Andy's Custom Turbo Install.

[dasnoboarder]

Finally got some cash together and dropped it off to Al's Mufflers.

When I was in contact with Pit Stop a few days ago, they said they would do it. I went in yesterday to drop it off and they changed their minds. So I came home, and looked in the Yellow Pages .

The guy's at Al's Mufflers said they are going to have to trace the gasket to get the bolt pattern right for the turbo's exhaust housing, and send that off to the plate cutters.

That will take a couple of days, and then they are going to fabricate a 3" dump pipe that will temporarily join into the standard 2" exhaust. I changed my mind to 3" because I'm going for close to 200hp and 15+ psi. I have yet to decide wether it's better to go full 3" after the body lift, or go for a 2.5" tail section based on astro49's results...

We'll see how it goes... I had a nice bike ride home lol...

[polcat]

invinceble said:

Das...

Does the exhaust impeller diameter matches the exhaust housing diameter? I'm guessing the impeller is smaller.


I'm "experimenting" with a similar hybrid turbo on my 3.1 bighorn, again thanks to Jarrad.
I've gone the same, with a 20R exhaust housing, but running the exhaust impeller from a Vi-95 (std. replacement). Inlet side uses all VF-10 parts.

I've got a 2.5" straight thro' exhaust from the turbo too.

....and guess what, not all is well under the bonnet either!

The old turbo would produce 12psi. This set-up tops out at 7psi.
Opening the boost controller only adds another 1psi !!

I'm not getting any temp. or smoke problems, although I have made a small adjustment to the fuel rate.

Bottom line is... I've lost 10-20kmh going up hill on SH1. Off-road I can't say I've noticed anything difference either way.

I'm going to reduce the size of the exhaust housing (to 15R - which matches the Vi-95 impeller) which I hope will spin the impeller faster.

I'll let you know.

aftermarket alterations on turbo's can be fun, re your project onece you have the turbo sorted don't forget the exhaust, and inlet, I have a 4JG2 which I have put the later ball bearing turbo onto (mine was the non bearing type) and did not notice too much difference other than quicker spool up from rest, the setup was put in by Diesel and Turbo here in wellington with boost altered from 9psi up to 13psi + upped the fuel pump pressure. Took my 2.5" freeflow and added a second leg of the same size split at the transfer case point, suddenly alowed the baby to breath and get rid of the exhaust, really noticable! This left the other end that came off the snorkel but reduced to 2.25" into the aircleaner from 3" off the snorkel inlet so I made up a 3" stainless inlet that splits into 2, added another aircleaner and special baffle box to connect the 2 allowing full airflow into the turbo.

works like a dream, motor behaves like a multivalve motor and revs, noticable increase in hp for hills and brilliant off road, have to feather the thottle now but brill for sand dunes etc. can provide pics if you wish.
cheers
Stu ;D

[dasnoboarder]

Polcat

Thanks for the info. I'm waiting to do a body lift before doing the rest of the exhaust, so it can be mounted as high as possible. My intake side of things is still standard, except for a K&N air filter. Pics of what you have done might help visualise things though . Cheers.

[InVinceble]

polcat said:

invinceble said:

This left the other end that came off the snorkel but reduced to 2.25" into the aircleaner from 3" off the snorkel inlet so I made up a 3" stainless inlet that splits into 2, added another aircleaner and special baffle box to connect the 2 allowing full airflow into the turbo.

works like a dream, motor behaves like a multivalve motor and revs, noticable increase in hp for hills and brilliant off road, have to feather the thottle now but brill for sand dunes etc. can provide pics if you wish.
cheers
Stu ;D

not being an engine expert, and still messing with my turbo set-up.....
if the inlet I/D of my turbo is 40mm is there any benefit in making all the hoses running to it 3"? (3" to match the snorkel)
I have increased the hose sizes, but still have the 2" restriction at the airbox.

[geeves]

There is a huge science in airflow technoligy. Some of it sounds more like black magic. A straight pipe can cause more restriction than the same pipe with a small dent in the right place in certain circumstances. Generaly though anything over 150% of the size of the smallest pipe size in the system wont make much difference except when you start thincking about plenum chambers. Plenum chamber is the area between the filter and the throttle and should be 3 times the volume of the engine if non turbo. Dont know what happens to this in a turbo or engine without a throttle butterfly ie diesel.
confused???

[polcat]

invinceble said:

polcat said:

invinceble said:

This left the other end that came off the snorkel but reduced to 2.25" into the aircleaner from 3" off the snorkel inlet so I made up a 3" stainless inlet that splits into 2, added another aircleaner and special baffle box to connect the 2 allowing full airflow into the turbo.

works like a dream, motor behaves like a multivalve motor and revs, noticable increase in hp for hills and brilliant off road, have to feather the thottle now but brill for sand dunes etc. can provide pics if you wish.
cheers
Stu ;D

not being an engine expert, and still messing with my turbo set-up.....
if the inlet I/D of my turbo is 40mm is there any benefit in making all the hoses running to it 3"? (3" to match the snorkel)
I have increased the hose sizes, but still have the 2" restriction at the airbox.

Hi I agree with greeves there is a lot of tech out there exept when you want to do something then it seems to vanish, I took the approach from the boy racer cars and what I could establish from others on diesel engines and have utilised standard available bends except the baffle connecting box and splitter pipe wher it taks airflow off the snorkel inlet at 3" (76mm) both of these pieces I had made up.
I will try to upload pics to show how it looks
cheers
Stu

[dasnoboarder]

These are a few photos of Jarrad Whall's 3.1L MU.







He's having problems logging on and posting messages, so that's why I'm posting them .

He says that now I and another guy he's supplied a turbo to (a 3.1) have had boost problems, and thinks it might be best to change to a 15-R. Even though when on his MU, it was making boost by 1900rpm and pulled hard through the rev range. Can't understand it.

I'm still going to wait and see what it's like when the dump pipe is done. Should be ready by the weekend. ;D.

Still hopefull it works out with the 20-R .

[polcat]

dasnoboarder said:

Polcat

Thanks for the info. I'm waiting to do a body lift before doing the rest of the exhaust, so it can be mounted as high as possible. My intake side of things is still standard, except for a K&N air filter. Pics of what you have done might help visualise things though . Cheers.

Hi Dasnoboarder, here are the pics, hope this might help explain things. cheers
Stu




Snorkel inlet where it comes in and is split into 2


connection to the second air cleaner



the connection is to the std isuzu connection, that black hose will not compress, and is rated to 140C it is my interim until I get a flash stainless connection made up as per previous post.


Exhaust split behind gearbox into 2 and same 2.5" freeflow out back.



mirrored twin pipes!

[dasnoboarder]

Polcat

That intake system looks complicated to say the least. It took me a few mins to figure it out. Do you think it makes a big difference?

Also the exhuast. I was planning a 3" incl. dump pipe going into 2.5" tail section.
How do you find power and sound with the two 2.5" tail sections? Especially 100-130kph overtaking speeds.

I'd like to know anyone elses theorys about what difference two 2.5" tail sections will have compared to a single...

Cheers. Thanks for the info .

[polcat]

dasnoboarder said:

Polcat

That intake system looks complicated to say the least. It took me a few mins to figure it out. Do you think it makes a big difference?

Also the exhuast. I was planning a 3" incl. dump pipe going into 2.5" tail section.
How do you find power and sound with the two 2.5" tail sections? Especially 100-130kph overtaking speeds.

I'd like to know anyone elses theorys about what difference two 2.5" tail sections will have compared to a single...

Cheers. Thanks for the info .

Re the intake, the biggest problem when you sort the exhaust (and there was a noticable difference when I added the second leg to the exhaust ) is deciding what method to use, I had already upgraded to the 2.5" freeflow and the only other option was a 3", working out the gas flows from the 3" and also the 2.5" espesially since increasing the boost I found there were more than sufficient gains by adding the second 2.5" leg as opposed to renewing the whole thing.

The only limiting factor for this is therefore the inlet which is 3" coming off the snorkel but it reduces to 2." going into the air filter and surface area is the problem (or lack of it), choices are to upgrade the air filter to a Prado of Landcruiser one but these are expensive to buy so adding a secondary Isuzu one makes sense.
The connecting box you see on top is 100mm x 50mm, more than enough flow from both filters.

As you know it is important to get the air through the motor esp when you increase boost, that was the whole drive to improve the performance and still look after the motor, operating temp has dropped a couple of needle widths and stays rock steady

The noise you refer to at the 100-130 and above is not that noticable, with the exhaust capability, the flow is never really audible and is quiter the faster you go. Is loudest off idle.

there are some good sites that can assist with pipe flows, the rest is economics.

hope this helps
cheers

Stokes along very nicely now, and only the rubber joint elbow going into the turbo compresses when you try the snuff test

[InVinceble]

Just changed my turbo's exhaust housing from a 20r to a 15r. Had to change the impeeler too as the VI-95 impeller was too tight when the core was fitted to the housing. So basicaly how I'm running a whole VF-10 turbo.
A quick run up the hill and... MUCH better. Spools quicker and I'm getting 3psi more on the gauge.
Planning on a more "in-depth" review at the weekend, got a couple of other niggles to fix first!

[quack]

hey andy do you know were his oil return feed from the catch can is going?

[dasnoboarder]

So...

The muffler shop got the plate today, went to fit it, and realised the way they were going to do it, they could only do about a 1" pipe off it.

This was because on the standard pipe, the bolts go through the pipe, allowing a bigger diameter. He was planning to bolt the plate onto the back of the turbo and weld the pipe coming off the plate (between the bolt holes) if you understand what I mean...

So, if anyone has pics of how they have done their dump pipe, I'd appreciate them being emailed to me or posted in this thread .

Instead, he took out the butterfly and welded the hole up. Took it for a test drive. Starts making boost at 2000rpm, and maxes out at 2400rpm at 6psi. I'm guessing that means the gasses arn't restricted enough to spin the turbo fast enough to get big boost numbers.

Best thing of the day, because he couldn't do what I wanted, if I promised to go back to him when I want my exhaust done, he wouldn't charge me for the plate & taking out the valve. Sweet deal to me.

It looks like I'm going to need the 15-R housing. It's fully driveable, just can't give it full gas because its not getting enough boost to burn it. And is now a bit slower than standard.

Some interesting things though; it takes longer to warm up (less exhaust restriction?), and accelerates easier going uphill on the motorway (when standard i'd put my foot down and nothing would change, now it slowly but steadily accelerates. More gases able to get through the bigger housing, where the standard one was maxed out?).

So, 15-R sounds the go. Have emailed Jarrad, he hopefully will be able to supply one so I can drop it off at Alltech Diesel & Turbocharger next Friday. I might be able to do it myself, but don't feel like undoing all my hard work and probably breaking something else ;D .

Have also asked him about the catch can oil return.

Cheers. Andy.

[powertruck]

Hey guys been a long time since i been on here had problems logging onto this site.
Thanks for uploading those pics andy.
Got some usefully information regarding turbos. Ive been playing around with my 3.1 mu we have changed the turbo yet again ive gone back to a 15r housing vi95 turbine wheel with a toyota 1kzte compressor wheel machined into the vi95 cover bit of work involved in maching it but it fits in good, ive also made up a aluminium belmouth which sits on the inlet of the turbo speeds the air up into the compressor which gives more bottom end torque. boost comes on at 1500 pulls through to 3300 So far compared to my old turbo that andy has boost comes on a tad earlier and seems slightly more torquey its going on the dyno next weekend so i will post the results

[superturbocompound]

dasnoboarder,what your experiencing in your car about the lower restriction is true,when you have a bigger ar turbine housing the pre boost power is good up to 2000-2200k,then power drops off alot after that,this is when the turbo really kicks in on smaller turbines ARs,you should also notice that it will run quiter on highways at higher rpms.true also that its takes longer to warm up due to the low restriction,

[dasnoboarder]

Superturbo

Cheers for the info. Interesting to know that it'll run quieter on motorway ... untill i get the exhaust done ;D .

I still need to find out how some/most of you have done the dump pipe off the turbo (3" or 2.5"), Guy at Al's Mufflers doesn't believe you can fabricate one straight off the back of the turbo...

Andy.

[superturbocompound]

slight error here,the engine will run quieter,this is due to low boost when cruising thus less load on the engine, the exhaust will be a bit louder in this case.

[dasnoboarder]

SuperTurbo.

O ok. So when I put the new housing on, and adjust boost to what it was before (10.5psi), the engine should be back to being noisey, and exhaust still louder?

If I wanted a quiet car, I would have bought a corolla ;D

[superturbocompound]

should sound the same again,

[dasnoboarder]

Hey.

Have booked the MU in for next friday at Alltech to get the exhaust housing changed.

Still interested in how people have done their 2.5 or 3" dump pipes.

Here's a pic from a WRX (I believe it's an IHI turbo too).
Thought it might be how our's have been done.




Can anyone show pics of theirs or describe how theirs has been done?