We finally finished the remote turbo setup on my buddy's '96 F-250 CC SB 460 E4OD.
It's a TP-38(I believe?) Garrett Turbo from a 7.3 PSD Van (so it has the larger turbine housing). It's mounted just behind the cab, the exhaust from the turbo goes right into the y-pipe for the stacks (Stacks on a gasser ). Exhaust is 3" all the way from the collector to the turbo, no cat, no muffler, smog pump + related ancillaries removed. All emissions equipment has been disabled in the computer.
Boost piping is 2" from the turbo and runs along the passenger side frame rail, where it goes up into the engine bay. It goes from a 2" to 3" adapter, where it goes to into the intercooler. The cooled air charge than goes through a 90mm Lightning MAF to an adapter for the dual throttle bodies.
Wastegate is some cheap ebay thing, seems to work. BOV is an OEM Bosch unit from some porsche, was only about $15 and works great.
36 lb/hr injectors (might be 38, can't quite remember) being sequentially controlled through a 95 F-150 California E4OD 5.0 computer. We're using a Moates QuarterHorse and the BinaryEditor software to tune it along with an AEM Wide-Band O2 gauge + sensor.
Here's the video I'm sure you're all waiting for. It was running horribly rich in this video, probably 7:1-8:1 air-fuel ratio. He's only averaging 5 mpg right now. He went about 3/4 Throttle @ ~6PSI in the video. I'm sure he'll gain quite a bit of power once we get the tune dialed in, and he is actually able to open it up fully. There will be a build thread with pictures later.
We need pictures of the setup along with more video! I'd like to see how you mounted the turbo, piping, and where you're intaking air to keep it dry and free of debris. Also, could you get any video of the truck from outside (I'd like to hear the exhaust).
How's the turbo working out? Does it spool correctly? How's the lag? Does it run out of steam with the higher RPMs of the 460 over the 7.3? I've got plans to do a turbo 460 of my own (probably with a Megasquirt ECU), but am unable to decide if a "remote" mount turbo behind the cab is the way to go over smaller twin turbos in a front mount setup.
Is the motor stock or have you made internal upgrades?
We haven't really tested lag, etc..because we need to get the tune straightened out first. It's injecting about twice as much fuel as it should be. But so far it doesn't seem to have any trouble getting the turbo going.
The larger housing on the van turbo is better suited to the 460 than the standard 7.3 truck turbo. The 460forum guys seem to agree that the 7.3 turbo is pretty well matched for a mild 460 turbo build. But we have the rev-limiter set at ~4300 RPM for now anyways. There's a local speedshop with a chassis and engine dyno, so we'll see where its running out of steam.
Internals are stock, so we're keeping boost to around 7 PSI for now. After my friend gets back from basic, he's going to pull the engine and drop some forged pistons and rods in it. Probably going to be looking at around 10-12 PSI with that.
The truck turbo has a 1.0 AR housing, the van has a 1.15. I'm not sure exactly what that means in terms of performance, but in general, the more exhaust flow your engine makes, the bigger your housing should be. A larger exhaust housing will take more to spool however.
He'll probably keep the stock heads to keep costs down. The 460 already has fairly low compression, but he'd probably go 8:1 at the lowest. Part of the turbo goal was to try and keep stock-like drivability without really hurting fuel economy.
There's still a lot left for us to research when he finally does decide to take it to the next level.