Fitting a Cummins 6BT engine to a Zil-131.

We've been asked a few times about more details on the DAF/Zil engine swap.
There was a lot of video kicking around that hadn't made it into the Project Awesome playlist on Max's channel, so I've edited the good bits together into some more detailed videos for those who want to know more of the gory details!
Here you'll find a full description of Max's engine template and the various modifications that were necessary to fit the Cummins engine into the ZIl.

[@edgeeffect]

When Max says "their approach to engineering is very different to ours... 'better' is probably the word"... that's when I know I'm definitely in the right place here.

[@Pete.Ty1]

Just wanted to say thanks. After your reference to Project Binky I had a look at their channel, and as you stated they are brilliant, and I have now subscribed.

[@stevek3036]

Looking forward to how Awesome progresses. Great work. More please

[@zabdas83]

Truly truly truly. . . This channel is awesome and you sir are the salt of the earth. God bless you brother, and thank you for sharing. . .

[@rangerismine]

Great job bud, that is gonna be an awesome truck!

[@peteryeates6624]

Good vid. I am doing the same to my ZIL. I have a 6 speed box on mine and also havent quite figured out how to change the gear selector but I am toying with the idea of cobbling up some kind of cable shift arrangement. I cut away most of the Zil front crossmember then welded plates into the chassis and used the daf mounts and made up a new crossmember of my own. I've got a 12v starter from a Case 5150 tractor on mine. Works a treat as all the other Zill electric are also 12v. Better than running a dual voltage system imo.

[@MrTrevithick]

Brilliant

[@stephenmurphy4717]

Great work lads. I have a zil itch I need to scratch but it’ll be a few years. Are there any forums on zil builds that you might know of? Thanks from Ireland. Stephen

[@BrianM0OAB]

I do prefer the longer more detailed video's.

[@spungletrumpet]

We've got a lot of footage, but most of it is pretty dull. I'm all up for putting more of it on here, hopefully we'll have more to share soon! 73 DE M0MTT. ;)

[@BrianM0OAB]

@@spungletrumpet I can't see the harm in putting up the extra footage even if it is dull, the short attention span viewers don't have to watch it all if they so wish too, as for me I find it interesting and entertaining. 73 88's from both OAB's now off to qrz to check your station out :)

[@GaffLife]

Thank you for posting! I was looking for more info on engine swaps in a Zil. Unfortunately my Russian is terrible, though I'm learning. The Cummins would be my second choice of engine, albeit it's an excellent engine. My first choice is a Deutz, either the straight 6 turbo or the non turbo V6. Can't beat an indistructable aircooled diesel👌.

[@joostfarries5690]

Hi, did you get going with the engine swap in the Zil? I put a Deutz engine in mine, I could share some experience with you

[@GaffLife]

​@@joostfarries5690 I never bought the Zil, I bought a big sailboat instead😂. You fitted a Deutz? Which one? I think they would be an excellent engine for in a Zil. Which gearbox/transferbox did you use?

[@joostfarries5690]

@@GaffLife A boat is cool too. I have a BF6L913T with 135hp in mine. It was in a Iveco 80-13 before. I used the Deutz Transmission and adapted the gearshift. The Transfer Box is the zil original.

[@GaffLife]

​@@joostfarries5690 Very nice! What is it like to drive now? Quieter? Less revs I assume. Better fuel consumption?

[@joostfarries5690]

@@GaffLife It is pretty awesome to drive! The project is still far from finished, I Just made the first test drive last week. That was without muffler... Loud but awesome! I Upload some Clips later. Still have to do electrics and a Lot of other Things. Hope to Finish it in spring next year.

[@erikthekippa]

Hi any update about the project ?

[@jonnoMoto]

Nice work! Is there a difference in ratios between the DAF and zil box?

[@spungletrumpet]

As far as I remember, both gearboxes give a 1:1 in top gear. But the DAF engine is lower revving so we'll end up with a top speed of around 45Mph. Though, as Max keeps saying, with the rather delicate and fiddly load we'll have on the back of it we probably wouldn't want to be going much faster!

[@jonnoMoto]

@@spungletrumpetlet me know when you're out on the roads so I can avoid the queues. 😁

[@pitmoleuk]

@@spungletrumpet I'm just down the road from you, and am just popping a cummins into a Sumb military truck from the 60's. you should find that your gearbox has an overdrive 5th gear 0.77 to 1, so you might manage 50 mph! :)

[@pitmoleuk]

spungletrumpet don't suppose you still have the old Daf gear mech do you? I have a direct fit gear selector from a dodge truck

[@Helloverlord]

How do you plan to balance that inter-shaft after cutting/welding it?

[@spungletrumpet]

Many plans have been discussed, from rigging up the lathe with a bunch of accelerometers and microcontrollers to actually taking it to someone who knows what they are doing. I think a lot will depend on how bad it is, and how much vibration we get with the low RPM.

[@Helloverlord]

I did it few times (modify a shaft) and if not taken seriuosly (balancing) it always end up as nightmare, replacing cross joints at every petrol station, also it will affect exit roller bearing in daf gearbox and eventually destroying it. ZIL tranferbox bearing is overengineered anyway. At first I balanced mine in agricultural workshop at slow rpm balancer (100-200rpm) and it didnt turn up well but when done at 3000rpm in proper shop it lasted...for some time :D. It doesnt matter if the shaft is at much lower rpm (engine gives 2500rpm so gb output is like 600-2000rpm). Microcontrollers? :D by mounting magnetic pickup and to monitor oscillation? You got a assembler based uPIC colleague talking here...nice project, I see myself there as I did pretty much the same...

[@troyboy4345]

Fitting an internal pipe/sleeve insert, {interference fit} will reduce the connection issues, just the welding needs to be spot on, the low revs shouldnt really effect it, if hes just plodding around in it.

[@lefzer7713]

you should have paint the internal before placing the engine...i think

[@glaid20century19]

Where's next videos?

[@spungletrumpet]

We have been working on lots of other stuff. But there should be some new content very soon!

[@breastman60]

A 5.9 cummins would fit in the old engine space.

[@spungletrumpet]

Yes. I think you might be right.