One Stop Safari Turbo Thread! - Repairs, Upgrades, Challenges

Discussion in '80-Series Tech' started by yoda-g3, Jun 13, 2018.

  1. yoda-g3

    yoda-g3 SILVER Star

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    Hi all,

    After starting on my second round of Safari repairs over the last 6 years I decided to compile all of the threads into one place to help other Safari owners if they get into the same boat as me.

    In a nut shell, my rig had the turbo installed professionally by a dealership around 50k, still on original HG. At that time there was a Unichip installed.

    Years later at 144k I discovered cracks in the turbo housing caused most like by running excessively lean.

    Here is a post with Dyno results / Parts info that led up to that discovery: SAFARI Turbo Dyno Results - AFR Questions

    That turned into quite the saga in finding "current" replacement parts that kept me from re-working the entire system. That can be found here: Help sourcing Safari Turbo Exhaust Housing - .82AR

    With a little follow up on the post "upgrade" tweaks here: Help ASAP! - Safari Turbo Rebuild - Too Much Boost - Heading on camping trip!

    The summary of my repair was I had the manifold welded, turbo rebuilt / turbine housing converted to a 5 bolt Ford style flange, then mated a flapper gate to the turbo (allowed me to retain the internal wastegate), and had my shop custom build a new down pipe. I also removed the Unichip to get AFR's back to non-insane levels.

    Now 6 years later and 26k on the "refreshed" unit, I have discovered more issues. You can track that saga here: Need turbo gasket advice - Copper vs SS vs V-band?


    Summary take away so far:

    - Flex pipe by the down pipe was added 2015 after discovering stripped studs off turbo housing. It was a cheaper flex pipe I realize now and has failed. Flex pipe is a must! But don't go cheap, next one will be a Vibrant TurboFlex Coupling with Interlock Liner

    - Don't skimp on exhaust hangers.... I think it caused some of my issues. Make sure to double up where you can to take that weight off of the manifold / turbo.

    - Ceramic coating on everything has essentially worn off of the turbo and down-pipe. (Waste of time and money.)

    - HG is still solid (knock on wood) at 170k, with 100k of 7lbs of boost / running LEAN, plus another 24k of 7-9lbs of boost running right. (Not saying to now change it, just giving a data point for those worried about it.)

    More to come...
     
    Last edited: Jun 13, 2018
    Bludozer, NLXTACY and nigelsiam like this.
  2. yoda-g3

    yoda-g3 SILVER Star

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  3. yoda-g3

    yoda-g3 SILVER Star

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  4. yoda-g3

    yoda-g3 SILVER Star

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  5. yoda-g3

    yoda-g3 SILVER Star

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  6. subzali

    subzali

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    yoda-g3 likes this.
  7. subzali

    subzali

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  8. LandCruiserPhil

    LandCruiserPhil Peter Pan Syndrome Supporting Vendor

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    Just found this thread having just breaking the ice on mine after having stored for 2 years since my purchase.

    Inter cooler bushing were first on the list having only one good one to work with I took the ghetto approach by using 2 different size hose. Im super happy with the results of a tight fit.


    [​IMG]
     
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  9. yoda-g3

    yoda-g3 SILVER Star

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    Nice! I used some poly bushing from an old shock kit, they have worked ok, but this seems like a better solution. Mine are too rigid and I'm worried it will wear too quickly.
     
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