Turbo 2H build thread (1 Viewer)

[arnott1t]

Turbo 2H build thread (warning tons of pics)

decided to start a new install thread that would be easier to search for new people. So here it goes:


I am turbo charging my 87 HJ60 with a 2H engine. It had 260k on the clock and runs like a top. Has great low end but needs something for hills and windy days on the highway. I am running 33" At's with 370 gears. I have a 5 speed as well.


The turbo I selected is a garret M27 with an A/R of .48 and .49 on the exhaust. I got it new of the net. I decided to run a flipped manifold and wanted as big of exhaust as possible. Here are the photos.

Some oil fitting parts. Supply line. Small metal one for the turbo and the return stuff.

Turbo itself

more parts

Stock Set up with heat shield removed.

a close up

Oil supply location from oil pressure sending unit above starter on right hand side.

Stock Overall view

 

[arnott1t]

more

Stock manifold removed

manifold prepped for drilling of the pyro port.

Exhaust flange mounting.

pyro port drilled tapped and plugged. We used an existing hole for the heat shield.

Side cover removed for oil return fitting

fitting welded in place. I would have put it opn the front cover if I was to do it again. I suppose I could switch the covers to. It doesn't have much clearance with the finished exhaust.

Cover reinstalled

oil pressure sending unit removed

installed supply hose that is tee'd into where the sending unit is. Had some leak problms here but there all tied up now.

Barb install for return oil line.

Pre fit for clearance and the start of the exhaust pieces. I made a home made w\exhaust flange for the back of the turbo and molded a 3" mandrel bent elbow into it that the rest of the exhast will tie into.

Low clearance with the brake booster. I hope some header wrap and the reuse of the heat shields will protect it.....

Just for reference

Oil return line installed. Don't worry real clamps are used later on...

Supply and return installed. Went for a start here to see how it sounded....sweet

down pipe upside down.

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[arnott1t]

more

IMG]http://i11.photobucket.com/albums/a187/arnott1t/Turbo%202H/Turbo2H046.jpg[/IMG]
tail pipe

routing. It dumps before teh rear tire. There are 3 bend in the system two are mandrel bent and the last is a compound mitre. Should be free flowing. Lesss than 10ft of total pipe.

more routing

More to come. Still need gauges and my plumbing to and from compressor.

 

[In2cruisers]

Your going to have to shield your brake booster and fluid.....your going to cook them

 

[BC40]

Looks great so far. Though I think the brake booster won't appreciate the downpipe that close without a heat sheild. Not sure if header wrap would be enough.

 

[arnott1t]

Ya...Heat shield is in the works as well as header wrap. Ithink with both I should be ok. Have to keep a close eye on it though.

 

[arnott1t]

yes there are even more....

Sorry about the amount of pics but I always wish on other threads that there were more so......

This of apic of teh tip of the exhaust coming out infront of the rear wheel. Not sure thats its legal but wow does it sound cool. I went for a spin around the block and the whistle on this is really great. I may have to quite it down even...

Here is a pic of the heat shield. Its the same as the original shield. I'll go for a run or two and check the temp of my booster and fluid with a infrared gun. Not sure what an acceptable temp is but we'll try it anyway.

More heat shield pics

more heat shield

Overall pic from the front with air plumbing done.

line from filter box to compressor inlet.

another view

More pics

Well that will be it until I get my gauges....

damn UPS




from the brake side

 

[marting]

Looking good ! Another 2H gets its "comeupinns"

One think that might be a small problem though.. I don't have personal expirience with this but a friend told be he had used the original intake to filter- rubber hose and used it for the preassure side... like you have.. he said it didn't hold the preassure and expanded like a balloon..

I agree with what is probably your first reaction "whaaaat.. this solid rubber thing wont expand"...... We'll see i guess... just a tip..

 

[Tapage]

nice .. nice nice. Nice to know that I can flip my stock 2 piece exhaust manifold .. how much clearance you think between the turbo and the hood whet it's closed .. ?

Surprising that you have much more space for the 3" down pipe than my Tencha ..

 

[Dougal]

That's a small turbo for 2H. Be interesting to see how you like it.
I'm running essentially the same turbo on my Isuzu 4BD1T, but my Isuzu revs less.

 

[Tapage]

That's a small turbo for 2H. Be interesting to see how you like it.
I'm running essentially the same turbo on my Isuzu 4BD1T, but my Isuzu revs less.

small .. maybe .. it depends about the performance target.

 

[arnott1t]

Results

Some more notes on the Turbo install. After running it around for a bit with out any gauges I started to blow some serious smoke out the exhaust. Grey smoke or white. I was worried it was my head. After letting it idle a long time though you could find oil in the exhaust. My turbo oil seal was passing on the turbine side.

I pulled the turbo apart and inspected but everything looked good. I talk then to the folks a g-pop shop (they were great) and they mentioned that it can be caused by a blocked return line or to much pressure. I asked how much pressure is to much. They said the turbos can handle maybe 50 psi. Also mentioned minimum oil flow of .5 litres per minute. I pulled the oil supply line off to get an idea on flow. It was about 3 litres per minute. I then installed a gauge on my supply to the turbo. At idel cold it sat around 90 psi and spike higher with revs. I then installed a needle valve to restrict pressure. Its set at about 25psi at warm idle. It spikes to about 50 with revs. Seems to be no more smoke too. Nice...

Next the gauges showed up. I bought Glow-Shift gauges. They were cheap and looked good. Once they arrived the install was super easy and the work and look great. The back light can be changed to about 10 different colors at the touch of a button.

Once the gauges were hooked up it was time to test. Firt went with stock fuel settings and the waste gate controller. I was getting about 2.5psi boost and couldn't get my EGT's over 800. No noticable gain in perfomance.

Next I unhooked the boost controller so the waste gate would stay shut. I could get a peak of 8 psi and seemed to have a little more legs but wasn't terribly impressive. I was pretty bummed out to be honest. But the thing that kept me happy was the whistle. Went out hunting for a bit and once I got home decided to adjust the fuel.

I finally loosened the lock nut and backed out the fuel screw about 1/4".
Right out of the garge it felt good. Even in reverse. On the road it was wow. 1st gear go'sd by way to fast second fast 3 feels like second did. Just prior to turning the fuel up I came up a big hill to he house. I could barely hold 60km/hr in fourth. Prior to the turbo it was losing speed in 4th. Now with the fuel turned up I can blast pass 60 in fourth and climb as high as I want.

I also have teh signiture cloud of smoke with a blip of the throttle at idle. Boost now peaks somewhere around 12 psi. Egt's can get up to 1100 but can't hit 1200. Seems to be about perfect for me. The power is great. Cruiser woke up. My friend jumped in and after a row through the gears asked "Who's truck is this?"

DO NOT HESITATE TO TURBO THESE CRUISERS.....

I love it.

 

[Tapage]

I always take care about my oil press .. I let it warm enought after driving just to keep my oil press under 60-64 PSI .. that it's the max PSI that I saw in my 1HD-T ( factory turbo )

 

[Otterav]

Hello,
Couple of details, your oil line adapter is a tragedy waiting to happen. The weight of the oil line and vibration will quickly fatigue the metal line and it will fail, secure it so the metal line doesn't support the weight of the line. On your air cleaner to turbo it looks like rad hose, replace it with hard lines, metal is best, the suction from the turbo will collapse it once the engine heats the hose on a hot day(ask me how I know). On your down pipe, if you have the space rotate the u-bolt clamp, rotate it and put a piece of stainless steel(stainless is a poor conductor of heat)flat sheetmetal for a heatshield to protect your booster. Then run a cold air blast tube from the front of the truck to the booster area to remove heat.
Nice job!
eric

 

[rchalmers3]

https://forum.ih8mud.com/members/arnott1t.htmlarnott1t,

Well done! You are an inspiration to those of us stuck in the planning phase! Thanks for your photos and encouragement.

So hows it working these days? Are there problems arising from the install keeping you from enjoying the accomplishment? Or is it all good???

I'm curious about your use of the 2 piece manifold for your install. Are there any signs of leakage between the pieces?

Again, congrats and thanks for the details.

Rick

 

[maat]

this write up is perfect, i am going to attempt to turbo my 2H in the near future.. are you able to post pictures of the hose in regards to the oil feed how you tee'd it in?


cheers

 

[Tofudebeest]

Our set-ups will be quite similar. Did you see my new (Glowshift) guage thread? https://forum.ih8mud.com/diesel-tec...44-new-gauges-installed-heres-my-numbers.html

 

[arnott1t]

My oil suply was teed into the low oil pressure shut off. IT is located near the starter. By using and NPT tee and a BSP to NPT adapter you can plumb in there. I in fact just used all NPT since the threads are so close especially at that size. Thread the tee into the block and use one port for the oil supply and one for the low pressure switch. I ran a hydraulic hose up to an adapter to get to the -3 fitting. I have since revamped my adapter and would like to improve it even more if I could.

I havn't looked at this thread in a while and all the advice given to me has come true. The oil line did fail...bummer. So did the intake elbow (but not till 15psi)

I have kept the wastegate wired shut now so I peak around 15psi. At one time was running up to 20 psi...tons of power but I was worried about longevity. I'm hoping to try and intercool it now. Maybe rework some of the intake piping and exhaust. The heat shield has worked fine and I have had no troubles with my brakes.

 

[maat]

keep the pics coming mate, il duplicate your perfect trouble free set up when its all sweet

 

[sporty]

Hello Arnott1t

I am collecting parts for a turbo conversion like yours.
How is your system holding up?
I allready hav a turbo from a nissan patrol with .53 in and .64 out, i am not sure to use that.
Anny advise from the specialists?