Yet another Diy turbo kit td42

[97_gq_lwb]

I am about to fit up a turbo thought i would post up some info.
I am using a highmount cast manifold From maxingspeedingrods on ebay $349 delivered with manifold gasket included.
And a t3 t4 turbo .63 ar .50 comp $269 delivered comes with manifold to turbo gasket and a weld on v-band flange and clamp etc .
So far i have purchased a 1/8th bspt to 4an male to male adaptor from pirtek for the oil feed from the passenger side engine mount location $3.
I had a braided hose here already for the oil feed .
M8x1.25 exhaust studs and flanged nuts for the turbo to manifold.

[AB]

Very nice mate, thanks for sharing.

Would love to see some progress photos and reports if you can and feel free to ask any questions if you get stuck.

That little Allan Key plug on the block can be a pain to get off for the feed. Mine was ceased to the block and had to go around the other side for the oil sensor....Hope yours come's off!

Where are you putting the oil drain?

[YNOT]

I am about to fit up a turbo thought i would post up some info.
I am using a highmount cast manifold From maxingspeedingrods on ebay $349 delivered with manifold gasket included.
And a t3 t4 turbo .63 ar .50 comp $269 delivered comes with manifold to turbo gasket and a weld on v-band flange and clamp etc .
So far i have purchased a 1/8th bspt to 4an male to male adaptor from pirtek for the oil feed from the passenger side engine mount location $3.
I had a braided hose here already for the oil feed .
M8x1.25 exhaust studs and flanged nuts for the turbo to manifold.

That's very cheap for a turbo?

Tony

[97_gq_lwb]

I was going to weld an oil drain in the sump when i did the engine conversion but decided just to tee off into the alternator drain back.
The oil feed came out easy on mine i undid it when the engine was out i did fit a hex into it and give it a few taps with a 5 pound hammer before trying to undo it though just to help it along.
Yes very cheap turbo it is made in china will see how it goes being a bush turbo it should be ok if not pretty easily upgraded later.
It is a starting point though i am sure i'll be swapping and changing things as i usually do.
I had to grind a little off the manifold to clear the bit that holds the engine number.
And it looks like i'll be needing different nuts on the exhaust studs as their isn't enough clearance with the 17 mm head originals.
I made up a wastegate port block off plate and welded a bung into it for the egt sensor today as well.

[Bigrig]

That's very cheap for a turbo?

Tony

It's the same as the one in mine mate. Garrett copies I think - up until the last few weeks it's been off the road (not due to turbo as you know) I'd have to say the turbo seems a bottler thus far.

x2 on the photos also of the build 97 - would be good to see from scratch!

[97_gq_lwb]

Ok here are some pics

The bit ground down for the manifold to fit
http://i567.photobucket.com/albums/ss117/it250k/diyturbo004.jpg
The 1/8th male to male bspt oil supply attached to a braided line with an4 fittings
Engine mount needed a little grinding for fitting.
http://i567.photobucket.com/albums/ss117/it250k/diyturbo003.jpg

My pre turbo egt sensor fitting adapted to the external wastegate hole.
http://i567.photobucket.com/albums/ss117/it250k/diyturbo001.jpg

Manifold fitted up
http://i567.photobucket.com/albums/ss117/it250k/diyturbo005.jpg
Turbo fitted up
http://i567.photobucket.com/albums/ss117/it250k/diyturbo006.jpg

[AB]

Funny, I cut a bit of a section out of my engine mount too then found I couldn't get that damn plug out...lol

Interesting to see how it all goes mate. A lot of people, even turbo specialist's tap into the alternator for the oil drain and it seems to work fine. I heard a few stories about the oil drain building up due to the T section needed on the oil drain for both turbo and alternator which cause the oil to back up and ruin the turbo.

Having saying that I have never seen or had proof of anyone's doing this too...lol

Keep the info coming mate!

[97_gq_lwb]

Well it's running again i threw on a pod filter i had here just to start her up and it only has about 4 inches of exhaust pipe on it .
Took it for a quick run around the block and can notice the difference already.
Surprising how quiet it is with no exhaust.

[YNOT]

Well it's running again i threw on a pod filter i had here just to start her up and it only has about 4 inches of exhaust pipe on it .
Took it for a quick run around the block and can notice the difference already.
Surprising how quiet it is with no exhaust.

I love the sound of a TD42 turbo with no mufflers.
What boost are you running and have you wound the fuel up yet?

Tony

[97_gq_lwb]

Haven't connected the boost gauge up yet waiting for the weather to cool down and i will wire up the egt and connect the boost.
Then mess with the fuel.
I was going to go wth a 3 inch exhaust but it is 2 1/2 at the turbo so i don't see that it will make any difference so i might just go straight through 2 1 /2 one small muffler on the back for appearance sake.

[YNOT]

Unless you're planning to really crank the boost 2 1/2" will be OK.
If you think it goes well now wait until it's tuned!

Tony

[97_gq_lwb]

Yeah no doubt i already had the fuel turned up a little before fitting the turbo as it was pretty gutless without it.
Just took it for another quick run with the boost gauge hooked up and it is making 10 psi at about 2000 rpm.

[97_gq_lwb]

Looks good with the pod filter but it won't be sticking around to suck in the engine heat i have a zd30 airbox to fit .
http://i567.photobucket.com/albums/ss117/it250k/diyturbo.jpg

[97_gq_lwb]

Well i plumbed up the boost gauge properly and fitted an external controller and took it for a 10 minute drive so far so good.
Also fitted a gu zd30 airbox as well.
It is making over 15 psi boost at 2800 rpm my gauge only goes to 15 and it is going over that a little.
Boost starts to rise around 1500 rpm.
Wound the fuel up some more but still not getting smoke yet so i think their is some more power to come .
I drove up a hill i usually have to go back to third gear on and it pulled up in fifth without a drama.
Loving it.

[97_gq_lwb]

ZD 30 gu airbox fitted

http://i567.photobucket.com/albums/ss117/it250k/diyturbo007.jpg

[YNOT]

Looking very neat. I'd be fitting a pyro gauge before you turn up the fuel any further.

Tony

[97_gq_lwb]

Yeah i have an auber instruments pyro fitted.
Just need to finish the exhaust off then i'll go play with the fueling on a nice long steep hill.

[97_gq_lwb]

I cut and joined the 2 1/2 inch dump i made to the factory exhaust.
Talk about restrictive if you thought the factory exhaust appeared small wait until you see inside the flexi joint it steps down even further i reckon it's about an inch in diameter.
Anyway i took it for another run hit a hill pyro went to 750 so i backed off and came home .
Today i turned the ignition on when cold and seen it sitting on 90 degrees and realised it's in farenheight.
So i changed it to celsius time for another run.

[AB]

750 Fahrenheit on a steep long hill is close to 400 C so not too bad if it was a decent hill mate.

[97_gq_lwb]

Yeah it was only a short run my egt sensor is pre turbo.
Went for a little drive tonight no big hills and it sits around 200 celcius lol.
I will wait for a nice hot day then go load it up in the mountains and adjust it.

[Richo460]

for some reason the pics aren't showing up on my computer but you have done exactly what i want to do. Got a quote to install a kit at about 4k but i'm a tight arse and want to do it myself.
How is the cheap turbo performing? i was looking at getting a cheapie too as i only want 10psi max cause my engine is over 400 000k's.
Did you fit a boost compensator to the pump or any other pump mods?
are there any rules of thumb for doing a tune after a turbo install?

[97_gq_lwb]

Performing well stock pump.
I have fitted an electric fuel pump though the typical $40 one for a carb car.
To tune i really haven't had a real go at it i basically wound it in 1/4 of a turn at a time until the smoke pre boost was excessive.
Then i backed it out until it was not visible in the rear vision mirror and i have low egt's.

[Richo460]

so with diesel too much fuel will make it run hot? what happens if its too lean? will it just be lacking power? I have heard about boost compensators but know bugger all about them, and then there is injector timing, i might just get it as good as i can then take it to someone to check and fine tune.

Sounds like you have done a great job on your own.

[97_gq_lwb]

Basically yes you need to balance boost and diesel too much diesel not enough boost wiil make it run hot to monitor it you fit an egt gauge.
The stock pump is pretty basic one fuel adjustment.
An aneroid is like an add on for the pump wich gives you more control over fueling it basically lets you have less smoke pre boost and more control over fuelling as you then have 3 adjustments.
I like to do everything myself even if it takes a lot of time i usually get there in the end.
I am planning on playing with the pump timing myself and injector crack pressure one day just need to buy the tools.

[spektrum]

Quick question .. do you have a Safari Snorkel? How did you get a airtight seal between the snorkel and the ZD30 airbox?

I have the dual air filters on a TD42 GQ ... one air filter on top of the engine, and the second is in the front left. Does anyone know if I could just use the second one by itself on a turbo install? The ZD30 airbox looks a bit bigger.

[AB]

You probably could but It's not an ideal main filter.

I would prefer to run a flexi pipe from the main air filter (pizza box shape) to the quarter panel and hose clamp it to the snorkel than use the pre filter as the main.


EDIT: if your doing a turbo then you won't be able to use the pizza box one without modifying it a bit....I would use the ZD30 box and get a rubber reducer with clamps if the sizes are different.

I went to Pirtek and got a rubebr reducer from 4" to 3" with clamps and it worked a treat. Not sure on the Safari's sizes and differences but let us know the differences?

[97_gq_lwb]

I used a silicon reducer i think it was 3.5 inch to 3 inch between the zd30 airbox and safari snorkel i did have to die grind a lip down on the zd30 airbox from memory

[AB]

I used a silicon reducer i think it was 3.5 inch to 3 inch between the zd30 airbox and safari snorkel i did have to die grind a lip down on the zd30 airbox from memory

Yep I had to do that too....I used a hack saw because I'm a hack...LMAO

[spektrum]

Yeah thanks .. will have a look next week.

Unfortunately I have so many things on the to-do list to finish off the TD42 conversion. Hasn't been too bad, just time consuming.

[97_gq_lwb]

Yeah lol i think i used the tin snips to get the majority out of the way before die grinding and them some emery paper to tidy it up.

[Richo460]

i will have to find a new airbox as i can't use the pizza box one cause i bought a small intercooler for 25 bucks on evilbay. Might be a sidemount for a skyline but i'm sure i will make it fit, i won lots of grinders and a few welders. ZD30 airboxes are hard to find up my way, any other ideas? I have read something about the vn commodore boxes, i can get a whole vn como for the same price as a ZD30 airbox, I guess there isn't much you can't do with thin steel, rivets, zipties and sikaflex.

[97_gq_lwb]

I bought the zd30 airbox from central coast 4x4 wreckers was under $150 delivered

Or you could just put what your after into findapart.com.au that's how i found them in the first place

[spektrum]

PatrolDocta has airboxes available on ebay .. but they are very expensive.

[Richo460]

Hmmm. i will have to see what fits where when i get home. I just bought the same turbo and manifold as mentioned in the start of the thread and will be doing the install in 2 weeks.

[no eye deer]

Love this thread. Motivational!!
Gotta save me some dollars.

Mark

[nissannewby]

Compensators are near tuned out of the equation by most tuners as with a diesel you need fuel to make the heat to then make boost so the sooner you can get fuel in the sooner you will have boost and the sooner you have power and torque. Obviously all within reason so your egt's arent getting extreme.:)

[spektrum]

How does ZD30 airbox fit around the AC pipes? I can't see your AC pipes in this img.



ZD 30 gu airbox fitted

http://i567.photobucket.com/albums/ss117/it250k/diyturbo007.jpg

[97_gq_lwb]

Looks like that pic was taken before i had the aircon pipe made up as it was converted from the rd28 the pipe from the condensor was different and i got one made it basically goes between the radiator and the airbox.

[thebeatjackson]

can I ask where you bought your turbo? could you send me a link if you can find it?

[97_gq_lwb]

http://www.ebay.com.au/itm/HYBRID-T3-T4-T03-T04-Turbocharger-Turbo-all-4-6-Cyl-/170622389186?pt=AU_Car_Parts_Accessories&hash=item27b9e30bc2

[Richo460]

Hi 97_gq_lwb, i am about to do my conversion but when i am looking at the turbo they sent me, the tapped hole which i think is for the oil feed is on the bottom not the top where the oil should be fed from, was yours the same? Can i just undo the bolts and rotate the housing to suit? Its been bloody hard to find people in town that sell the oil lines, had to get them ordered in.

[97_gq_lwb]

Yeah just undo it a fraction and leave it loose until you get everything positioned where you want it then tighten them up.

[Fity]

97_gq_lwb, any chance you can post up a pick of your dump pipe? I am thinking of using the same manifold and am wondering where the dump pipe will fit without heaps of bends and how much clearance it will have from the firewall etc. Thanks.

[07gokhangq]

......follow-up...

[Benno7]

any chance of an update ?

[97_gq_lwb]

still going well i fitted a 3 inch system wich was an improvement.

[Benno7]

Did you go 3 inch dump as well?

[97_gq_lwb]

Didn't see the point just left it 2 1/2 coming off the turbo then into 3 after the bend.

[97_gq_lwb]

Heres pics of the dump people keep requesting it has more room since lifting the body 2 inches but it will give you an idea.
I just bought some mandrel bends and pipe from the local exhaust shop and welded them together with a tig.
He flared a piece of straight 3 inch down to 2 1/2 for me as i had already made it that size off the turbo .
http://i567.photobucket.com/albums/ss117/it250k/patrol072.jpg

[97_gq_lwb]

If you were thinking of going with a mitsubishi turbo like a t3 16g this is an option.
http://www.turbosystem.com/auto/Super%2016G%20Universal.htm

[luvpsi]

Hey mate know its been a while but how did you find the turbo so far considering it myself to turbo my n/a silver top

[Newbiee]

97_gq_lwb mate if you can remember for the oil feed off the lhs engine mount bung what thread was it? Or if anyone else knows aswell

[AB]

97_gq_lwb mate if you can remember for the oil feed off the lhs engine mount bung what thread was it? Or if anyone else knows aswell

Pretty sure it's a 1/8 npt bud.

[Newbiee]

Pretty sure it's a 1/8 npt bud.

cheers heaps for that mate!

[AB]

cheers heaps for that mate!

Before you go and buy the lines make sure you can get that bung off first. Mine was seized shut and I had to go around the other side and feed off the oil sender.

Oil won't come out, let the car settle after a drive, crc the bung, let it seep in overnight and try to get it off.

Very easy to strip it!

Then once off you can confirm size but I'm 99% sure it's 1/8 npt

[JJanzon92]

So how well did this turbo end up going and did it last long?
Am looking at doing the same setup

[vitox]

im the same boat as jazon wondering esp. about the performance of these china manifolds, i see them advertised all over but them being so much cheaper than other brands, one cant help wondering if its a legit product or not.