Project: BTB

HS108

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Project: BTB (before the baby)

So I have been stocking up on parts for the truck since I got it. I never had to time to install any of them, as it was always something going on in life, Buying a house, wedding, etc etc. Now with a baby on the way, I know its really all over for spare time, so I plan to get together over at my buddys house and knock out this massive list of parts I have been collecting.

I bought 4 ISSPro Gauges from Mel during his initial group buy. (Pyro, Boost, Trans Temp, Eng Temp)
I have a modded 3" inch elbow and down pipe from R&D performance, and 4 inch diamond eye exhaust.
Hydroboost set up from a member on the forum.
Plan on swapping in a rebuilt turbo with a Wicked Wheel 2 in it to replace my stock one with 200K+ on it
Replacing all glow plugs with new ZD9's as I have a mix of ACDelcos and Beru's currently and a few are burn out. (which concerns me a little, as to why they are failing, Ive replaced 2 with ZD9s and one of them is already dead again)
Plan on moving the fuel filter, and piping a 4 inch intake from the turbo to the passenger side with a AEM dry flow filter
Install a new CDR Valve and catch can set up.

I have also ordered a few supporting Items from Russ with an turbo install kit and new stainless oil feed line, and Brain who went out of his way to ship my a fitting for the IP to run a new line to the filter.

I plan on starting this on Friday the 1st. I usually try to go one project at a time, Keeps things easier that way.

I guess my main concern this project is going to be the turbo swap over. Mine is still factory with the crushed DP and metal heat shielding all over it, any tips for removing that would be great, I also pray that my up pipes will be in good condition

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Greg5OH

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good stuff! i am sure you will really enjoy the diamond eye muffler. Mine sounds absolutely phenomal. deep burble at idle, and over 2200 has an awesome diesel bark to it.
 

HS108

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Also what are opinions on the boost gauges pictured above, Im leaning towards the Banks one, as it is more in the realm of IDI boost levels. The gauge is made by ISSpro as well

Ill post more pics as they come, The Elbow and down pipe are at the ceramic coating place now.
 

icanfixall

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These are the isspro gauges I run. They are the EV type with the 270 degrees of sweep.
 

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HS108

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Nice Gauges!!!

Question, Can I run just regular vacuum line from the port on the turbo to the waste gate valve? I'm guessing so, but I notice on the stock turbo its hard line for almost all the way except for the last inch or so.

Also adding to the list of projects is the ranger heater core valve install, and finding the leak in my AC system :(
 

IDIoit

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aas long as the turbo to WG seals, shouldnt be an issue.
the biggest chore you got ahead of you is firewall clearance.

ive used a pry bar with some heavy tubing welded to it to push the firewall, worked rather well.
notch the pinch weld with a saw zaw and crease to flush.

time for some fun!
 

HS108

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Ok cool, yep deff cut the pinch welds and fold it in, plus hammers and pry bars. It's why I went with the ceramic coat vs wrap. Gain as much space as I can

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pafixitman

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I ran Isspro for turbo and pyro. You are correct in that the markings on the Banks is better suited for lower boost readability. I clocked my gauges so that the sweet spot reading was 12:00. Made glancing at them easier. As for the fire wall +1 on notching. I used a scissor jack between the bellhousing and firewall to push the firewall seam in. Worked good for me.
 

HS108

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So project BTB is officially in progress...

Im loaded up ready to go!!!!

Ive got all the parts, See how many parts and companys you can count!!! I have sourced parts from, thanks again Russ, Mel, and Brian for all the products!!!
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I had my Elbow and DP ceramic coated inside and out, here they are back from the coater, (total cost 90 bucks) Went with a nice polished look, should help keep heat down :) they say about 300 Degrees
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HS108

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I am in the process of removing the old turbo, but I am having a hell of a time getting it out, all this heat shielding, and I'm trying to leave the up pipe in place as I don't want it leaking.

But the nuts are on there and in a real tight spot with all the shielding in place.

Any tips??


UPDATE:

Ok the 4 bolts are off, just working on trying to get the snail and drain bolts off.

Damn these bolts!!!

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HS108

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It's done.

So in hindsight, I didn't remove both the bolts holding the drain casting to the engine!!!!!! Which caused us to struggle with the turbo for about 1.5 hours longer than we prob had to. So I struggle and removed the 2 bolts on the bottom of the turbo like an idiot, but when I was still fighting with the turbo my buddy noticed the bolt that was still in place. He removed the bolt, and bam-o turbo is off

Finally
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HS108

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Ok, called it quits for the night.

It was a major struggle fest all night, cuts on my hands, cut the pad of my pinky open on some heat shielding which bled all over like a stuck pig.

But atlast, I finally got the turbo out, and down pipe off, and thankfully the up pipe stayed in place and is still tight and firm.

Phase 2 is Install the Wicked Wheel, This too is Fighting ME. I need a socket to hot the hot side nut so I can remove the wheel. I am going to try this gator grip socket I've seen in a youtube video, also can someone confirm if the nut is left hand thread or right hand?

I've read it is reverse thread, but it looks normal.

Also replacing the glow plugs is next on the list while the turbo is out.


Before
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During
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Here we are removing the dumb forgotten bolt!!!
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Showing it who's boss
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After
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Also ran into some major flooding of the garage, as we were under a tornado warning, it was pouring out. Thankfully we had plenty of pads!
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Getting prepped for the WW2 install
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HS108

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Day 2, Cut short due to family time

Here is the install of the WW2, The gator grip socket worked miracles on the hot side nut. Its awesome when things like that save you. Who would have thought an "as seen on TV" thing would work so good.

Here is the old wheel VS New Wicked wheel
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Installed photo after finally getting the nut off. God I hope this holds up. If I could go back in time, I would have spent the extra money and gotten the Typ4 modded turbo just to have the peace of mind that it was put together correctly.
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Here is the new turbo next to the old
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Old Outlet
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New Outlet
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Here are the glow plugs going in, thankfully they all came out no issues, I had a hodgepodge of plus, Mix of Delphi's and Beru's Only issue was the one under the turbo, had a little bit of carbon on the tip and took a bit of pressure to get it to seat, but a gentle push got it through.
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HS108

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Day 3 Update

Again not much progress, after fiddling around trying to figure out what to do on the valve cover gaskets, I lost a lot of time. I then became over whelmed with all that needs to be done, and almost had a mental break down lol. I made a list and did single man jobs because there was a lot of people over and it was hard to focus on work. I need to install the turbo and downpipe, but didnt have a second set of hands or eyes.

I did however wrap the crossover pipe and the up pipe(as best i could) so it should help keep a little heat in. It is not the worlds best wrap job by any means as it was done while on the truck.

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laserjock

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That moment when you go... *** did I just do to myself. Mine happened the night I pulled the cab off the frame. LOL

Eat the elephant one bite at a time. My problem is I've run out of ways to fix elephant and I'd kill for a steak. [emoji6]

Lists are a good way to organize and keep moving. I need to update all of mine (I have several).

Keep at it. It'll pay off.
 

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