On-board Air for 4.8 GRX

Vehicle modifications/repairs/rebuilds
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Bruin Beer
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On-board Air for 4.8 GRX

Post by Bruin Beer » 18 Dec 2013 20:35

Well,
Read up allot on on-board air systems and watching multiple related YouTube video's.
After obtaining an second hand air conditioner pump, gathered for an on-board air system I intended to fit to a Willys CJ2A I had back in the day, I finally have a proper troll which would not be to bothered about the additional added wait. (Spesiaal paar prentjies vir Oom Mac)
1.jpg
New pump
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2.jpg
New pump
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I also wanted to add a reservoir to add some volume (if required).
I obtained the following Helium Filter. What I liked about this tank is that it is stainless steal so rust might be a little less of an issue.
The filter material was removed and the tank re-welded together. After welding I had the tank pressure tested to 30 Barr just to be 100% sure and if possible I would like to push the system air pressure a little higher to increase the stored air volume.
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Compressed Air Tank
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First trick was to determine the optimal place which would incur the minimal modifications and changes to the current set-up and configuration.
I decided to remove the current air conditioner pump bracket and tensioner and design a new bracket which would mount the current air conditioner pump higher up on the side of the engine opening enough space below this pump to allow me to fit the second pump to be used as the air compressor.
This design took more that 6 months as I am a mechanically minded electronic person. I first had to get to grips with the design package but managed to design the following replacement mounting bracket. :redface:
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Replacement Bracket with new tensioner
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The next picture indicate the test installation to optimize the pump alignment and ensure the new, longer replacement multi groove belt is tracking correctly.
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Both Pumps Installed
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Next would be to complete the plumbing into the back of the Trol.
I will update this tread as it progress.
Hope to get this along quicker than it started off. :thumbup:
Cant wait to run the pump and check the air delivery of the system. :pray:
If all go well I would end this of with a short video indicating the installation and operation.
Bruin Beer

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Re: On-board Air for 4.8 GRX

Post by DawidT » 19 Dec 2013 07:16

Hi daar Bruin Beer,

You are doing something I wanted to do a while ago but never had the guts to do it :clap: I have a pump and a GRX but after opening the bonnet I decided to let go of the plan - waar pas jy daai ding in!!! :surprised: . I am certainly looking forward to your final video :thumbup: - great job :salute:

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Re: On-board Air for 4.8 GRX

Post by Clem » 19 Dec 2013 09:36

Excellent! I have a York compressor and maybe one day I will be able to get someone to fit it for me too (I'm not as handy as you are with these things!). On the other hand, I do have a decent electrical compressor too...

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Re: On-board Air for 4.8 GRX

Post by Bruin Beer » 19 Dec 2013 18:19

David,
Ek skuif die bestaande pomp hoer op en sit die nuwe pomp reg onder die bestaande pomp.
Dit is maar 'n 'tigh fit' maar ek glo is nog steeds prakties.
Hoop dit gaan so goed werk soos ek verwag.

Clem,
I am not familiar with the York Pump.
Does it look similar to the NiptonDenso pump in my pictures?
I tried to keep modifications to a minimum to se if it would be possible to have this as a DIY bolt on.
The new mounting bracket would/might have to be customized for the different pumps but for the rest it should be fairly straight forward.
I will keep you posted.

Bruin Beer

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Re: On-board Air for 4.8 GRX

Post by Clem » 19 Dec 2013 19:16

Bruin Beer, similar in appearance but its a piston unit. Gives every good flows and pressures.

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Re: On-board Air for 4.8 GRX

Post by Bruin Beer » 23 Dec 2013 21:22

Ok,
Pump is fitted.
Had to adjust the tensioner again after initial fit.
This meant strip all again for re-alignment.
Fortunately this time all work 100%.
The pump is fitted and today the tank was also installed with the pressure hose routed from the pump to the tank.
Was able to manually test the system as the pressure switch and internal switch still have to be obtained.
Pump is running nice and quiet and with both pump and AC running the 4.8 is still wandering if anything changed. The motor does not even flinch.
With the engine idling at +- 900 RPM (Cold Start) I was able to pump the 4.3 Litre tank to 150 PSI (6Barr) in roughly 40 to 50 seconds.
I will do a proper time check when all is in.
Hose to the load bin will go in tomorrow and then have to obtain another regulator/water trap to be fitted in the back at the compressed air port.
Will post some more pictures tomorrow of the current installation.
Bruin Beer

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Re: On-board Air for 4.8 GRX

Post by Tinus lotz » 24 Dec 2013 06:26

Very cool man :blonde:
We did a similar one on a suzuki jeep in the days before 12v air compressors. We used a casper aircon pump a frige pressure switch and 2 10l scuba tanks.....we were able to pull 2 spray guns on it and it still switched on and off . We were a big hit In the henties area because all the guys use to follow us fishing so that they could get their tires pumped .
You are braver than me to fit it to the 4.8 didn't think that their was space ........cant wait for the pics of the finished product
:salute:

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Re: On-board Air for 4.8 GRX

Post by Bruin Beer » 06 Jan 2014 19:02

Guys,
A short video indicating that the 4.3 Litre tank is pumped to 8 Bar in 18 seconds.
The switch indicate 10 Bar but kicks out at 8 Bar. I will push it up a little.

[BBvideo 425,350]http://www.youtube.com/watch?v=9LZOEql8HvE[/BBvideo]

Hope this work.
Bruin Beer

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Re: On-board Air for 4.8 GRX

Post by Chris Skinner » 07 Jan 2014 06:57

Hi Beer, this looks awesome - I would really like to do such a mod. Just need to find a place to source the hardware....
What is the volume of the tank, and, without engine running is it enoough to pump a couple of tyres up from flat?

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Re: On-board Air for 4.8 GRX

Post by Bruin Beer » 08 Jan 2014 17:06

Chris,
According to my calculations the volume of a 33" is 123.5 Litre.
I have a 4.3 Litre tank.
This alone would not be able to inflate a completely flat 33" without engine running.
My gut feel would be you would require a +- 160 Litre tank pumped to 10 Bar to be able to inflate 4 x 33" tyres to 2.5Bar.
Somebody might have to double check my calculations.
Hope this helps.
Breen Beer

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