'86 Extended cab project thread

BlindAmbition · Mar 6, 2024

Figured out the intake piping, took way longer than I thought. Ended up taking a piece of aluminum, bending it by hand to make a mockup of the angles, and ordering the correct bits which arrived today.

2" - 3" 45*
3" cast aluminum 90
3" coupler

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BlindAmbition · Mar 7, 2024

Worked on the intercooler reservoir today. It's an old 3.4 gallon propane tank from a VW Westfalia van, was going to use it for my air tank but I don't trust it to hold the pressure. TIG welded some steel for the first time today on it, pretty happy with how it came out for a first try. First pipe thread I added was too low once I figured out the exact mount, so I turned it into the drain and welded a different bung to feed the intercooler pump.

Saw a bit of advice on another thread to run different color coolant for the intercooler so as not to confuse where a leak is coming from.

Will finish mounting and then start plumbing.

Tank → pump → radiator → intercooler → back to tank

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BlindAmbition · Mar 7, 2024

Mounted a smaller reservoir to be the fill spot for the system. Will likely need to lift it when filling to get the air bubbles out since I cannot mount it higher than the intercooler. Fuel heater and the motorguard final fuel filter are also mounted. Still need to trim the heater bracket and give it some paint.

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The_Josh_Bear · Mar 8, 2024

What's the plan for the oil line coming out of the turbo? It's dead-headed from the factory, just a spot for the pressure sender. Or is that two feed lines coming in? I've never seen it either way.

BlindAmbition · Mar 8, 2024

Oil line is plumbed. 1/8 npt on the block to 4an fitting and then a 24" line. Oil block on turbo has two feeds, second feed is 4an as well to my oil gauge

BlindAmbition · Mar 13, 2024

Finished the oil bypass setup, got the coolant/windshield reservoir mounted, mounted the fuel regulator setup, clocked the turbo and tightened it down, and installed a CCV/CDR adapter on the timing cover to prep for installing the Mann Provent 200.

Will work on installing intercooler reservoir and intercooler plumbing tomorrow.

Soon after that is creating my fuel filter/pump setup

Then starting the engine.

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BlindAmbition · Mar 14, 2024

Got the intercooler reservoir mounted. Will work on the pump and routing hoses next. 3.4 gallons is overkill but I don't think I'll get heat soak except on perhaps very long drives

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Nero · Mar 14, 2024

No heat soak, but what about turbo lag?

BlindAmbition · Mar 14, 2024

Shouldn't be much at all, if any really. The run is super short, something like an 1/8 of the distance for most air to air intercoolers that folks are successfully using. I'll likely have lower pressures overall by a small margin, like one or two psi, but much denser air. Given it is a 6.9 I like the lower pressure idea so I can hold off on studs until I get the ability/space to pull the engine and stud it.

IDIBRONCO · Mar 14, 2024

BlindAmbition said:
3.4 gallons is overkill but I don't think I'll get heat soak except on perhaps very long drives

Plus you'll get extra air cooling from that big tank and the long lines/hoses. If you do get any heat soak, you can always add a heater core in one of the hoses to get some additional cooling from the air.

'86 Extended cab project thread

BlindAmbition

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Nero

HD Diesel nut

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