1988 Mitsubishi Shogun 2.6 HT BBR Turbo
Discussion
t welding on the manifold.. I predict you shall have to use a lot of patience and perseverance in your task 
Hi, I’d like to thank you all again for the encouragement; we are in this for the long haul.
I think that yesterday the BBR restoration reached that critical point where I had to decide that I was fully committed; the list of actual and potential concerns was and is growing each day but I am going to hold on to my original purpose; to bring something rare back to life, to get involved in it’s restoration (despite my limited skills) and ultimately for it to be paired up with this in a classic period tow car & racer combo:
Renault 5 Turbo 1
Anyway, enough of the dreaming, on with the work:
In a bid to clean up the whole intake side of the engine the intercooler is going to be replaced and the air filter and intercooler pipe work is going to be cleaned and painted.
The turbocharger is going to Universal Turbo's to be rebuilt along with T3 that belongs to the 5 Turbo. The exhaust manifold remains a concern and I’m hopeful that we can have it made good. I’m going to wield a spanner again tomorrow & remove the radiator and deliver it for re-coring.
In trying to establish a way forward at the start of this project it became clear that the BBR Shogun had many failed ancillaries and weak points (the current MOT came with 16 advisories) ranging from an unsecured battery to a leaking steering box.
In addition, although the chassis is sound, the bodywork is not, all four doors are rusty and the OSR perforated and the wings & bonnet were in a very poor condition, the photo on page one makes this clear. Trims and mirrors are also missing, the grille badge & rear vent in particular.
Furthermore, the interior is tired, there is no carpet in the boot and in particular all four door panels have large holes where aftermarket speakers have been fitted & removed.
It quickly became apparent that although these items are available at breakers, individually they add up to an enormous cost. So, what do you do when you have one Shogun; obviously you buy another one.
A further eBay purchase, I know, but try finding a cheap/spares/repair Mk1 anyway else, at the bargain price of £300 has netted a Mitsubishi Shogun 3.0 V6 LWB Mk 1.
It is going to resolve a good number of the outstanding issues & will provide a handy backup of easily broken parts such as lights that can be removed and stored before the Shogun is scrapped.
Bonnet & grille, going to lose the V6; perhaps have a BBR Turbo motif made up;
Alloy wheels, period Mk 1 wheels fitted with good tyres & we now have 5 together with a spare wheel cover;
Rear door – all good, especially the door cards;
Front door – as above;
The bumpers are in good condition & it has poly bushed anti roll bar bushes, a proper tow hook and new front shocks and a refurbished steering box. There's even a battery clamp.
Unfortunately not all is good, in fact the chassis is poor (MOT fail) & the at least one of the front wings, which we had wished to use, is toast.
The observant amongst will also of noticed my major fail on this one too; it is not the same shade of blue but for the purposes of this ‘rolling restoration’ I hope you won’t quibble.
I hope that you too are enjoying the ride.
I think that yesterday the BBR restoration reached that critical point where I had to decide that I was fully committed; the list of actual and potential concerns was and is growing each day but I am going to hold on to my original purpose; to bring something rare back to life, to get involved in it’s restoration (despite my limited skills) and ultimately for it to be paired up with this in a classic period tow car & racer combo:
Renault 5 Turbo 1
Anyway, enough of the dreaming, on with the work:
In a bid to clean up the whole intake side of the engine the intercooler is going to be replaced and the air filter and intercooler pipe work is going to be cleaned and painted.
The turbocharger is going to Universal Turbo's to be rebuilt along with T3 that belongs to the 5 Turbo. The exhaust manifold remains a concern and I’m hopeful that we can have it made good. I’m going to wield a spanner again tomorrow & remove the radiator and deliver it for re-coring.
In trying to establish a way forward at the start of this project it became clear that the BBR Shogun had many failed ancillaries and weak points (the current MOT came with 16 advisories) ranging from an unsecured battery to a leaking steering box.
In addition, although the chassis is sound, the bodywork is not, all four doors are rusty and the OSR perforated and the wings & bonnet were in a very poor condition, the photo on page one makes this clear. Trims and mirrors are also missing, the grille badge & rear vent in particular.
Furthermore, the interior is tired, there is no carpet in the boot and in particular all four door panels have large holes where aftermarket speakers have been fitted & removed.
It quickly became apparent that although these items are available at breakers, individually they add up to an enormous cost. So, what do you do when you have one Shogun; obviously you buy another one.
A further eBay purchase, I know, but try finding a cheap/spares/repair Mk1 anyway else, at the bargain price of £300 has netted a Mitsubishi Shogun 3.0 V6 LWB Mk 1.
It is going to resolve a good number of the outstanding issues & will provide a handy backup of easily broken parts such as lights that can be removed and stored before the Shogun is scrapped.
Bonnet & grille, going to lose the V6; perhaps have a BBR Turbo motif made up;
Alloy wheels, period Mk 1 wheels fitted with good tyres & we now have 5 together with a spare wheel cover;
Rear door – all good, especially the door cards;
Front door – as above;
The bumpers are in good condition & it has poly bushed anti roll bar bushes, a proper tow hook and new front shocks and a refurbished steering box. There's even a battery clamp.
Unfortunately not all is good, in fact the chassis is poor (MOT fail) & the at least one of the front wings, which we had wished to use, is toast.
The observant amongst will also of noticed my major fail on this one too; it is not the same shade of blue but for the purposes of this ‘rolling restoration’ I hope you won’t quibble.
I hope that you too are enjoying the ride.
Edited by TurboBlue on Wednesday 21st November 00:44
Hi,
Should be a couple of updates over the course of the next week but just as a teaser here's another BBR brochure picture, this one from circa. 1985; I don't know who did the marketing for BBR but it's not often you see beige/yellow cars in adverts, anyway, enjoy:
The brochure has also cleared up an outstanding question about boost pressure, it appears that the recommendation is for 8 psi or 0.5 bar which I think will be sufficient!
Should be a couple of updates over the course of the next week but just as a teaser here's another BBR brochure picture, this one from circa. 1985; I don't know who did the marketing for BBR but it's not often you see beige/yellow cars in adverts, anyway, enjoy:
The brochure has also cleared up an outstanding question about boost pressure, it appears that the recommendation is for 8 psi or 0.5 bar which I think will be sufficient!
Edited by TurboBlue on Wednesday 21st November 00:35
Hi,
Slowly starting to get the pieces back together:
Picked up the re-cored radiator;
Together with lots of SAMCO in bright blue;
The carburettor plenium, air filter (for which we now have a K&N filter), and intercooler pipe work has been chemically cleaned and blasted with a fine powder by Malmesbury Metal Cleaning. They have done a lovely job and wrapped the steel items in cling film to keep the onset of rust at bay.
I’ve made up my own spray booth to coat them in primer out of a cardboard box and some metal railing from a slide; going to coat them tonight, one side at a time, two hours in between.
I’ve also purchased some of this – seems to be doing the job really well.
I am hoping to get to grips with the V6 to swap the bumpers and remove the wings, so that we can get at the doors but time and the weather has been against me but we may yet get there this week – I also have to set up for this on Saturday; if it’s wet it becomes a complete nightmare and yes that’s me in the smoke.
Regards, Simon
Slowly starting to get the pieces back together:
Picked up the re-cored radiator;
Together with lots of SAMCO in bright blue;
The carburettor plenium, air filter (for which we now have a K&N filter), and intercooler pipe work has been chemically cleaned and blasted with a fine powder by Malmesbury Metal Cleaning. They have done a lovely job and wrapped the steel items in cling film to keep the onset of rust at bay.
I’ve made up my own spray booth to coat them in primer out of a cardboard box and some metal railing from a slide; going to coat them tonight, one side at a time, two hours in between.
I’ve also purchased some of this – seems to be doing the job really well.
I am hoping to get to grips with the V6 to swap the bumpers and remove the wings, so that we can get at the doors but time and the weather has been against me but we may yet get there this week – I also have to set up for this on Saturday; if it’s wet it becomes a complete nightmare and yes that’s me in the smoke.
Regards, Simon
Edited by TurboBlue on Wednesday 21st November 00:16
Edited by TurboBlue on Tuesday 27th November 00:21
Hi,
Started but didn’t finish some stripping work on the V6; swapped the grille’s; removed the side lenses, headlamps to follow (to be saved for replacements), front bumper (to replace the rather tired BBR items) came off but couldn’t get the back one off with two obstructive bolts and a rather short socket handle; I’ve also removed most of the nuts holding the front wings on (so that we can swap over the doors) together with the inner mud guards, but couldn’t free the last couple so that too will have to wait.
This is why the doors have to go;
Here’s a picture of after. Do you like the later Mk 1 grille or do you prefer the earlier slated version; personally I’m inclined to the earlier simpler version but it’s an easy swap and perhaps I’ll keep both! Sorry had to lose the former picture as photobucket keeps loading the unedited version (including reistration mark as this is going to scrap).
The BBR is about two inches lower than the V6 (see the first of the pictures above), taken together with the great s/s down pipe off the turbo/manifold I’m going to put my neck out and suggest that this is the 240 Mogul specification; I’m now quite excited to ask Scott at SG Motorsport to take the head off to confirm but I’m going to have to be patient.
Here’s the turbo boost & the oil pressure gauge’s – lots of little nice touches, shame the sticker has been worn away – 24 years old though.
Having read up a bit more about the truck it appears the LSD was a factory option which has been fitted to the BBR. Both the intercooler & manifold have been sent away for repairs so we are making progress.
Regards
Simon
Started but didn’t finish some stripping work on the V6; swapped the grille’s; removed the side lenses, headlamps to follow (to be saved for replacements), front bumper (to replace the rather tired BBR items) came off but couldn’t get the back one off with two obstructive bolts and a rather short socket handle; I’ve also removed most of the nuts holding the front wings on (so that we can swap over the doors) together with the inner mud guards, but couldn’t free the last couple so that too will have to wait.
This is why the doors have to go;
Here’s a picture of after. Do you like the later Mk 1 grille or do you prefer the earlier slated version; personally I’m inclined to the earlier simpler version but it’s an easy swap and perhaps I’ll keep both! Sorry had to lose the former picture as photobucket keeps loading the unedited version (including reistration mark as this is going to scrap).
The BBR is about two inches lower than the V6 (see the first of the pictures above), taken together with the great s/s down pipe off the turbo/manifold I’m going to put my neck out and suggest that this is the 240 Mogul specification; I’m now quite excited to ask Scott at SG Motorsport to take the head off to confirm but I’m going to have to be patient.
Here’s the turbo boost & the oil pressure gauge’s – lots of little nice touches, shame the sticker has been worn away – 24 years old though.
Having read up a bit more about the truck it appears the LSD was a factory option which has been fitted to the BBR. Both the intercooler & manifold have been sent away for repairs so we are making progress.
Regards
Simon
Edited by TurboBlue on Wednesday 21st November 00:03
jamiebae said:
Heat is your friend when stripping down an old Shogun, I think I emptied an entire butane canister trying to remove the bull-bars from ours!
I hear you but the idea of me & butane next to the fuel (petrol) tank is one no-one in his right mind would recommend; I'm hopeful that a more manly socket arm will remove the offending bolts in short order.TurboBlue said:
jamiebae said:
Heat is your friend when stripping down an old Shogun, I think I emptied an entire butane canister trying to remove the bull-bars from ours!
I hear you but the idea of me & butane next to the fuel (petrol) tank is one no-one in his right mind would recommend; I'm hopeful that a more manly socket arm will remove the offending bolts in short order.jamiebae said:
Targeted heat on the bolt itself should still be fine, even if you are near the fuel tank, as long as you're not blasting the tank itself. Otherwise, a scaffold pole on the end of a breaker bar will hopefully do the job!
Thankyou. I'm very new to this - working on your own car and I'm a bit nervous about getting it wrong - but I am really enjoying it & I have almost the perfect simple vehicle on which to work. I am grateful for your help and encouragement.Edited by TurboBlue on Friday 2nd November 21:12
Great progress Simon. Like the improvised spray booth. I think the replacement pipe system will look great, must view that for B. Glad the donor is providing what's neded. Very encouraging to see the progress so far stay focused and this is going to be a great project. On the bolts etc I found a bit of planning is well rewarded by soaking in WD40 days ahead every time you get the opportunity. Most wil not have moved since new and so will need every bit of help. Havering to drill out and re-tap is a pain so the effort is worth it. I have use heat as above and found that helpful. But as every the WD40 is a winner.
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