Finally got the finishing touches completed of my turbo build...I would have more step by step but no camera handy at the time. =(

All I have to say is WOW!

First off, a nice shot of the rig:


New Exhaust location:


Underside shot of exhaust:


Crossover pipe:


Crossover pipe (driver's side):


Now the best part, the engine bay:






Now that the picture show is done, I figure I will give a little more detail about this build.

Overall, it fought me tooth and nail to get it done. That is an older "conventional" Hypermax turbo kit with mild modifications.

As you can note i the pictures, I relocated the glow plug relay as well as the senders and the CDR vent location.
For the glow plug unit, I opted to do the banks relocation design. Overall it was planned to give me more room to work on the driver's side. Simple wide strip of flat iron with a bar brazed underneath to accept the bolts for the unit. (Thanks to Dad for the master brazing work...too bad I lost the first set of pictures of it.)

The senders for oil pressure and oil feed line you can see are VERY different. For the oil feed line, I used the port on the back of the block, feeding into a 90* brass fitting, running 3ft of high grade hydraulic line (5000 psi rated). That assembly runs to double tees with each sender for the stock oil sender and my aftermarket one. Seems to do well and shows ~30-35psi oil pressure. I ran with double tees to clear the air cleaner/turbo housing if you were wondering.

The CDR vent...well lets say I didn't want to drill into my valve covers. So I used the banks design once again and ran a line of heater hose to the IP cover plate which I drilled and brazed in a fitting. This might need some adjusting later on. Also fabricated a flat iron bracket to seal the back of the intake manifold.

Exhaust was assisted in custom fabricating by a local muffler shop. The guy that did the crossover pipes was VERY talented and almost copied the hypermax design perfectly without having ever seen it. Only needed me to point him in the direction of how I wanted things. Surprisingly, it was almost the same price had I ordered the pipes from Hypermax. They did a good job sneaking that 3" stainless steel powerstroke downpipe in there too. With me beating the firewall senseless for them.

All in all, a very tiring experience as I had to fabricate almost everything except the turbo, intake hat, and turbo manifold. If I had to do it again, I would definitely pull the engine. No question about it.

The only things I am running into now...is my toasty floorboards. I had planned to wrap and ceramic paint the up pipes...but I can't get them apart now. I will have to come up with something as about 30min of driving gets the floorboards hot to the touch.

I have to say thanks for the tips I had from various members from here and over on OBS. Two to note was Dave Sponaugle on here for his expert advice. And from OBS, Agnem with his helpful hypermax install writeup.

Enjoy the pics, videos to come! Old smokey is loud! Although it isn't that bad when the windows are up. The turbo chops up the straight pipe 3" sound pretty well...minus the insane turbo whistle. LOL

 

id like to have those toasty floors in the winter! Heated floors in that ole truck?, rollin in style now lol fancy

 

Nice work man... I bet that thing gets up and goes now!

 

I bet your neighbors know when you leave the house!!!

 

run your exhaust out a little farther back and she wont be quite as loud in the cab

 

I agree with john there... behind the tire is so much nicer in the cab then in front of the tire! My 92 goes behind tire... the old 75 goes in front of tire... BIG difference in cab noise!

 

mine is in front of the tire and i can hardly hear the exhaust and its a 5" pipe from pretty much the crossover back

 

Actually, the noise isn't a problem for me at all. The only time you notice it (even when you stand on the throttle) is when the windows are down. Otherwise, you can't even hear it.

You bet the neighbors know when I head to work in the morning though! Surrounded by farm country and the sound realllllly travels.

The only concern I have is probably finding a heat blanket of some sort...or finesse my header wrap around the pipes on the truck.

Believe it or not...I haven't adjusted the IP yet...it already hauls *** off the line! As soon as I get a new fitting for my boost pressure, I will start dialing it in along with my EGTs.

>EGTs so far:

Stock N/A: ~600*F cruising 60mph
Turbocharged: ~450*F cruising 60mph

Heavy throttle (3k),
Stock N/A: 1000*F
Turbocharged: 800*F

No boost pressure figures yet...but you can sure hear it spool. More to come on this during the weekend. Thanks for all of the replies guys!