So I started this a month ago, work has been getting in the way so it's taking forever. At last I see the light at the end of the tunnel and am almost done.
Specs:
1984 BJ60 with a stock 3B and 514,000km on the factory engine with no rebuild. Other then minor maintenance, alternator, starter and water pump replaced, injectors done a while ago but that's it.
The turbo is from an early 80s Mercedes 300D, rebuilt by ADP in Port Kells (Langley), needed minor machining done on the bearing surface and comes with a 1 year warranty. Cost $450. The turbo was donated to me by a friend.
The manifold is custom built by me, 1/2" thick steel for flanges machined by a friend, all done by hand plasma cutter. Steel costs $0, all stock from other projects already paid for. Also fabricated an extra support for under the turbo (the idea I got from the factory 13BT manual) that bolts onto the oil filter assemby as well as acts as an exhaust system bracket.
Lines and fittings, all purchased from Greenline in Vancouver and New Line in Port Kells, under $100 for all but I was doing extra sensors.
Exhaust addition, bought a pre bent 180 2.5" pipe from KMS and some exhaust flanges from a parts place $ 37. Made the flange for the turbo myself. The existing exhaust that went to the factory manifold got cut down and a flange welded on, there's a flex pipe right below the flange. That way the next time I need to re do the exhaust it doesn't have to go to the turbo.
Air filter box needed to be shortened due to the location of the turbo, it was too tight of a 90, so I modified the stock one.
Guages, I'm installing an EGT, Boost, Oil pressure guage from Glow Shift $150, which turned out to be a birth day present from a really, really good friend - I'm still trying to give him money for it. Also a water temperature guage is going in, from Princess Auto $35. The guage cluster, also built by me is all 18ga sheet metal, bent, and welded with hidden mounting screws.
What's left: Ceramic coating of the manifold, and exhaust extension. Powder coating of everything else that is metal. Buying the air hoses and 90s for the intake. making an exhaust gasket for the output of the turbo, apparently Mercedes doesn't even have a part number for it, if someone has one - please help!
Installation and finish wiring of the sensors, relocate my on board shower setup and fire it up - I really hope after all this it works.
now for the pics:
Specs:
1984 BJ60 with a stock 3B and 514,000km on the factory engine with no rebuild. Other then minor maintenance, alternator, starter and water pump replaced, injectors done a while ago but that's it.
The turbo is from an early 80s Mercedes 300D, rebuilt by ADP in Port Kells (Langley), needed minor machining done on the bearing surface and comes with a 1 year warranty. Cost $450. The turbo was donated to me by a friend.
The manifold is custom built by me, 1/2" thick steel for flanges machined by a friend, all done by hand plasma cutter. Steel costs $0, all stock from other projects already paid for. Also fabricated an extra support for under the turbo (the idea I got from the factory 13BT manual) that bolts onto the oil filter assemby as well as acts as an exhaust system bracket.
Lines and fittings, all purchased from Greenline in Vancouver and New Line in Port Kells, under $100 for all but I was doing extra sensors.
Exhaust addition, bought a pre bent 180 2.5" pipe from KMS and some exhaust flanges from a parts place $ 37. Made the flange for the turbo myself. The existing exhaust that went to the factory manifold got cut down and a flange welded on, there's a flex pipe right below the flange. That way the next time I need to re do the exhaust it doesn't have to go to the turbo.
Air filter box needed to be shortened due to the location of the turbo, it was too tight of a 90, so I modified the stock one.
Guages, I'm installing an EGT, Boost, Oil pressure guage from Glow Shift $150, which turned out to be a birth day present from a really, really good friend - I'm still trying to give him money for it. Also a water temperature guage is going in, from Princess Auto $35. The guage cluster, also built by me is all 18ga sheet metal, bent, and welded with hidden mounting screws.
What's left: Ceramic coating of the manifold, and exhaust extension. Powder coating of everything else that is metal. Buying the air hoses and 90s for the intake. making an exhaust gasket for the output of the turbo, apparently Mercedes doesn't even have a part number for it, if someone has one - please help!
Installation and finish wiring of the sensors, relocate my on board shower setup and fire it up - I really hope after all this it works.
now for the pics:
mat that RULES! i am fired up for you. your a wicked fabricator!
