turbo replacement - clearance issues

[Saev]

Blew my turbo about a year and a half ago. Posted a thread about it - https://www.oilburners.net/threads/turbo-ate-some-rubber.91625/

Work being what it is I kept getting sidetracked, now finally have some downtime (and dry weather) to put it all back together. Even though I should have just ordered an exact replacement - I didn't. Ordered from CDD the stage 2 upgrade with a t51r housing, along with the low pro intake hat since description said oem wouldn't work. I've got everything back on, except now I'm running into clearance issues between the compressor housing and the intake hat. I can hook up one, not the other, regardless of order or orientation. There seems to be about .5in of material clearance needed to gain to fit both.

Any tips from the pros on this? Thanks!

 

[Kdo58]

I would post this on cdd facebook group, cdd will usually chime in.

 

[The_Josh_Bear]

That hat looks much taller than it "needs" to be. You should be able to cut that hat down shorter with a chop saw/tall bandsaw and some really steady hands...stay safe if you do! That's a tricky cut. You could put a some kind of screw through that hold down hole onto a block of wood that's wider than the hole to edge of hat so the block stays flat during the cut!

Otherwise I've seen someone notch it and re-weld, but that's tricky with aluminum unless you're setup to weld that.

I looked at your other thread, didn't see any info on the engine. Do you have headstuds? Aftercooler? The stage 2 is a lot of turbo if not, I'd worry about blowing a head gasket.

 

[Saev]

Yeah the turbo is wildly overkill as the truck sits. In hindsight I should have simply ordered a rebuilt ATS with a wicked wheel and called it a day but I wanted to be special or something.

No headstuds or engine work of any kind, all I've done is replace the exhaust and add gauges. In any case, I'm not removing the wastegate (not in the photo since I just have the housing on there to protect the wheel) so I...shouldn't? run into overboost issues, at least with how/where I'd have to drive it. Not my primary truck thankfully.

No access to any sort of welding or 'real' shop tools unfortunately so I'm fairly limited on improv modifications.

 

[Nero]

Better do them head studs before you try to goose the throttle... Might have a head go flying off

 

[Lumberjackchuck]

I had the same issue with that intake hat. I found that if you tighten the inside bolt on the y pipe to the passenger side exhaust manifold first, it swings the turbo out and away from the hat. If you tighten the outside bolt first it swings it in.

I still needed clearance after that so I grinded it down a little. Really not proud of it lol. I got enough clearance so that I was able to wedge a piece of high voltage rubber blanket between them as a cushion.

If I was going to do it over, I would definitely have gotten v-banded intake manifold instead!

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[The_Josh_Bear]

Yeah the turbo is wildly overkill as the truck sits. In hindsight I should have simply ordered a rebuilt ATS with a wicked wheel and called it a day but I wanted to be special or something.

No headstuds or engine work of any kind, all I've done is replace the exhaust and add gauges. In any case, I'm not removing the wastegate (not in the photo since I just have the housing on there to protect the wheel) so I...shouldn't? run into overboost issues, at least with how/where I'd have to drive it. Not my primary truck thankfully.

No access to any sort of welding or 'real' shop tools unfortunately so I'm fairly limited on improv modifications.

Ok good call. What IP do you have?
Unless it's like a 110 pump or greater you'll be fine for boost, I agree. In my signature you can see my mods, IP is just maxed out and I get up to 15psi aftercooled boost. This is with the WG pressure line unplugged from boost reference and I plugged the hole from the engine. The WG starts to blow open around 11-12 psi, max of 13-15 sustained. Without charge air cooling it would be a bit higher with higher EGTs.

So with your more efficient turbo(same hot side right?), you should see similar numbers but get there easier. I'd be interested in what she does when you get it back on the road!