What have you done to the injection pump since fitting the turbo? The 4BD1 (non turbo) doesn't have a boost compensator to limit fuel until the turbo spools up, so black smoke before spoolup is tricky to avoid. The A pumps we have run a fuel plate inside the governor which sets fuel based on rpm. This can be modified to reduce fuel at lower rpm to limit smoke but I haven't tried doing that.
I would look for air intake restriction as the source of your high EGT and black smoke while still in the shed.
For your exhaust manifold. The size is fine, the shapes are awkward as the Isuzu ports are rectangular and the pipes are round. A better design if you keep using pipe fittings is to use elbows exiting each port and trim them into the manifold tube so all the pulses are pointed in the exit direction. Sort of like a row of r's. rrrrr
Are you the same Keith from AULRO who once lived in my home town?
I would look for air intake restriction as the source of your high EGT and black smoke while still in the shed.
For your exhaust manifold. The size is fine, the shapes are awkward as the Isuzu ports are rectangular and the pipes are round. A better design if you keep using pipe fittings is to use elbows exiting each port and trim them into the manifold tube so all the pulses are pointed in the exit direction. Sort of like a row of r's. rrrrr
Are you the same Keith from AULRO who once lived in my home town?
