Dave7.3
Diesel ******
Finally got the finishing touches completed of my turbo build...I would have more step by step but no camera handy at the time. =(
All I have to say is WOW!
First off, a nice shot of the rig:
New Exhaust location:
Underside shot of exhaust:
Crossover pipe:
Crossover pipe (driver's side):
Now the best part, the engine bay:
Now that the picture show is done, I figure I will give a little more detail about this build.
Overall, it fought me tooth and nail to get it done. That is an older "conventional" Hypermax turbo kit with mild modifications.
As you can note i the pictures, I relocated the glow plug relay as well as the senders and the CDR vent location.
For the glow plug unit, I opted to do the banks relocation design. Overall it was planned to give me more room to work on the driver's side. Simple wide strip of flat iron with a bar brazed underneath to accept the bolts for the unit. (Thanks to Dad for the master brazing work...too bad I lost the first set of pictures of it.)
The senders for oil pressure and oil feed line you can see are VERY different. For the oil feed line, I used the port on the back of the block, feeding into a 90* brass fitting, running 3ft of high grade hydraulic line (5000 psi rated). That assembly runs to double tees with each sender for the stock oil sender and my aftermarket one. Seems to do well and shows ~30-35psi oil pressure. I ran with double tees to clear the air cleaner/turbo housing if you were wondering.
The CDR vent...well lets say I didn't want to drill into my valve covers. So I used the banks design once again and ran a line of heater hose to the IP cover plate which I drilled and brazed in a fitting. This might need some adjusting later on. Also fabricated a flat iron bracket to seal the back of the intake manifold.
Exhaust was assisted in custom fabricating by a local muffler shop. The guy that did the crossover pipes was VERY talented and almost copied the hypermax design perfectly without having ever seen it. Only needed me to point him in the direction of how I wanted things. Surprisingly, it was almost the same price had I ordered the pipes from Hypermax. They did a good job sneaking that 3" stainless steel powerstroke downpipe in there too. With me beating the firewall senseless for them.
All in all, a very tiring experience as I had to fabricate almost everything except the turbo, intake hat, and turbo manifold. If I had to do it again, I would definitely pull the engine. No question about it.
The only things I am running into now...is my toasty floorboards.
I had planned to wrap and ceramic paint the up pipes...but I can't get them apart now. I will have to come up with something as about 30min of driving gets the floorboards hot to the touch.
I have to say thanks for the tips I had from various members on this site and FTE. Two to note was Agnem and his awesome Hypermax install write up. Along with Dave Sponaugle on FTE for his expert advice.
Enjoy the pics, videos to come!
Old smokey is loud! Although it isn't that bad when the windows are up. The turbo chops up the straight pipe 3" sound pretty well...minus the insane turbo whistle. 
All I have to say is WOW!
First off, a nice shot of the rig:
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New Exhaust location:
You must be registered for see images attach
Underside shot of exhaust:
You must be registered for see images attach
Crossover pipe:
You must be registered for see images attach
Crossover pipe (driver's side):
You must be registered for see images attach
Now the best part, the engine bay:
You must be registered for see images attach
You must be registered for see images attach
You must be registered for see images attach
Now that the picture show is done, I figure I will give a little more detail about this build.
Overall, it fought me tooth and nail to get it done. That is an older "conventional" Hypermax turbo kit with mild modifications.
As you can note i the pictures, I relocated the glow plug relay as well as the senders and the CDR vent location.
For the glow plug unit, I opted to do the banks relocation design. Overall it was planned to give me more room to work on the driver's side. Simple wide strip of flat iron with a bar brazed underneath to accept the bolts for the unit. (Thanks to Dad for the master brazing work...too bad I lost the first set of pictures of it.)
The senders for oil pressure and oil feed line you can see are VERY different. For the oil feed line, I used the port on the back of the block, feeding into a 90* brass fitting, running 3ft of high grade hydraulic line (5000 psi rated). That assembly runs to double tees with each sender for the stock oil sender and my aftermarket one. Seems to do well and shows ~30-35psi oil pressure. I ran with double tees to clear the air cleaner/turbo housing if you were wondering.
The CDR vent...well lets say I didn't want to drill into my valve covers. So I used the banks design once again and ran a line of heater hose to the IP cover plate which I drilled and brazed in a fitting. This might need some adjusting later on. Also fabricated a flat iron bracket to seal the back of the intake manifold.
Exhaust was assisted in custom fabricating by a local muffler shop. The guy that did the crossover pipes was VERY talented and almost copied the hypermax design perfectly without having ever seen it. Only needed me to point him in the direction of how I wanted things. Surprisingly, it was almost the same price had I ordered the pipes from Hypermax. They did a good job sneaking that 3" stainless steel powerstroke downpipe in there too. With me beating the firewall senseless for them.
All in all, a very tiring experience as I had to fabricate almost everything except the turbo, intake hat, and turbo manifold. If I had to do it again, I would definitely pull the engine. No question about it.
The only things I am running into now...is my toasty floorboards.
I had planned to wrap and ceramic paint the up pipes...but I can't get them apart now. I will have to come up with something as about 30min of driving gets the floorboards hot to the touch.I have to say thanks for the tips I had from various members on this site and FTE. Two to note was Agnem and his awesome Hypermax install write up. Along with Dave Sponaugle on FTE for his expert advice.
Enjoy the pics, videos to come!
Old smokey is loud! Although it isn't that bad when the windows are up. The turbo chops up the straight pipe 3" sound pretty well...minus the insane turbo whistle.
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