FTN's T4/SXE Build/Conversion Thread
2 Attachment(s)
The time has come for this to have its own thread. This project started over a year ago when I read @Sous ' thread on his own T4/SXE conversion. After switching to FFD 205/80 injectors, my GTP38R is/was simply unable to keep up and EGTs were getting unmanageable any time I got on the go pedal. I believe it was contributing factor to my blowing a hole in piston #3. Even then, I was reluctant to switch to a T4/SXE setup because it meant the loss of the EBPV. Living in MN, the EBPV is a necessity to get the engine warmed up quickly. @Dan V might disagree though. That is when I started exploring ideas on how to incorporate an exhaust brake with a T4/SXE setup. Turns out @brokestroke had already done a considerable amount of work on this front. I was pretty much resigned to needing to fabricate my own EBPV/Exhaust Brake when @countrycar posted about the DPS Turbonator VGT/VNT Exhaust Housing. After several calls to DPS, I made the decision to use their exhaust housing as it is the cleanest way to incorporate an EBPV/Exhaust Brake into a T4/SXE conversion. Parts buying then commenced. After several months (and credit card billing cycles), all the major components have arrived. First mockup occurred on June 25th. Here is where we are at currently:
Edit 2: It appears I have not adequately described the need for the 4” v-band flange on the DP based on the questions I’ve been getting so here goes. The standard T4 exhaust housing has a v-band flange with an overall outer diameter of 4.21”. Therefore, all the T4 conversion kit manufacturers supply downpipes with a matching 4.21” v-band flange. The v-vand flange on DPS’ VGT/VNT housing is 4”. Therefore, I had to source a v-band flange with an overall diameter of 4”. This was shipped off to CSD so they could weld that onto the DP that was going into the kit I was buying. Carson was very accomodating with this request. The links to this 4” v-band flange and matching v-band clamp are in the parts list attached. This parts list will be updated as I discover new parts needed as I work on this conversion. https://cimg1.ibsrv.net/gimg/www.for...6b866f88e9.jpg The standard T4 housing has a DP flange dia of 4.21" https://cimg6.ibsrv.net/gimg/www.for...d33ec52968.jpg The DPS VNT/VGT housing has a DP flange dia of 4". https://cimg8.ibsrv.net/gimg/www.for...abc23e22e4.jpg A custom 4" v-band and v-band were required. https://cimg3.ibsrv.net/gimg/www.for...dc2d2079ee.jpg The VGT/VNT housing also has an actuator that sticks quite a ways out from the housing. https://cimg8.ibsrv.net/gimg/www.for...7ed7bd0e17.jpg It will have to be reclocked to not interfere with the y-pipe. https://cimg0.ibsrv.net/gimg/www.for...e0bf8a5c3c.jpg Here's what it looks like from the other side. https://cimg9.ibsrv.net/gimg/www.for...94660c39a9.jpg https://cimg9.ibsrv.net/gimg/www.for...f8663aa02e.jpg https://cimg0.ibsrv.net/gimg/www.for...bac97470c9.jpg https://cimg2.ibsrv.net/gimg/www.for...0a2651e068.jpg https://cimg4.ibsrv.net/gimg/www.for...47c97af83d.jpg https://cimg6.ibsrv.net/gimg/www.for...896539823a.jpg https://cimg7.ibsrv.net/gimg/www.for...78ee87c918.jpg EDIT 1: Oops, forgot to to attach my parts list initially. |
Noob, I don't disagree with the EBPV being a nice warm-up feature, and the trick of using it for an exhaust brake....but, at the time of my SXE install, I didn't see a workable solution to keep it.
Anyway, I'm super excited to see how this progresses for you,and as I mentioned when you stopped by...if I can facilitate some part of the fab for you I'm surely willing. The other parts of the shop are on a 2 week shutdown, so I should have plenty of time. |
This is going to be a lot of fun to watch and all of us are hoping for only the best results.
I have included a link to this thread in my T4/SXE Parts List thread. Keep up the good work Leonard! |
Really..
Many would disagree that keeping EBPV for warming up is not required.. (plus its so sickening) I still have mine BTW.. Why not just plug in your truck on those extremely cold days ?? - that trumps all here in Ontario Canada.. - Our weather is likely very similar !. What size BW is that ? Kyle |
How is the exh housing controlled? Does it come with its own tuning that reacts to rpm, boost and fueling? Is it somehow controlled by oem pcm and a custom flash?
VGT can work very very well but the tuning/control seems to be the key, this is exciting |
Originally Posted by KubotaOrange76
(Post 19350903)
How is the exh housing controlled? Does it come with its own tuning that reacts to rpm, boost and fueling? Is it somehow controlled by oem pcm and a custom flash?
VGT can work very very well but the tuning/control seems to be the key, this is exciting |
Originally Posted by Dan V
(Post 19350818)
Noob, I don't disagree with the EBPV being a nice warm-up feature, and the trick of using it for an exhaust brake....but, at the time of my SXE install, I didn't see a workable solution to keep it.
Anyway, I'm super excited to see how this progresses for you,and as I mentioned when you stopped by...if I can facilitate some part of the fab for you I'm surely willing. The other parts of the shop are on a 2 week shutdown, so I should have plenty of time. Thank you again for the offer. I have a feeling I will be tapping you on the shoulder pretty soon.
Originally Posted by Macmathews
(Post 19350843)
Really..
Many would disagree that keeping EBPV for warming up is not required.. (plus its so sickening) I still have mine BTW.. Why not just plug in your truck on those extremely cold days ?? - that trumps all here in Ontario Canada.. - Our weather is likely very similar !. What size BW is that ? Kyle
Originally Posted by KubotaOrange76
(Post 19350903)
How is the exh housing controlled? Does it come with its own tuning that reacts to rpm, boost and fueling? Is it somehow controlled by oem pcm and a custom flash?
VGT can work very very well but the tuning/control seems to be the key, this is exciting
Originally Posted by Sous
(Post 19351235)
This.......
https://cimg4.ibsrv.net/gimg/www.for...465ff41112.jpg Parameters are modified via a program from DPS on a laptop. How it is programmed is explained in this video: https://www.youtube.com/watch?v=zN1F...ature=youtu.be I have to say I am quite impressed with the engineering on this thing so far. The build on the housing seems robust and the programming interface is intuitive. |
The software seems very robust. Thanks for posting it.
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:-jammin:-X22
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I have EBPV delete pedestal,in freezing temps i use block heater..It sits in high idle while im on my morning dump,windows has plenty of time to defrost..
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It's going to be interesting to see how you manage the actuator and the Y.
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Originally Posted by Dan V
(Post 19352945)
It's going to be interesting to see how you manage the actuator and the Y.
https://www.youtube.com/watch?v=5pLp...ature=youtu.be If that doesn't work, then I'm going to have to start looking into fabricating a custom y-pipe. I hope it doesn't come to that. |
Originally Posted by FordTruckNoob
(Post 19353744)
First thing I'm going to try is reclocking the actuator per the instructions in this video:
https://www.youtube.com/watch?v=5pLp...ature=youtu.be If that doesn't work, then I'm going to have to start looking into fabricating a custom y-pipe. I hope it doesn't come to that. |
Originally Posted by Dan V
My guess is that there is going to be some extensive fab work on the Y pipe.
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I'm following this, going to be another expensive upgrade for our trucks!
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Originally Posted by Bonanza35
(Post 19356118)
I'm following this, going to be another expensive upgrade for our trucks!
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I'm going to be interested in seeing you layup the carbon fiber.
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Originally Posted by Dan V
(Post 19357298)
I'm going to be interested in seeing you layup the carbon fiber.
https://cimg8.ibsrv.net/gimg/www.for...ee264b033d.jpg https://cimg3.ibsrv.net/gimg/www.for...15bd6029f3.jpg |
Ahh, a fellow cyclist....
Mad skills/ patience to R&D your seat :-X22 I spent more than I'd like to admit just adjusting mine up/down/front/back/tilt to fit me just perfect on all the hills and flats after many rides :9 |
You cycling people....This is a saddle, not that carbon fiber thing attached to a post.
https://cimg0.ibsrv.net/gimg/www.for...714afe1e96.jpg |
:-offtopic
I used to ride sport bike motorcycles... Does that count? 2003 GSX-R 600cc Alstare and a 2008 Hayabusa 1340cc. https://cimg4.ibsrv.net/gimg/www.for...9b776c06f5.jpg https://cimg8.ibsrv.net/gimg/www.for...dc57960c98.jpg ------------------------------------------------- On a thread related note, what would you change in the shape or routing of the Y-pipe if you did make your own out of carbon fiber? Would you put a dent or diversion in the upper part of the Y that goes to the IC tube? Have you thought that far yet or just set a COA in case you need to go that far? |
nope......
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Im with Dan on the saddle issue.
Noob,If theres going to be trouble with y-pipe,just fab completely new with different angle..? |
Originally Posted by Wes444
(Post 19357934)
Ahh, a fellow cyclist....
Mad skills/ patience to R&D your seat :-X22 I spent more than I'd like to admit just adjusting mine up/down/front/back/tilt to fit me just perfect on all the hills and flats after many rides :9
Originally Posted by Dan V
(Post 19357972)
You cycling people....This is a saddle, not that carbon fiber thing attached to a post.
https://cimg0.ibsrv.net/gimg/www.for...714afe1e96.jpg https://cimg0.ibsrv.net/gimg/www.for...0191f4dde7.png
Originally Posted by Sous
(Post 19357986)
2008 Hayabusa 1340cc. https://cimg8.ibsrv.net/gimg/www.for...dc57960c98.jpg ------------------------------------------------- https://cimg6.ibsrv.net/gimg/www.for...0ed8979229.jpg
Originally Posted by Sous
(Post 19357986)
On a thread related note, what would you change in the shape or routing of the Y-pipe if you did make your own out of carbon fiber? Would you put a dent or diversion in the upper part of the Y that goes to the IC tube? Have you thought that far yet or just set a COA in case you need to go that far?
Originally Posted by FinnishStroker
(Post 19358109)
Im with Dan on the saddle issue.
Noob,If theres going to be trouble with y-pipe,just fab completely new with different angle..? https://cimg2.ibsrv.net/gimg/www.for...c3e0fdf4de.jpg So to answer your questions about the y-pipe directly, I am planning on a minor reshaping of the upper portion that connects to the CAC pipe. A simple dent is easiest but not the best thing for flow. I'm thinking the part that has to clear the actuator will be a flattened oval being careful to maintain the same cross-sectional area as the round part, and then extending it so it sticks out over the passenger VC a little more to give room for the boot and clamp to clear the actuator also. That means I will have to trim the CAC tube and silver solder on a new anti hose pop off bead. Geez that's a lot of work now that I have typed this all out. Anybody want to buy a VGT/VNT housing? |
Time for a 1 or 2” body lift?:-down
reduce your suspension lift to compensate? |
Originally Posted by KubotaOrange76
Time for a 1 or 2” body lift?:-down
reduce your suspension lift to compensate? |
I know you are not in the same ballpark regarding injectors or turbo, but most of us did not use the CSD Y-pipe mounting bracket.
If you could leave the bracket off, would that give you enough clearance for the VGT? @countrycar , did you use the bracket? I ask because your build is closer to FTN's build than most of the others on here. |
Originally Posted by Sous
(Post 19359025)
I know you are not in the same ballpark regarding injectors or turbo, but most of us did not use the CSD Y-pipe mounting bracket.
If you could leave the bracket off, would that give you enough clearance for the VGT? @countrycar , did you use the bracket? I ask because your build is closer to FTN's build than most of the others on here. |
Originally Posted by FordTruckNoob
(Post 19359034)
It's the pipe itself that is contacting the actuator as it sits currently.
Interesting and highly anticipated build you have going on. |
Noob you may want to look into getting a bead roller as opposed to silver solder, or have a shop slap a bead on your CAC pipe.
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I had a shop weld a bead around the IC pipes when I did my install. I believe that with the 5" boot to the turbo has contributed to me having zero blow offs.
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Originally Posted by Sous
(Post 19359577)
I had a shop weld a bead around the IC pipes when I did my install. I believe that with the 5" boot to the turbo has contributed to me having zero blow offs.
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Originally Posted by Sous
(Post 19359025)
I know you are not in the same ballpark regarding injectors or turbo, but most of us did not use the CSD Y-pipe mounting bracket.
If you could leave the bracket off, would that give you enough clearance for the VGT? @countrycar , did you use the bracket? I ask because your build is closer to FTN's build than most of the others on here. |
Originally Posted by Dan V
(Post 19359658)
Originally Posted by SkySkiJason
(Post 19359832)
A piece of wire tacked to the pipe would be fine for this. Easier and better than solder or a weld bead.
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Apologies for the lack of updates. I have been preoccupied with replacing the home's HVAC system after it crapped out. I am in the process of editing the video of my baseline 38R run. Trying to synchronize video and data from disparate sources is quite the headache.
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Originally Posted by FordTruckNoob
(Post 19370011)
Apologies for the lack of updates. I have been preoccupied with replacing the home's HVAC system after it crapped out. I am in the process of editing the video of my baseline 38R run. Trying to synchronize video and data from disparate sources is quite the headache.
We look forward to updates when you have them. |
A video of my baseline for the SXE/T4 setup to be compared to. EBP data from FORScan is super noisy which is why the gauge is flickering so much. This is the one and only time I will let the EGT get that high. I usually back out of it when it hits 1200.
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Holy crap look at that EGT gauge go!
Wow... Despite the boost and RPM climbing, the EGT continues to climb to 1600 where the gauge is pegged. I think you will be very pleased with the new SXE turbo and hopefully the VGT/VNT is a great performer too. On a side note, I really like the gauge overlay that you used. I should have done that for my gauges when I was creating some of my videos... |
You're not going to miss that 38r one tiny little bit once you get your conversion finished up!
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