Brown Truck Under the Knife Project - Engine

[6 Nebraska IDIs]

Well FINALLY got the intake spacer to fit. I should have had it made another inch or so taller and wouldn't have had any issues with needing to cut out the upper land to clearance the compressor housing. I also had to clock the compressor housing around to the back, which I think will work better in the long run anyway. It was the only way it was going to fit so hopefully it clears the firewall.

You must be registered for see images attach

There are no local dealers that carry silicone couplers of any kind much less elbow
couplers so I purchased a short 90* 2" radiator hose and it works perfectly. I really don't see having any problems with it for a short term use. So you can see the radiator hose back there and the 2" pipe piece is actually a cut section of the fuel filler neck from a parts truck. Works great too. I had to leave the breather section in there but I don't see it causing too much trouble for the short term either.

You must be registered for see images attach

Aside from jacking the cab up and cutting the transfercase shifter hole in the floor I'm ready to put this thing in the truck. Crossing my fingers to have it in there and running tomorrow.

 

[david85]

That engine looks like its ready to take someone's arm off. Don't turn your back on that thing and be sure to chain it to a BIG tree.

Only problem is I see a clearance issue with your turbocharger because of the way you pointed/routed your compressor outlet. That line is pushing into the firewall zone. Can you rotate it down some more? There really isn't that much room between the firewall and the circular part of the compressor housing.

 

[6 Nebraska IDIs]

Lol David. Big Dog eh. lol

The next clocking point sets it straight down into where the bellhousing would be. I'm not sure if I can move it down there or not. I guess I could try. That radiator hose flexes quite a bit while holding its shape, because I left the spring in there. So it can move. But does it sit so close to the firewall that even the turbo flange may run into the firewall?
I'm more than willing to take a 10lb sledge to the firewall but if it isn't going to help then it's not worth it.

 

[FordGuy100]

Looks damn good

 

[david85]

Put it to you this way, Sean. I can't squeeze my girly little hand between the turbo and the firewall in my truck. Now my compressor is a little bigger, but not by enough to really make enough difference here. Even if you didn't have to think about the hoze coming off the turbo outlet, you still wouldn't fit the turbo in that position.

If you look at the turbine housing, you can see how there is a sloped flat area on the side that is against the firewall. That was so close in my truck that for the longest time, it would rattle against the firewall until I finally figured out what was going on. DROVE ME BONKERS FOR MONTHS!!!!!!!

Seriously though, ATS stuffed the turbo as far back as they possibly could. I would almost suggest wielding up a metal U pipe and then use a hose to connect to that instead if you can't find a hose that turns tight enough after you rotate the outlet to point at the tranny.

I've got some photos I can post later to show you how close it really is. I'll see if I can get them up later tonight.

 

[6 Nebraska IDIs]

Yea if you've got some pics David that'd be great. I've only got one crappy pic of a 088 system in a truck and it doesn't really show how close it is. I'm almost tempted to take a torch to the firewall. I'll go clock it down and post pics of it like that.

 

[david85]

These pictures show the turbo kit after the 60-1 compressor was installed, so I included a shot that shows both the old and new one to get an idea of the size difference - which isn't really much considering what you have to clear in there.

Hacking the fire wall might seem like an easy way out, but the problem is you are actually going to run into the drain gutter seam so simply bashing it out of the way isn't possible because the metal is backed by a rather strong seam joint right there.

 

[6 Nebraska IDIs]

Yea, but DAMN it'd make me feel good for a few seconds. lol

Well this one had better work or I give up. I think I just screwed my compressor oring clocking it this time. There's a spot in it that I can definitely tell its been flattened or something, its definitely out of shape and I don't have anywhere to go to get one of those unless the service dept at my IH dealer is open tomorrow and they can get me one. God I hope it seals.

You must be registered for see images attach

You must be registered for see images attach

Anyway I had to file down the compressor housing lug to clear the hat this time and had to change my IC piping a bit but that radiator hose and fuel filler still work great and I think it'll clear this way. If it doesnt I'm gonna get mad real quick.

 

[david85]

I think I still have the old seal from my original compressor. If you can't find anything locally, I can try and send it to you for the cost of mailing it. Unless its actually cut or really pinched, you will probably be fine though.

That should clear the way it is now, and there is also a decent amount of room on that side of the engine to allow for routing of the hot side IC line. Since you don't have the original cold air duct anymore, you have at least a 3" zone to shoot through if you need it. Looks like it will still clear your glow plug controller, injectors, glow plugs and return lines

 

[Brimmstone]

You two are going to get me in trouble because I have an intercooler from a 95 dodge diesel sitting in my garage just staring at me every time I go out there. I hadn't done anything yet because my hypermax setup looked to be a chore to route. Now I'm going to have to go play with it in the morning.

 

[6 Nebraska IDIs]

You think that radiator hose elbow should work for a couple weeks? I don't see why I should have any problems with it since it's rated for like 20psi and I'm running 15psi tops.

Another question for ya, all Extreme Velocity gave me for a seal for the stud hole in that hat was a stainless washer and nut. Will that stainless washer by itself seal this thing?

 

[david85]

All I have is a simple steel washer on mine and it seals just fine. Metal can get plyable when you clamp it properly. Unless there are nicks or defects in the area that the washer clamps down on, it should seal. Will it be sealed well enough to prevent an anthrax outbreak? probably not, but will it affect performance? no.

SS is softer than steel and aluminum is softer than SS, so they should seal if all the surfaces are smooth and flat.

Rad hose should be ok for PSI but I wonder how hot the intake charge will get. Should be ok for a few weeks as long as you don't go nuts.

Brimstone, Tell me about it!!!

These guys are a bad influence. Right now I have a moose pump, intercooler, AND camshaft having a brawl in my head right now. Silly me, I thought my truck was hot because it was turbocharged

 

[ameristar1]

You're doing great, looks like she's going to be a beast. And Dave, I saw Empire Diesel's centrifugal compound set up for the Powerstrokes and DMaxes that uses a Procharger to stuff the stock turbo..........heh, heh.........hahahahahahhhaha!!!!!!!!!!!!!

By the time all said and done, the IDI will conquer the world! Or at least a small part of it.

 

[The Warden]

You two are going to get me in trouble because I have an intercooler from a 95 dodge diesel sitting in my garage just staring at me every time I go out there. I hadn't done anything yet because my hypermax setup looked to be a chore to route. Now I'm going to have to go play with it in the morning.

You're lucky that your intercooler only teases you when you're in the garage. My IC's sitting in the kitchen! :-D I can see it even as I'm typing this. Poor thing's been sitting there for a year now, waiting for me to tear my truck apart.

Sean, looks good!! God, I wish I had had the facilities to pull my engine out of my truck when I did my heads....I wasn't able to paint the block at all, so the only painted parts are the parts that were removed.

The radiator hose should work as a temporary fix, but I think I would get the "proper" hose for the long term. And, after seeing some of these pics and reading what people have posted, I'm starting to think that my buddy who took my turbo apart didn't do a very good job of it...maybe that's where some of my boost issues are stemming from

 

[dyoung14]

this makes me want to pull my engine out and go crazy with it