[smokey]

did you get a industrial manifold?

 

[Jcarrick]

No, its from a 2003-2007 common rail truck

 

[4runnerChevy]

In your 10th build pic, how many degrees is your engine tilted. Thanks

 

[my96z]

Here is another option for your exhaust manifold. It is a Ford 6bt type that lets out at the same location as the Common Rail just has the proper port for your application

Cummins P/N: 3931744

 

[Jcarrick]

In your 10th build pic, how many degrees is your engine tilted. Thanks

It is tilted 5* back.

my96z,
Thanks for that part number! Im just going to stick with the common rail mani cuz it only cost me 90$ and all i need to do is a little trimming on the gaskets. If all said and done it doesnt work i will get the Ford type.

 

[Jcarrick]

Well i got the Common Rail mani mounted up this weekend. I just took the gasket and marked where i needed to take material off and took my die grinder to it. Everything worked out quite nicely. Here are a few pics. I forgot to take some before i put it on of the porting:

Now i did have some troubles with the wastegate actuator. It is hitting the block. I guess theres a turbo that has it mounted 90* from where mine is, i dont know. Or you can remount it 90*... I dont see how to do this, but maybe you guys know? Here are some pics of how it mounts now:

-Jon

 

[gr8shot]

a wh1c off a Ford medium duty cummins will have the wastegate actuator mounted differently. If I remember right it points toward the front of the truck. But the little wastegate tab itself was attached at a different angle too. That's what was on my motor and I sold it and used a Dodge manifold and turbo since it fit better for my application.

Sent from my Droid using Tapatalk 2

 

[Jcarrick]

Ya, i found an exhaust housing wastegate for it. Goldfarb and Associates is my number one place to buy turbo stuff. I called them up and they have everything i need. They even sell whole core turbos for $150 dollars. Great place to do business.

Right now i need to get my intercooler piping and downpipe made. My engine did not come with an exhaust elbow that goes to the turbo so i am trying to figure out how to go from the 3" v-band to a 4" downpipe. Maybe someone has an exhaust elbow they'll sell or a link to a 4"-3" reducer? Im going to try to go to the exhaust shop this week to have them bend a tube for me for my lower coolant hose. From there the only thing really left to do is wire it up. Does anyone have any engine wiring diagrams? The main thing i need is for wiring in relays for the push and pull on the full shut off solenoid. Im hoping to be able to start in the next month or so. We'll see how things go

-Jon

 

[Jcarrick]

Hey guys, its been a little while since my last update.
I got my new turbo housing with the 90* mounted wastegate actuator and it fits perfect! As of right now about the only things left to do on the truck is finish up the wiring, weld up the piping for the downpipe, intercooler, and lower coolant house, modify the sender for the return line and a larger feed line, and run a couple fuel lines. Im hoping to get most of the wiring finished up tomorrow so this thing will be ready to start as soon as we finish some welding. I have all the piping, just need to get the tig ready to go. I also need to remember to install my GSK and fuel plate, but that shouldnt take to long. Im thinking the first start up will be in about 2.5-3 weeks. Maybe sooner, but we will see. Here are a few pics of the progress. You will have to excuse it being dirty, i will clean all the dust off once the wiring and plumbing is done.

Heres a picture of how the new wastegate actuator works. The comp housing is off because i was removing the silencer ring and cleaning the housing out.

Oh, and the cover for the blower motor is off because i was seeing if i could section it for the stock manifold, but obviously i couldnt. Haha.

Heres a picture of the mount for the clutch slave(?) cylinder. It is a 1/8" piece of stainless steel with two 90* bends for stiffeners.

And here is a quick glory picture. I got out my great grandfathers 1941 Mauser K98 this weekend. It had been sitting in my dads closet for 30 years and had never been shot. He thought it had the wrong bolt in it so i took it to the gun smith. He confirmed that it was in fact the right bolt and an especially rare/valuable one at that. So i picked up 20 rounds and went out and shot it for the first time in 35+ years. It is a beautifully firing gun. Oh, and my great grandfather built the stock for it. Thats why theres so much sedimental value to it.

 

[Grey Wolf]

The exhaust manifold looks good on there, how much time do you have in it?

 

[Jcarrick]

Thanks! Maybe like 1.5 hours? It really didnt take too long to open up the ports on it. I just used a carbide bit on my die grinder to "rough" cut it and then went back around with a stone bit to make them smooth. Should work great!

 

[CR_Magruder]

Right now i need to get my intercooler piping and downpipe made. My engine did not come with an exhaust elbow that goes to the turbo so i am trying to figure out how to go from the 3" v-band to a 4" downpipe. Maybe someone has an exhaust elbow they'll sell or a link to a 4"-3" reducer? -Jon

Jon-- Here are a couple of options for the reducer fitting:

http://sourceautomotive.biz/3to4exhaustflange.aspx

http://www.atpturbo.com/mm5/merchant.mvc?Screen=PROD&Product_Code=ATP-FLS-043&Category_Code=FLS

If there is no room for these and a tight-radius 90° elbow, then you could consider going with 3" OD off the turbo and increase to 4" immediately downstream of the 3" elbow with a reducer like this:

http://store.airflo.com/4315-340-3.html
The slip connections make it easier to fit up and tack than butt welded connections next to the firewall.

Best,

Chuck

 

[Jcarrick]

Thanks chuck. I actually already found on from Columbia River. Everything 'should' fit ok. I'm hoping to have the downpipe nearly finished this weekend. Just need a 3" v-band assembly.

Oh and I messed up one of the intercooler tabs. I'll show you tonight.

-Jon

 

[Jcarrick]

Well, the truck is done and running good! Im sorry for the lack of pictures lately, i have just been working on getting the rest of the truck good to go. I pulled my first trailer with it today and it did awesome. I towed my boat up a 6-7% grade doing 70. My egt's were just around 1000*. I have lot more left to do, but i am gaining on it slowly but surely. Heres a quick pic of the setup and basically the reason i built this thing:

I love this thing so far. It is working out great! I do need the bring the front up about 1-2" because it sits a little nose down.. I have a major rubbing problem right now with the arm that comes off the steering box. Does anyone know of a custom one that brings it away from the tire more?

Other than the things that need to be changed on it like door and window seals, etc. the truck has been running great. I have put around 700 miles on it so far with no problems at all! Im absolutely loving it. I will post up more finish pictures soon.

-Jon

 

[cRiPpLe_rOoStEr]

nice boat... does it also spot a diesel?

 

[CR_Magruder]

Congrats Jon-- that looks really great. Glad you will be able to have some summer fun with it now. I looks kinda long; don't you need a special permit or something when you are towing?

Chuck

 

[Jcarrick]

Rooster,
The boat does not have a diesel in it. It has a 350hp Black Scorpion 350 motor in it. A 4bt would be a good idea in it, but we would have to figure out the gearing and prop for it.

Thanks Chuck! It will definitely be a lot of fun. Its also going on the mexico trip this year towing the tool trailer. Haha, nah no permits needed right now.

-Jon

 

[cRiPpLe_rOoStEr]

The boat does not have a diesel in it. It has a 350hp Black Scorpion 350 motor in it. A 4bt would be a good idea in it, but we would have to figure out the gearing and prop for it.

this is not really so hard to do... and a 4bt would be really fine... a friend of mine has a boat with a 320hp chevy 350cu.in. small-block, those are cool but the fuel consumption is too high... once i inquired him why wouldn't he consider a diesel instead of that gasser and he told me that "diesels are too loud", despite the v8 screaming as hell...

 

[Jcarrick]

I really wouldnt mind the noise, im just worried about speed. I ski at 36mph, wakeboard at 21mpg, and surf at 8mpg. I would actually be very happy about the weight of it. Its hard to get motivated to do this though when it runs great right now. You know, dont fix what aint broke? But talking about it is interesting.

-Jon

 

[Jcarrick]

Today the truck made its second trip towing the boat to the lake and it did awesome! Now that i have it driving there are a lot of things i want to tidy up. First off is my fuel tank. Right now it is running a crappy aftermarket tank that has broken twice so far. So i definitely need to get that tanken care of. Since i want to put a tool box in the bed anyway, i decided to look for a toolbox fuel tank combination. I found a great one here: FT-50 Truck Fuel and Tool Box Combinations - Custom Truck Fueltank & Toolbox Combo | Handy Industries
I really like the idea of having a 50 gallon tank, but this would end my ideas of getting a camper for it. What do you guys think? Any other ideas for fuel tanks? Or does anyone have stock tanks for under the bed they would sell?

The next thing i need to address is brakes. They arent terrible, but not awesome. Right now the master cylinder cap is leaking a little bit so i was going to order a new one, but then though about a hydroboost setup. Is it worth it? And what would i pull the hydroboost out of? Anybody have an estimated cost of converting this?

The last major thing that is on the list right now is the front suspension and steering. I just traded a guy some parts for a kit from Ballistic Fab for converting the front end to coils and 4 links. I wasnt looking for this kit, but he needed the parts i had and offered the kit so i took it. Im not sure i really want to do this yet, especially with my 44, but its nice to have. Do you guys think its really worth it to convert to coils, or should i just stick with some better leafs? Either way, something has to be done about the steering. This thing already doesnt turn, but when you cant go full lock to the passenger side, it REALLY doesnt turn. Here are a few pics of the steering setup:

Here you can see where the pitman arm and tire are rubbing

A little background info on the suspension/steering setup. This truck was a factory longbed f350 2wd that was converted to 4wd with a dana 44. They said it was out of a hi boy, but who knows. The only other thing i know about is that it has a Saginaw steering box.

So the truck needs to come up almost 2" in the front either way to make it level. The question is what can i do to fix the steering and what should i do for front suspension? Ive been told to do 95-97 powerstroke 4" lift springs work well, but i would like some more advice and help on planning the whole front end setup.

-Jon