Custom turbo build
 

I'm starting a rat rod build this winter and I really want to put a 6.9 idi in it. I don't think I will be able to find one that has a turbo already on it. So my question is how hard would it be to build a custom turbo system (getting the right boost, piping, connecting to the exhaust manifold, air intake and intercooler). I don't want to buy a kit because I feel like they are a little to expensive. Also they have a lot of parts I won't need such as the full exhaust system. What are some of y'all thoughts?

If you have time and can weld, you can do it. You can get things that may be hard to fabricate, like turbo flange brackets, online cheaply enough. Mandrel bends are cheap enough to buy.
If you want to design a kit like R&D(using new exhaust manifolds), he sells the bolt-plates, so you can just weld tubes to the ports and bolt it on.

Awesome thank you! Do you have any suggestions for a reasonably priced turbo that runs well at 8 - 10 psi?

A Holset Hx40 is cheap and would get you where you want.

turbos for these trucks usually sell for between $500 and $1000 on ebay-craigslist.

I just sold an entire turbo kit take off for $500

For that range, just get yourself a Banks Sidewinder kit(wastegated if possible) used. Look in the $500 range.
The turbo on that (TE06H) is pretty small and handles 10-12 PSI nicely; it's not so efficient above that. You can adjust the wastegate to limit boost to whatever you are comfortable with.

Edit:
I mean, honestly, if you are going to all the trouble to make a custom kit... make it worth it.
Shoot for 25+ PSI. Maby go with a VGT, so you can use your power right off idle. Add an intercooler for towing performance. Get a decent performance injection pump to match your new air capacity. You'll need headstuds, but you'll be able to hit 350 HP at the wheels without too much difficulty. Going above that and you'd need to do some serious mods to the engine, like better connecting rods.

If you think that the engine could take that much boost with just head studs. that sounds like a sweet set up maybe I'll start looking into that also! Thanks

Take a look at Justin's Bronco - https://www.ford-trucks.com/forums/1...idi-build.html
He took a bog-standard 88 7.3 motor, added headstuds, a massive injection pump and turbo... and not much else. He got over 400 HP(perhaps 450), 800-1000 ft/lbs torque at the wheels; it failed at that level a few weeks later. He was pushing like 45 PSI of boost, too.
So, as long as you keep it safely under that...
I think something like 350 RWHP would be a relatively safe level. You can hit 250RWHP with a basic turbo kit and pump; more than that requires a slightly more exotic turbo.

A 6.9 wont do that and keep the gaskets, 7.3, sure. If you just want a turbo to wake it up a little, dont try to reinvent the wheel. If you think 500 is too much for a turbo kit you really really need to rethink having a project vehicle. I built a kit for my 79 and had about 300 into it. Wish i wouldve just bought a kit to make work, wouldve been alot less hassle and alot less down time. The turbo kits dont come with the full exhaust system, at least that i know of. Get an ATS or Banks kit and go from there, if later you want more, you can easily swap on a larger turbo and even go intercooled with not much hassle. There are people that are always looking for a core turbo so if you did upgrade, its not like you would be sitting on your old one.

Good point, I totally missed that.

I am willing to do a 7.3. my only reasoning for the 6.9 was that not many people have that engine so it's different and unique. but if y'all think I can make more power easily with the 7.3 I think it could be worth it.

Don't worry about being too unique, it's been 22 years since the last 7.3 IDI was produced, that's pretty good!
Besides I've never even met a person that could tell a 6.9 from a 7.3 anyways. Plenty on the forums, sure, but that's about it.

Sam, It would be nice to know what state you are in. Makes it easier to source good deals.


Macrobb, I was In Justins bronco as it hit 50 lbs, fun ride, a week or 2 later the rods got pissed.lol

[QUOTE=typefour;16460978]Sam, It would be nice to know what state you are in. Makes it easier to source good deals.


I'm in Utah