Build Fresh Start For A Tired 60 - 1HZ Conversion

[The Machinist]

I also tossed a cheap ebay top mount intercooler specifically for the 1HZ/1HD on it just to try it out. Obviously, it doesn't make a much difference without a hood scoop, but I have a spare hood that I am planning on grafting a 4th gen 4runner Sport or second gen Tacoma hood scoop into; just need to keep an eye out in the local junkyards for one. Ultimately if I'm not satisfied with the end result, I'll go back to the stock hood and spend some real money on a water to air system. Only problem is that the cheap intercooler core was welded together horribly crooked

I also ordered a pile of 3" exhaust tubing that I will eventually get around to turning into a new, free-er flowing exhaust. Ski season is just around the corner though so all of that might end up waiting until spring,... unless the snow sucks this year.

Also took it for a quick overnight trip up to the Sawtooth's and poked around the upper Salmon river looking for good fishing spots. This is the same general route that prompted me to add the turbo; unsurprisingly, it performed significantly better with boost than without.

 

[The Machinist]

A few weeks ago I grabbed a hood scoop off of a late 90's Subaru Impreza and started mounting it in my spare hood. The paint and body working stuff I ordered won't be here before the holidays, so I decided to test fit it yesterday. I'm glad that I did before painting because this hood got a bit tweaked from its time in the junkyard; definitely going to have to straighten it out in a few spots before painting it.

To test the intercooler, I did the same drive on Saturday and Sunday, with the only difference being the hood swap. The scoop successfully dropped EGT's while cruising at 70-75mph by 100-150*F on flat ground, which is where I have previously have had trouble keeping things cool. Yesterday's ambient temps were about 45*F and at 75mph my EGT's were sitting comfortably at or below 700*F. Taking it up a long grade, I was able to maintain 65-70mph in 5th gear and could not get the EGT's above 1000*F; interestingly when I repeated the same hill but used 4th gear like I normally would, EGT's ran hotter exceeding 1100* if I let it. This confirms what I already knew: the exhaust or turbine housing is too restrictive at higher rpm. It will be interesting to see how much of a difference the 3" exhaust will make when I eventually get around to it, but I still believe that the 7cm exhaust housings are too small for US highways and will likely swap the turbo out for an 8cm version down the road.

 

[cruisermatt]

looks great!

 

[Knowbuddy]

A few weeks ago I grabbed a hood scoop off of a late 90's Subaru Impreza and started mounting it in my spare hood. The paint and body working stuff I ordered won't be here before the holidays, so I decided to test fit it yesterday. I'm glad that I did before painting because this hood got a bit tweaked from its time in the junkyard; definitely going to have to straighten it out in a few spots before painting it.

To test the intercooler, I did the same drive on Saturday and Sunday, with the only difference being the hood swap. The scoop successfully dropped EGT's while cruising at 70-75mph by 100-150*F on flat ground, which is where I have previously have had trouble keeping things cool. Yesterday's ambient temps were about 45*F and at 75mph my EGT's were sitting comfortably at or below 700*F. Taking it up a long grade, I was able to maintain 65-70mph in 5th gear and could not get the EGT's above 1000*F; interestingly when I repeated the same hill but used 4th gear like I normally would, EGT's ran hotter exceeding 1100* if I let it. This confirms what I already knew: the exhaust or turbine housing is too restrictive at higher rpm. It will be interesting to see how much of a difference the 3" exhaust will make when I eventually get around to it, but I still believe that the 7cm exhaust housings are too small for US highways and will likely swap the turbo out for an 8cm version down the road.

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This is so cool you are making me want a top mount intercooler instead of my front mount.

 

[The Machinist]

Took a while for me to get the hood cleaned up and painted, but I'm pretty happy with the end result. Its far from perfect, but perfect from afar. I'm very happy with how the scoop came out now that its all color matched.

This hood came off of a 62 in a local junkyard that had a blown up transfer case and had clearly sat somewhere for a long time before it was sent to the junkyard. I had to fish a bunch of vines out of the hood supports before I could do any paint work!

 

[davegonz]

Great job!

 

[The Machinist]

Knocked out a new 3" stainless turbo back exhaust over the last two weekends. A while back I ordered a generic and cheap DIY exhaust tubing assortment off of ebay, along with a 4 pack of cheap vband clamps, and a nice quality flex pipe and muffler/resonator from Vibrant. The v-bands were branded "evilenergy" on amazon and are actually pretty nice.
This exhaust is by no means show quality, but its way better than the 2.5" rusty junk I had previously put together. Was great to get almost two full days of TIG practice while welding it all up, but its definitely a lot more challenging than you might expect to get it to all fit nicely. You can definitly tell the difference between my work and someone who does this professionally, but I'm quite happy with the end result. It should flow a lot better which will help keep EGT's more manageable and it sounds amazing. The resonator toned down some of the rasp from the old setup and the overall tone is lower. Idle is quieter in the cab and highway cruising is notably better than before. Under load while accelerating it sounds smoother and has a killer tone; overall I am extreamly happy with how it sounds!

Here's the resonator that I used. Vibrant Performance 1142 3" Ultra Quiet Resonator

 

[Ditcherman]

Enjoyed reading through your build thread, nicely done.
That evil energy stuff is pretty good.
Did you purge your pipe when you welded it? I re rally enjoyed welding stainless for the most part but worried I didn’t take purging seriously enough.

 

[The Machinist]

Enjoyed reading through your build thread, nicely done.
That evil energy stuff is pretty good.
Did you purge your pipe when you welded it? I re rally enjoyed welding stainless for the most part but worried I didn’t take purging seriously enough.

Thanks!

Stainless is definitely my favorite material to tig weld! I did not backpurge for any of this stuff. The way I look at backpurging is that for anything downstream of the turbo it is just a waste of gas. Would be a different story if this was for a show car, but I'm not good enough at tig welding to make anything that nice anyway.
If I was making charge pipes or a custom intercooler I would probably give back purging a try just to reduce any chance of getting a chunk of overheated weld from breaking off and getting consumed by the engine.

 

[Miloslavich]

Nice work!! enjoyed reading your thread.

Love the 1HZ, workhorse of an engine. Makes me want to find a beater 60 to diesel swap for off-roading. My 60 is too nice for those duties anymore

cheers

 

[The Machinist]