ATS 093 Turbo and Water to Air IC

I'm not sure if anyone has done this here yet but I thought I'd post about my setup I will be installing/fabbing.

The truck is a 91 F350 CC w/7.3idi and a zf-5.

I bought a 093 wastegated ATS turbo system from Discbrks here on the board. He was very thorough with his instructions and cleaned almost every piece I would need to do the conversion so to him

I came across the silicone intakes website from searching on here, and after doing a little searching and finding out their intercoolers were actually mentioned in a diesel mag I figured why not try them?

Now what makes my setup different from most on here would be the fact I'm going to do a water to air ? maybe...

Water to air kit: http://www.siliconeintakes.com/prod...=1006&osCsid=625235cc6015ead488b0f40574e3d019

14x24" radiator and a 10" cooling fan.

I also upgraded to the Bosch pump instead of the cheaper "ballast" pump they include.

I have all the couplers, clamps, coolant hoses and clamps coming too.

I plan on rotating the compressor housing up and using the "air hat" included in the ATS kit. All I'll be doing is turning it around so it will point towards the intercooler as much as possible.

Ive read and read about the crushed down tube on these trucks and it is absolutely the dumbest thing Ive seen. There is about 1/2" space for the exhaust to pass thru?
So to fix that I've got some 3" tubing on order at the fab shop so I can build my own 3" down pipe.

One question on that, why is the turbo inlet pipe crushed too? Does that hamper its flow at all? I can fab up a new inlet and flange that isnt crushed but I'm just not sure if 1) its worth it and 2) will a fully circular inlet pipe fit behind the block and the firewall?

Then after the 3" down pipe I will be doing a 4" exhaust all the way back, possibly a single, short black stack.

And I'll be getting these gauges but the tranny temp sensor will be used for keeping track of the intercooler coolant temp.

http://cgi.ebay.com/ebaymotors/ws/e...0384816704&sspagename=STRK:MEWAX:IT&viewitem=

Once I can get my truck to my house (awaiting a new front 60) I will immediately start posting pics, I know I know, pointless post without pics! but I need some of my questions answered first so I can make this install as smooth as possible.

Tyler

Btt anyone have any answers to my questions?


I have another one for you, Is the waste gate designed to not open 100%? When I was rotating my compressor housing I had to remove my wastegate actuator and noticed it only moves probably 75% of the total travel possible. Should it go farther?

I run the stock ats airbox and with the modded turbo I make 13 lbs easy so it is not too much restriction.
The wastegate only needs to move a little to be fully functional. Water to air is very effective, my son did it on his MB.

Good to hear. I'm anxious to see how the water to air on a dd'd diesel will work, as Ive not seen too many street driven. I'm hoping to bring the truck home tomorrow if the trailer situation works out.

I have been toying around with the idea, too. I think I want to use the straight through intercooler. I think it would be easier to mount and plumb a remote radiator than a CAC. It probably would not tax the cooling system as much either(if mounted away from the cooling system)

A little bit of everything pic



Rad. for the intercooler



Intercooler box

the last time I has experience with a water to air IC was with a Buick GN.
the AC system was used to chill the water. the radiator was put downstream of the evap core. I didn't care for AC back then, but I certainly do now.
I have a 87 chev CK 6.5td project that is being considered for water to air due to space constraints, so I will be following your experiences

Ok thought I'd post some pics, been working on this off and on all week during vacation.



Cute lil guy huh?



Everything is tight as your moms {expletive} since Im trying to intercool it using non intercooled parts.











Had to custom mount the air box to clear the air hat







Intercooler will obviously be mounted on the passenger side since the air box is in the way



Mmmm hope that fits or I can clearance the hood somewhat

New door



Fitting the gap






Going to make the 3" down pipe, route the exhaust, then mount the radiators and intercooler over this weekend. Then slap the front clip 100% back together, change the oil and start her up!

LOOKIN' GOOD!

Do you guys like pics? because Ive got a lot of them!

"new" cowl on



New lights



Grill back on





Made a 3" down pipe, it isnt perfect, but I didnt have a 3" die to make a bend so I pieced it together, its still 333million times better than the ATS crushed down pipe.





3" down to the original ATS 2.5" flange





3 to 4



Turn out



Need a fancy tip now!



Its TIGHT





Started mounting the intercooler system

Bolted in some tabs up top and welded in some tabs on the bottom



Laying out my possible routing



Water to air intercooler mount



A lil janky but it works and will never be seen.



Bent up an intercooler mount



Intercooler mount welded on









Intercooler mounted

Tomorrow, I'm planning on bending up the intercooler pipes, add the water pump, plumb the system, change the oil & add the psd filter, change to Rotella and attempt to start her up. If I have enough time, I'll mount the radiator and try plumbing it. ( its a 460 gasser $$$ radiator so I have to make it work with the diesels input/output positions.)

Didnt get to start it today due to not having an extra elbow
So tomorrow I need to get some clamps to finish mounting the intercooler tubes, make a battery mount for my trays, make some new ground cables then change the oil and hopefully start it up. Well after I install the front brake lines.

Here is the intercooler layout



Its super tight in there, not even a **** hair.







Mounted the water pump to the core support using a t bolt clamp from my intercooler kit.





Intercooler fan mounted up



Hose routing









Awaiting the intercooler tubing (paint drying) and I need to pick up a few more t bolt clamps in the morning.

I really like the work you are doing and cannot wait to see results.