New member, new 60 project

[eknomf]

Well I havent had time to do the rear main again yet, but I have been collecting parts for the turbo build... I also got a speedisleeve for the crankshaft, and a new input seal for the tranny. After the setback with the rear main seal and getting a better DD, I have lost some of the urgency to get the truck running, with this winter or spring as my new goal.

I was debating going with one of the reproduction 13bt manifolds, but I couldnt justify the $500 price, especially since I would still need an adapter, and I would like a cleaner looking setup than that. I am debating an intercooler - I would like a top mount (and have a perfect intercooler for it), but dont want to hack up my hood. Any suggestions? Would an electric fan on the IC and no hole in the hood work?

Here is what I have accumulated so far:

For the turbo I went with an 08 wrx turbo (TD04) that was pulled off when almost new (3000 km on turbo apparently) to upgrade to a bigger turbo from a local guy for $180. He has a stock downpipe I am probably going to hack up as well, as the exhaust outlet is a weird shape.

I had an exhaust flange cut at Island Waterjet the other day - he does nice work quickly at a good price (flange was about $60, and ready within 4 hours of sending him the CAD file), and he also hooked me up with a pile of material for welding practice. I would highly recommend him.

I also have a bunch of long radius 1.5", steam pipe bends to pick up tomorrow at a local distributor (got 8 about $5 each)

I am planning to make a steampipe manifold along the lines of what is pictured here. I think I can do it for under $500 with everything.

The only things remaining to obtain will be the turbo flange for the manifold and oil and water lines.

 

[eknomf]

I finally got the truck "finished" to get it through inspection, imported, insured, and plated today. I also got to drive it for the first time today. A big thanks to those on mud who gave me a hand (tootall and seapotato) and helped me out with parts. Now that it has gone through inspection I am going to start working on the turbo

Took it out for a bit of a test in the snow and got surprised by the depth of some puddles that are normally not as deep..

 

[Diesel Cruiserman]

I finally got the truck "finished" to get it through inspection, imported, insured, and plated today. I also got to drive it for the first time today. A big thanks to those on mud who gave me a hand (tootall and seapotato) and helped me out with parts. Now that it has gone through inspection I am going to start working on the turbo

Took it out for a bit of a test in the snow and got surprised by the depth of some puddles that are normally not as deep..

That up Dumont?

Rob

 

[eknomf]

Nope, its out on the way to barsby lake off of Nanaimo Lakes Road.

 

[eknomf]

I started on the turbo manifold today:

 

[too tall]

Looking good . How's the leak ?

 

[Toshi38]

Cool!

Really neat design ... is there a reason you didn't do a log style turbo manifold?

I can't wait to hear how your turbo ends up? I know that I couldn't be happier with the improvement.

 

[eknomf]

Theres a bit of oil on the engine, but nothing drips on the ground. I should deal with it before the turbo goes on.

I finished the manifold today. I am pretty happy with the result, as this was my first real welding project (I had a ticketed friend do the engine and trans mounts).

I based the design on the 8 pipe elbows I had and the design to get the right turbo placement with those pieces.

 

[eknomf]

Today I got a bit more done:
-Ported out the manifold so there is a smooth transition between the flange and the tubes.
-Installed my EGT and boost gauges. I used some Auber Instruments gauges. Ryan warned me about his experience with Auber, but I'll risk it as they seem like the easiest gauges to install cleanly. I have the flashing buzzer hooked up to the EGT gauge so that there is an idiot light if others are driving my truck.

Gauges installed into a blank insert that was in the FJ60 dash, but not the BJ60 dash. I was originally going to put them in an aluminum plate in the pocket below the stereo before I realized this location was the perfect size for the 2 gauges.



Gauges installed



Flashing buzzer hooked up to EGT



Wiring



Powered on

 

[slowandsteady BJ]

Right on!

 

[seapotato]

cool man.

they are nice little gauges...and the ability to ad a warning light is great...

it's good to be able to give people simple instructions..."if this light comes on, get off the damn skinny pedal"

I damn near have to give people a notebook if they want to drive one of my trucks, describing the various vibrations in detail, (most can be ignored, beware the kidney jiggler) watch these dials, here's the numbers you want to avoid for each, hold this down when turning left, etc.

Course, plus side of all this, they quite often just decide to walk or drive their own vehicle...

My issue with auber was really with that "Suyi" character at the company. they sent me old stock that was broken quite obviously by mistake, and then wouldn't admit to the remote possibility they'd erred, and it's impossible to prove either way .

*stops talking about it before a new rant starts...*

 

[Diesel Cruiserman]

Looking good, glad you did not have to pay for that little bit of aluminum..


We have a brake in the shop 4 footer, you need anything bent you know were I am Saturdays..

Rob

 

[eknomf]

Turbos sure sound awesome...

I finished up the turbo build last night. I ended up cutting off the turbo flange and flipping the manifold so that the two studs are easy to reach and so that the turbo is mounted downwards. The only think left is to get some hose to connect the airbox to the turbo. I aso want to hook up an intercooler, but I wanted to get it running first.

I havent turned up the fuel yet but it is making about 5 psi at 3000 rpm.

 

[Diesel Cruiserman]

Is that a air compressor mounted on the engine?

Looking good...


Rob

 

[eknomf]

It is the compressor for the AC off the 2f. Apparently the AC all worked well before the gas engine gave out so I made a bracket for mounting the compressor on the 3b and retained it. I still need to figure out how to wire up the AC and source a pulley for the crank.

 

[slowandsteady BJ]

Is that a air compressor mounted on the engine?

Looking good...


Rob

I thought that was some sort of turbo joke Rob..... Yes Rob, thats a turbo, and yes Rob it does indeed compress air LOL

Looks good eknomf

Did you hook up the water cooling? How'd you run the lines. I remember mine were a bit tricky. Also, Ive never seen anyone turbo a cruiser and get around to mounting the intercooler right away (me incl)! Everyone goes turbo first.... get around to intercooler in 6 months or so. (although Able did it pretty fast)

 

[lineman_fj40]

Just one point, the flex pipe should go down the line farther, there should be a bracket I belief that rigged mounts the exhaust to the tranny where the engine and tranny meet. But hey if it works don't worry about it.

 

[Toshi38]

Just one point, the flex pipe should go down the line farther, there should be a bracket I belief that rigged mounts the exhaust to the tranny where the engine and tranny meet. But hey if it works don't worry about it.

Why should it go further down?

Mine is in a similar position... I thought it was simply to separate the engine mounted turbo which might move with the engine from the frame/body mounted exhaust which would be moving with the frame/body?

 

[Diesel Cruiserman]

It is the compressor for the AC off the 2f. Apparently the AC all worked well before the gas engine gave out so I made a bracket for mounting the compressor on the 3b and retained it. I still need to figure out how to wire up the AC and source a pulley for the crank.

I thought it was one wire for the magnetic clutch?

Rob

 

[eknomf]

I havent hooked up the water lines. I plan to but I need to figure out the best way. Where in the system would be the best place to hook in for cooling?

The AC wiring doesnt look very hard, but the turbo has been the #1 priority. I have an AC amplifier off an FJ62 which I heard will work on a 3b. I have heard a pulley off a toyota LE van will fit for an AC pulley; can anyone confirm this?

I think my wastegate is actuating at 4 psi (stock on the wrx is 7 psi, but I had to mount it differently which may have effected it). I turned up the fuel (feels like it accelerates about twice as fast as NA), but I still max out at 4psi at 1400 rpm and then it holds steady at 4. I am going to just wire shut the wastegate and see what it does.

As for the flex pipe, I think this mounting will be fine. Everything is solid. I will mount the exhaust rigidly to the frame right below the flex pipe. The BJ60 didnt have any kind of flexpipe and never had any problems.