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  #321  
Old 09-27-2012, 05:31 PM
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After seriously weighing the risks vs. rewards I decided to go ahead and wrap the turbo relocator. Ultimately, I decided to do it for heat management in the engine compartment. I've never had some of the problems others have had with wraps, so knock on wood I don't have a situation like Ross80truck wrote about.


Tomorrow I'll work on the support for the turbo end flange
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  #322  
Old 09-27-2012, 05:41 PM
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Today I worked on something else, also.

The other day when I thought about how I could have flipped the intercooler over it made me take a serious look at clearances. I realized that I could move the inlet and outlet up a few inches, which would allow me to clear the bottom of the pillars and run full diameter 3 1/2" pipes. So after some cutting, relocating, welding, and painting I ended up with this.

Thanks again to Turbo Technologies for more welding.






I also didn't like how restrictive the stock inlet and outlet were






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  #323  
Old 09-27-2012, 05:43 PM
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I'll eventually fill the bottom of the sheetmetal back in, which will put some of the original strength back.

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  #324  
Old 09-27-2012, 05:44 PM
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Very nice surgery on the intercooler. I never liked that necking.
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  #325  
Old 09-27-2012, 06:00 PM
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Me either. It just took awhile for my pea brain to see a simple solution.
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  #326  
Old 09-28-2012, 09:43 PM
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Before and after relocating the intercooler pipes. By moving them up 3" and making them 2" shorter it gave 4 more inches of clearance from the tires. Before I'm pretty sure there wouldn't have been any contact, now I know there won't be any contact.


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  #327  
Old 09-28-2012, 09:57 PM
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I also made some progress on the turbo support. It should be finished tomorrow.
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  #328  
Old 09-30-2012, 12:36 PM
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Finished the turbo support last night and painted it. This morning I assembled and installed it. It turned out pretty good and stout. There's more room around the oil filter then appears in the pics, but I'll probably relocate it after the break-in run.




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  #329  
Old 09-30-2012, 12:40 PM
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I reached another major milestone today. I FINALLY installed all the turbo system pieces for a test fit. Everything came out perfect. I still need to do some fine tuning, minor fitment things, and double quadruple check everything on the engine, but as of this morning the major engine fabrication is complete.








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  #330  
Old 09-30-2012, 01:20 PM
tndonor tndonor is offline
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Looking great! I like the intercooler mod!!!
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  #331  
Old 10-02-2012, 09:02 PM
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Before securing the oil line to the top of the filter housing I used a funnel and prefilled some of the oil passages. Between that and filling the filter I was able to precharge the oil system with almost two quarts of oil.


The turbo is now installed for good. I turned the wastegate diaphram around and shortened the boost hose, installed a 3" adapter on top of the oil filter housing that allowed the oil line to sit farther away from the manifold extention, and fabricated the oil drain piping. The drain hose is 400psi, 500 degree oil line. Also, by fiddling with the placement of the turbo compressor outlet I was able to eliminate one of the 45 degree silicone pieces I originally had in the air line to the intercooler.


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  #332  
Old 10-02-2012, 09:09 PM
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After getting everything mounted I moved the cab back out of the way and wheeled the truck outside to get some pictures of the engine in better light. Still not the greatest pictures.












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  #333  
Old 10-02-2012, 09:32 PM
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Thumbs up

This is a work of art. You definitle pay attention to the smallest of details.
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  #334  
Old 10-03-2012, 07:17 AM
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Thanks. I've appreciated all the comments people have made.

Yesterday was a huge stress relief day. For over two years I've been planning, thinking, and visualizing how everything was suppose to fit together and share space, but until I actually put it all together I never knew if I'd overlooked anything. For example, miscalculating the clearance for the downpipe, then having to come up with a fix by relocating the turbo. To be honest, I don't think my finances and timeline could handle coming up with another fix like that.

For the next couple of days I'm going to put the truck on hold, move it out of the shop, and do a major cleaning. I haven't made any effort to keep it clean since I started the engine rebuild phase and it's to a point I can't stand working in there.

Resbum
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  #335  
Old 10-06-2012, 07:10 PM
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After taking two days to do a really deep clean on the shop I got back to work on the truck today. I managed to get past what I knew was going to be the hardest part of making the exhaust.

A 4" exhaust had to squeeze by the frame, front driveshaft, and transfer case.

This almost new 4" exhaust came off the same truck I got the front axle, springs, and transfer case from. It actually cleans up really well and will look a lot better than this.


To make sure my welding was up to the job I cut the old 3" end off. It originally mated to the stock Dodge downpipe. I cut it apart, then welded it back together and beat the daylights out of it with my maul. Passed with flying colors.


This is clearance I had to work with.


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  #336  
Old 10-06-2012, 07:15 PM
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When I stopped today I had this. There's barely room for everything. I'll put a few well placed dents in the pipe with my press, then make a couple heatshields to keep some of the heat off the CV joint and transfer case and I should be OK.




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  #337  
Old 10-07-2012, 10:13 AM
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Just stopped by for my weekly dose of humility. I look at this beautiful work and go back to my garage hoping to do 1/10th aa good a job.
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  #338  
Old 10-08-2012, 07:38 PM
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Amazing!
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  #339  
Old 10-09-2012, 10:15 AM
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Looking good. I was amazed at how much movement these engines have when shutting then down and when there is a serious load on them. I would double check the clearances on your exhaust pipe. Mine moves quite a bit in these situations and had to relocate the exhaust a couple times before I prevented all the annoying rattles and clangs. I'm running a 24v intake horn on my 92 engine and when backing up a steep hill the engine torques to the driverside just far enough for the intake horn to graze the master cylinder. It took a while to find what was causing that one.....
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  #340  
Old 10-09-2012, 10:47 PM
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Originally Posted by jeepmj_tj
Looking good. I was amazed at how much movement these engines have when shutting then down and when there is a serious load on them. I would double check the clearances on your exhaust pipe. Mine moves quite a bit in these situations and had to relocate the exhaust a couple times before I prevented all the annoying rattles and clangs. I'm running a 24v intake horn on my 92 engine and when backing up a steep hill the engine torques to the driverside just far enough for the intake horn to graze the master cylinder. It took a while to find what was causing that one.....
Thank you very much for the first hand knowledge. It's something I've been wondering about. I'm not quite done but should have it finished tomorrow and will post more info.
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