that was 2" longer, I've got plenty of room between the pulley and the hose now. ...but, I may have another problem... The new reworked pivot point was about an inch lower. Between that, and the longer belt, the pump swings way farther out than it did before...resulting in very little belt contact on the York :( [IMG]http://chrisco.texas-222.com/20090321/YorkVeryLittleBelt.jpg[/IMG] I'm hoping that it's not going to be a problem... I guess I'll find out when I get the York all plumbed in. If it's going to be a problem, I expect it'll be after it's built up a little pressure. I forgot to grab a transmission cooler while I was in town today, so I'll probably run into town and grab one tomorrow... I'll get it plumbed in, and get the reservoir setup in it's new location (I didn't like where it was). ---- WOO-HOO! Power steering at last! I looked all over the place for 3 1/2" exhaust tubing last week, but couldn't find any :( I ended up stopping by Homeless Depot, and picked up a sheet of metal (I forget what gauge -- it's about 1/16" thick). First step: Figure out the dimensions... The PS reservior was 3 5/8" around (or something like that), and the R=Dxpi (or, in this case, length of cut = 3 3/8" x 3.14) worked out to just under 13". I wanted to extend the reservior by about 5 inches, so I marked a 13x5" block to cut out of the sheet metal: [img]http://chrisco.texas-222.com/20090401/SheetMetalMarkedForCut.jpg[/img] Next up, chop the stock reservior in half. I randomly chose a cut point. OK, not so randomly. I chose a point that'd leave me with plenty of overlap between the stock reservoir and extension... Here's the cut: [img]http://chrisco.texas-222.com/20090401/PSResMarked.jpg[/img] [img]http://chrisco.texas-222.com/20090401/PSResCut.jpg[/img] ...and, in the interest of getting something done... fast forward an hour or so, and you end up with this: [img]http://chrisco.texas-222.com/20090401/NewPSResMounted.jpg[/img] ...zoomed out... [img]http://chrisco.texas-222.com/20090401/NewPSResMounted2.jpg[/img] I also replaced the 52+" belt with a slightly shorter one (a shade over 51")... I still need to bleed the system...but it's already better than before :rockon: [/QUOTE]
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