Classic Diesel Designs 61mm drop in replacement for a banks turbo.

[Kdo58]

Starting a thread on my journey on installation of a cdd 61mm, I could not find anything on the internet.

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[Kdo58]

It's not exactly drop in, the first obstacle was the exhaust down pipe, it comes with a adapter to connect the 61mm to the banks down pipe. It seams the adapter could gave been made with a double flanges so it could have been just clamped on.
But it needs to be welded on, I have a mig welder, and I am a grinder and not a welder unfortunately, so this took me quite a while to weld and grind to work.

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[Kdo58]

Next was the oil drain tube, the banks is metric and the 61mm garret is sae/american, 3/8" bolt holes, a easy fix I just drilled out the hole in the drain tube.

 

[Kdo58]

The banks comes with a block plate for the oil feed, this will bolt up with same bolt holes, the Garrett is sae, banks is metric no big deal so I just bought the right size bolts.

 

[Kdo58]

The next issues was the intake, the banks is 3" and the 61mm cdd is 4" I thought I was going to run a whole new intake tube and run it over to the fender, but the injection line is in the way.

 

[Kdo58]

So I started looking at my old banks system, and figure out I would have to use part of it. So I would need a 4x3 intercooler adapter. I went to the plumbing store to see if they had some that might work, but they didn't so I had to order one off the internet.

 

[Tristan]

Looks like you are getting there! That injection line gets in the way on mine as well. The boot is flexible enough that the intake tube just dog legs up a bit. It was this way when I got it and I haven't had reason to change it yet.

I do however need to change that horrid green color!

Sorry not the best picture and hard to see with the hoses.

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[IDIBRONCO]

I remember seeing your posts on Facebook.

 

[Kdo58]

Yea somethings fb is good for, but a build thread is not one of them, I could not find any info on doing this on the internet, I was having guys pm me on how it was going, so I thought I would just post here. And let them know to come here.

 

[nelstomlinson]

This is great! Following.

 

[Kdo58]

Thanks to Amazon I got the 4"×3" turbo adapter looks like it will work. It's a tight fit the cdr is really close to the clutch master cylinder.

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[IDIBRONCO]

As my science teacher in school used to say, "close only counts in horseshoes, hand grenades, and atomic bombs." I think you'll be fine like that.

 

[Kdo58]

My new filter came into day, here is the difference between a stock banks size filter and power stroke filter

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[Kdo58]

And it mocked up, next will be the intercooler pipes

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[Dirtleg]

Okay I'm a little concerned by your stove pipe. Would be worried about rust inside eventually.

Had a friend one time who made his intake from PVC. That concerned me too.

Otherwise looking good. Thanks for sharing the process.