DIY - TB45E turbo install

[jff45]

As I mentioned at the start of this thread, I'm running an auto trans with this project and I added a Davies Craig cooler for the trans fluid.
This involved relocating one half of the power steering cooler from the right to the left side and I thought it might be of interest to others how cheaply this can be done.

For those using a manual box, this might also be a handy mod if they want to mount a radiator for a W2A IC.

This is the standard layout on a TB45E..



..and this is what we want to achieve:






These are aluminium tubes and I have nothing to weld them.. and they are probably too thin for the average amateur to attempt to weld anyway.

As luck would have it, the tubes are just the right size for these 1/2 brass plumbing elbows with the nylon olives..




You just need to be able to silver solder a short length of copper tube with 2 copper elbows to join this part here:




I decided to retain the original trans cooler and connect it in series with the new Davies Craig. I had to move the original ~25mm forward.




This is the finished mod. I've been running it now for over 6 months and not the slightest sign of an issue.
There's very little pressure there anyway.
From memory, cost of the brass elbows for this mod was <$15..




This is the cooler I used. Bought from Ebay.




The highest temp reading I've seen since is 80C. Before the extra cooler I could get it to ~105C so a turbo installation definitely needs this mod.
Standard temp on the highway with the TC locked is between 60 & 70C which is almost a little too cool.

I'm also planning on removing the cooling pipes that run through the radiator.
There has been more than one report of failure of these pipes resulting in mixing of trans fluid and coolant in both the trans and the engine.

[jff45]

This is a pic I received from a friend in WA who has also done a TB45E turbo install.
He started with the AXT turbo kit.

This is just to show his Frozen Boost water to air IC installation. He also chose the Millweld airbox.
Nice but both options were outside my budget

[Dales300exc]

What are the millweld boxes like in terms or flow capability?

[jff45]

What are the millweld boxes like in terms or flow capability?

No idea. That's a pic from a friend..

I know of another TB45E turbo install in Melbourne who swapped his Millweld out for the big PatrolDocta that has the snorkel coming through the bonnet and says it goes better..

[Dales300exc]

Yes thats good enough for me then. Ill not put it in the decision list haha.

Back on track though, your work looks superb and very well thought out. I like it very much!

[billyj]

great work mate, a low boost turbo makes a big improvement to the nissan tb engines, im running 4psi into my tb42e using an axt kit and with out intercooling and a restrictive exhaust it made 100rwkw on 33"s about 25% more than a na motor would. the power/torque also comes on so much earlier and is much more useable

[jff45]

Just thought I'd add some pics of fittings on the turbo. I initially used an adapter for the oil feed with the 1mm restrictor (as shown a bit earlier) but I was never really happy with the number of connectors needed to guide the feed line in.

This is what I mean - there's the adapter/restrictor then a F to F -4AN elbow (couldn't find F to M) then a M to M union to be able to fit the elbow from the feed line.




Then I found this the other day.. a banjo fitting with the 1mm restrictor in the banjo bolt and a -4AN inlet.
This is also a much lower profile and allows a lot better access to one of the T3 flange nuts. With the previous connectors, I had to clock the turbo a couple of degrees more to make sure I could get a socket onto the flange nut.






Here's a pic of how all the fittings should be as seen from the block side. The oil feed is much neater now. The water cooling will be also be banjo fittings with -6AN cones (also from Kinugawa) and the oil drain is -10AN.




I've seen installations where rubber hoses have been used for both the water cooling and the oil drain but the teflon braided hoses and fittings are not a lot more expensive if you source them from Ebay and make them yourself.
They certainly look a lot better..

[Dampies]

Did you finish the project or not yet?
Just keen for an update mate.
Haha

[jff45]

Did you finish the project or not yet?
Just keen for an update mate.
Haha

No, not yet.. I got involved in removing some big trees that were too close to the house and we decided to keep all the wood so I've bought a used log splitter that I've had to work on and it's all given me a fair bit of chainsaw work to do.
I'm having to use the Patrol to cart top branches to the dump with my trailer.

I'll need to put it off the road for a good week because I also have a front seal to do as well.
Also have to make my own exhaust from turbo to cat.

I'll update with pics as soon as I get back into it..

[v502]

Cant wait to see that thing roll.