12v Excursion Redo

[DCreed]

You have the 3B mounted a lot further back than what it would be in a Dodge, I'm figuring the engine mounts are in the way? Also remember you can cut off the extra comp inlet length of the 3B, about an inch or so. I'm also going to figure the spacer plate is undivided? You may also want to port the center divider in the manifold to more equally vent the ex. WG.

 

[therabbittree]

I had to work the turbo outlet flange. It flows well now. I plan to ramp the wastegate area into the hot pipe too.

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I blended in the big turbo turbine inlet of the hot pipe. .

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started working the hot pipe around the wastegate head and hopefully clear the A/C

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Tommarrow I'm off and I'll try to fit the setup into theexcursion before i finish th ehotpipe. . I'm nervous about hitting the firewall witht e hot pipe flange and the rear A/c Lines are real close there. . I may have to re route them . . mummn. . also th ebig turbos outlet is gonna be super close to the pass motor mount . . I may have to cut it off and have some one aluminum weld a bend there. . mummn . .

 

[therabbittree]

The big turbo is pretty tight to the engine

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Oh well see if it fits tommarrow.

Thanks

Deo

 

[Shadrach]

Pardon the dumb question, but wouldn't it be a lot less hassle using a single turbo? ( I have my bullet proof vest on so go ahead shoot ) Shadrach

 

[DCreed]

Pardon the dumb question, but wouldn't it be a lot less hassle using a single turbo? ( I have my bullet proof vest on so go ahead shoot ) Shadrach

Obviously easier, but He already had a single and wants the response AND top end that just isnt available in a single.

 

[therabbittree]

ha I like the vest comment. . I still have mine on now too. . ha I got to get out of the uniform and get to bed. . ha..... plus i already had these turbos . . a big nice single is $ and Im outta it ($) . . ha. . other wise i wouldn't be trying to use a ht3b style or a hybrid hx50 etc. . its a bunch of stuff i have. . I almost used a hx55 as the big turbo ha. . till Dcreed talked me outta that... Yeah carl the the Motor mounts are in the way. . the a/c is in the way too argh. . I yearn so much for my first gen engine bay after playing with this project ha. . and it still not as tight as a powerstroke ha. . thats scary. oh well, worst case scenario is just using the hx50 modified to a 9cm turbine, over the 6cm it currently has. . thats the worst case. . at least the 9cm housing may let it last longer then the 6cm . . I;ll know some time tommarrow if the wins will fit the way i started. . oh well.

Thanks,

Deo

 

[Shadrach]

If anyone can do then you can. Shadrach

 

[therabbittree]

Well I test fit it and it won't fit argh... . so I got thinking about doing it as just single ... . Then I had a idea of doing it upside down and backwards ha. . Some of the recent twin setups have been that way. . ie have the small turbo under the exhaust manifold with the ex manifold flipped down. . The small turbo would be backwards the compressor facing the fire wall, and the turbine the front of the truck. Then I'd mount the ht3b up top, with the hot pipe a short 90 degree bend... . I took some pictures of the ht3b sitting on top resting - ie not placed well, and it seems like it may work. The high pressure (small turbo outlet to intercooler ) would have to snake out and around the outside of the shock tower and to the intercooler. ( one of the Superduty ford guys did that in McCallies twins Thread) The big turbo compresser outlet would go down under the small turbo and do a 180 into the small turbo compressor inlet. The 5" exhuast would go straight back and down over the small turbo. . Since I am running 4" exhaust under the truck, and a 4" remote mount Exhaust brake, I may go from 5"turbo outlet to 4" immediately after the ht3b outlet to make the clearance easier. As for the waste gate issue... mummn I could pop the ats manifold apart and keep the wastegate in the back and either run the 1 1/4" pipe back along the top of the exhuast manifold and down into the hotpipe or just make the wastegate port into the down pipe. . any ideas????. .

Here are some pictures of the ideas:

NOT FITTING!

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If I just did a Single Turbo...

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Flipping it upside down and backwards. .

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Thanks

Deo

 

[therabbittree]

I think this will work the best. . might make taking the oil filter off a pain. . or I could do a remote oil filter setup like Hdroken (sp?) is doing. I may even do a Sledpuller did, and run a big canister air filter out front a under the bumper or inside a custom front bumper... . mummn I may have to modify the alternator mount too. . so I can get a boot and clamp in there. . as it just clears the under hood insulation withthe hood shut. . a turbo turbine heat blanket is in order...

What do you people think?

Thanks

Deo

 

[DCreed]

Deo, I think that can work if you rotate the 3B counter clockwise and push it out to the pass side as much as possible. going to be some tight bends to get it in though, esp. the hot pipe! Wish you were closer, I love to do this stuff!!

 

[therabbittree]

yeah I ended up getting it started the hot pipe is almost a 95" turn its tight and withthe hy waste gate port access its almost a box ha. . I ended up angelling teh ht3b so the whole turbo is pointing toward the passenger headlight at a angle. . I tack welded some scrap tabs to get the spacing correct for the flange and hot pipe, and took it apartto fab. I also ended up using my small spacer on the hy to let it hang down a little more and have more room up top. . I will post some pictures tommorrow. The big turbo does look pretty neat up top and angled . . ha. . not sure if should polish the compressor housing or smooth it and paint it the cummins beige . / tan?. . the tan seems to be the way I'm leaning... what do you think I should do wastegate my twins to the hot pipe or the down pipe . . or just use the hy wastegate?

tommarrow is going rain so I probably won't get much done as welding and grinding / cutting in my messy garage is not too fun. . its on my to do list and its getting worst and the list ois growing ha.

Thanks,

Deo

 

[therabbittree]

The hot pipe is a really tight 90 degree bend. I have been smoothing the inside of the manifold as I weld it up. . I broke my rotary mill / file last nighty, and will have to weld a longer shaft to it to continue. . but its a must do. . Also the cumins remote oil filter setup is looking really nice as the filter is going to be tight to remove and intall, I already wanted to redo the A/c hoses and I will be doing that too. Any one know how hard it is toi separate the ats manifold and re install the end pieces?. . is there any packing in there?... I have to swap the end I welded the waste gate flange on to . . argh. No consensis on waste get going back to hot pipe or into down pipe? Here are some pictures so far.

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I have to bend the wastegate bracket a little about 1/4" it doesn't touch now but it may under engine movement...

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final position

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welding and smoothing the flanges / hotpipe

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It looks a little strange be cause instead of a regular 90 degree elbow I had opened the small turbo flange to allow the waste gate gases to vent in to the big flange. . hopefully my modifed rotary mill / file will reach inside well enough to smooth the final welds

Thanks

deo

 

[DCreed]

can you still get all the bolts in there?

 

[therabbittree]

yup thats way its cocked kinda funny. . ha. . oil filter may need the cold pipes removed to reach it though. .

 

[therabbittree]

I worked on the hotpipe and smoothed it out inside. My Home modifed / lengthned rotary file worked nicely. I also had to swap my ats manifold ends. . Thanks chris & Jim for the "how to" advice. . heated the center section up and the ends were tapped out. . and cooled in water. . the center was then bolted up to my spare head and reheated up. . then put the cold end pieces in and bolted them up and let it cool down over night. . worked great. got a bunch of studs, bolts, and washers. retapped all the thread holes and mounted it up on my spare engine. . I have to fab the exhaust down pipe, The wastegate piping, and the intermediate pipe from big to small charge air. I hope my friends dad can get the 9cm turbine finished soon then we have to weld it and tap it to bolt the wastegate bracket arm onto it etc. .

Here are some pictures.

smoothed it out pretty nice inside...

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Thanks,

Deo

 

[therabbittree]

After sorting this Twin setup , I have this to do LIST :-laf:

- Finish neatening up front wiring and reinstall front clip. Possibly change to XL work truck style headlights or '05 and up black harley stle lights...

- Change balljoints to new Moogs.

- Lengthen front Driveshaft.

- Shorten rear Driveshaft.

- Install stainless flexible brakelines, and bleed em.

- Get upgraded Southbend clutch slave cyl, and install.

- decide if I keep the modified T code front leaf springs or get v or x codes. . any one have any?

- Buy & install the modified Bilstein shocks from CaryT of the Diesel Stop Web forum. Going with 4 in the front and two in the rear

- Buy and install the Helwig or Ford 30 mm rear sway bar.

- Reinstall my modified rear track / ladder bars.

- Figure out why speedo is not working...

- Fabricate new A/C lines, and install a new dryer.

- Fix front blower motor resistor.

- Hook up cruise control.

- Swap in Manual trans instrument cluster, & remove column shifter.

- Fabricate 5" to 4" down pipe.

- Install 4" remote BD Exhaust brake and its electric air compressor.

- Mount and plumb air supply reserve tank. Plumb some remote fill / dischrage air chucks, & maybe some air horns.

- Fabricate removable transmission tunnel hump.

- Install new vinyl floor.

- Reinstall tan leather seats. . maybe install two tone leather heated seats if I can find a good deal on some.

- figure out the stereo's illumination wire issue. or install another stereo.

- Fabricate a steel plate front bumper. bumper will have deer protection built in. Bumper may house air cleaner, winshield washer tank,and possibly a water meth storage tank.

- Fabricate a steel plate rear bumper, with a swing out external tire carrier. or buy one from Cross Engineering.

- Fabricate steel side steps. planning on 2x4 or 2x6 side steps that attach to the frame and are assisted by drop dwon brackets from the stock rocker panel bolt holes.

- Fabricate a rear storage compartment fold up storage area. . for behind the rear seat. also mount the stereo amp etc nicely in spare tire well and enclose. possible build a bass speaker sub enclosure in the rear doors.

- install extra rear back up lights.

- install a fuel plate either a # 4 or a 0 plate.

- Install Valet AFC Switch

- I'm sure I'll think of some other things . . any ideas?

Thanks

Deo

 

[Shadrach]

... . maybe install two tone leather heated seats if I can find a good deal on some.....

FYI You can buy seat heaters from Genos and install them your self ?? Shadrach

 

[therabbittree]

yeah I know but the $100 a seat for aftermarket seat heaters means $200 bucks for the two front seats . . but I've found some factory heated leather seats for around $300 or so for 2 front seats. So the 50 bucks more a seat and no messing with hog clips and being able to resell my non heated leather makes it easier for me to buy the factory heated ones. . If I can find a set of two tone tan leather or the Black and tan two tone that would be best. . the eddie bauer excursions had them etc. . my other wish list items include a dana 60 front axle. . preferabley with 355 gears. . which is hard to find unless I regear or buy '08 or newer axles used and cut off the radius arm ear etc. . argh

Thanks

deo

 

[Shadrach]

It never ends does it? Shadrach

 

[therabbittree]

I was off from work today and worked on the wastegate plumbing. Special hanks to Dutchess Mechanical !, they donated 2 1/2' of 1 1/4" Schedule 40 pipe for me . . cool. The place where I bought the weld els wouldn't sell me any 1 1/4" unless it was in 20 ' lengths ha. . so the small donation made my day... . Lots of cutting, fitting, and internal grinding with the rotary file etc. Any how it looks decent . . should flow pretty good. . Hopefully the cold pipe will still fit under this wastegate pipeing??. . we'll see. It rained all day, so I was couped up in the garage. . I'm tired too... not sure if its me or the welding / grinding. . either way. . tired is tired. I need to get another tial wastegate metal gasket also.

Here's some pictures :

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Thanks,

Deo