custom turbo for LX450
03-30-2006, 04:07 PM
#52
3.0 BAR
Join Date: Jul 2004
Posts: 4,029
Re: custom turbo for LX450
I wouldnt worry about the intercooler so much.Your not building a race care and that will be plenty for a 250-300hp setup.That turbo looks like it should work out pretty good on the big 6 as well.Def take lots of pictures as you go as this sounds like a awesome project. 
04-06-2006, 11:04 AM
#53
0.5 BAR
Thread Starter
Join Date: Mar 2006
Posts: 50
Re: custom turbo for LX450
Ok
all the parts are ordered and few parts are coming in:
turbo
intercooler
wastegate
gaskets
v-band flange and clamp
lots of silicone couplers and clamps
stainless lines and fittings to an from the turbo
miles of aluminized mandrel bends in many sizes
weld els (supra manifold far too short to modify)
a/f ratio gauge
boost gauge
welding bungs
turbo and wastegate flanges and gaskets
vacume lines
Im hoping to start this weekend and do a marathon build:
A few issues still bother me. I ordered a big K&N cone filter as I think the oe filter box just is going to get too much in the way and will get too hot. The MAF meter will need to be relocated which will entail lengthening the wires to it by saudering in longer ones. Will lengthening the wires affect how the MAF meter reads?
Next. I have worked out the down pipe from the turbo which uses a vband clamp and have adapters to take the 4 inch turbo exhaust down to the 2'' oe exhaust. I have a new weld in o2 sensor bong and plan on completely removing the 1st CAT but leaving the second. Assuming I a know shady california state employee who will let the cruiser pass inspection with illegal mods, will it pass smog with only 1 Cat?
Next. I wasnt planning on using a fancy stainless flex joint from the downpipe to the rest of exhaust but instead using just a simple exhaust joint (smaller pipe into bigger pipe) will i be ok without the expensive stainless flex joint?
Next. how have people plumbed in the Rising boost rate fuel pressure regulators? the inport scene can purchase cheap regulators that screw right in the fuel rail in place of the oe regulator-i hav't seen these for my rig
Ill neede to have a custom ac line made to go from the firewall to the compressor as the oe pipe is in the way. i have a guy at a ac shop who agreed to do the line for me
I need to run an oil return from the turbo so Im going to need to tap the upper oil pan with either 1/2 npt or 3/8 npt (ive got the fittings to do either) I know safari does this upper pan tap and I know where they tap it-i've read that the pan is thin so Im a little worried I wont be able to make a good thread. If I cant seat a good thread with the tap i have purchased some weld on bungs (3/8 or 1/2 npt) so I can weld to the pan. But then I will need to remove the upper pan. If I really wanted to take short cuts do you think the motor would catch fire if I welded the bung to the pan with it still on the motor? (just kidding) I know you import boys use JB weld but I feel uneasy about this.
Lastly I am a little worried about how I will bolting my home made turbo manifold to the oe manifold. I orderd new oe gaskets and bolts for the connection. The gasket between the oe exhaust manifolds (remember there are 2 as the manifold is a 2 piece-one for each set of 3 cylinders) are these metal (i hope they are stainless) donut things about 1/8 inch thick by 1/8 inch deep. (looks like a big wedding ring) I hope they hold up to the heat. I also purchased the gasket and bolts securing the oe manifold to the head in case I have to abondon my sub manifold idea in place of building an entire new log manifold . I have also considered welding my sub manifold directly to the oe manifolds-that is certainly a commitment.
all the parts are ordered and few parts are coming in:
turbo
intercooler
wastegate
gaskets
v-band flange and clamp
lots of silicone couplers and clamps
stainless lines and fittings to an from the turbo
miles of aluminized mandrel bends in many sizes
weld els (supra manifold far too short to modify)
a/f ratio gauge
boost gauge
welding bungs
turbo and wastegate flanges and gaskets
vacume lines
Im hoping to start this weekend and do a marathon build:
A few issues still bother me. I ordered a big K&N cone filter as I think the oe filter box just is going to get too much in the way and will get too hot. The MAF meter will need to be relocated which will entail lengthening the wires to it by saudering in longer ones. Will lengthening the wires affect how the MAF meter reads?
Next. I have worked out the down pipe from the turbo which uses a vband clamp and have adapters to take the 4 inch turbo exhaust down to the 2'' oe exhaust. I have a new weld in o2 sensor bong and plan on completely removing the 1st CAT but leaving the second. Assuming I a know shady california state employee who will let the cruiser pass inspection with illegal mods, will it pass smog with only 1 Cat?
Next. I wasnt planning on using a fancy stainless flex joint from the downpipe to the rest of exhaust but instead using just a simple exhaust joint (smaller pipe into bigger pipe) will i be ok without the expensive stainless flex joint?
Next. how have people plumbed in the Rising boost rate fuel pressure regulators? the inport scene can purchase cheap regulators that screw right in the fuel rail in place of the oe regulator-i hav't seen these for my rig
Ill neede to have a custom ac line made to go from the firewall to the compressor as the oe pipe is in the way. i have a guy at a ac shop who agreed to do the line for me
I need to run an oil return from the turbo so Im going to need to tap the upper oil pan with either 1/2 npt or 3/8 npt (ive got the fittings to do either) I know safari does this upper pan tap and I know where they tap it-i've read that the pan is thin so Im a little worried I wont be able to make a good thread. If I cant seat a good thread with the tap i have purchased some weld on bungs (3/8 or 1/2 npt) so I can weld to the pan. But then I will need to remove the upper pan. If I really wanted to take short cuts do you think the motor would catch fire if I welded the bung to the pan with it still on the motor? (just kidding) I know you import boys use JB weld but I feel uneasy about this.
Lastly I am a little worried about how I will bolting my home made turbo manifold to the oe manifold. I orderd new oe gaskets and bolts for the connection. The gasket between the oe exhaust manifolds (remember there are 2 as the manifold is a 2 piece-one for each set of 3 cylinders) are these metal (i hope they are stainless) donut things about 1/8 inch thick by 1/8 inch deep. (looks like a big wedding ring) I hope they hold up to the heat. I also purchased the gasket and bolts securing the oe manifold to the head in case I have to abondon my sub manifold idea in place of building an entire new log manifold . I have also considered welding my sub manifold directly to the oe manifolds-that is certainly a commitment.
04-06-2006, 11:23 AM
#54
Guest
Posts: n/a
Re: custom turbo for LX450
You want to get rid of your air box for sure. You're on the right track by just using a cone filter.
Lengthening your MAF wires is fine, won't change your readings any noticeable amount.
Dunno about it passing with just one cat. Why not just remove both of them, since you said you know a shady employee?
No cat is the best kind with any turbo system.
Get a flex joint. They aren't expensive. Search Jegs or JCWhitney, you can get one for about $30-35.
Just call that an FMU, that's what we all refer to it here as. The ones you talk about for the "import scene" are just adjustable fuel pressure regulators, and have nothing to do with boost. People usually install an FMU separately and can keep their stock fpr. You would do the same I assume by leaving your stock fpr and adding the FMU to your system (as long as you don't have a returnless fuel system)
Don't be scared about JBweld on your oil return. It has done many of us well, myself included. As a matter of fact, I haven't heard of anybody with problem with their JBwelded oil return fitting.
Lengthening your MAF wires is fine, won't change your readings any noticeable amount.
Dunno about it passing with just one cat. Why not just remove both of them, since you said you know a shady employee?
No cat is the best kind with any turbo system.Get a flex joint. They aren't expensive. Search Jegs or JCWhitney, you can get one for about $30-35.
Rising boost rate fuel pressure regulators
Don't be scared about JBweld on your oil return. It has done many of us well, myself included. As a matter of fact, I haven't heard of anybody with problem with their JBwelded oil return fitting.
04-15-2006, 12:44 AM
#56
3.0 BAR
Join Date: Jul 2004
Posts: 4,029
Re: custom turbo for LX450
www.imageshack.us
Go with the 1/2 drain as well.Sounds like you have a good plan and have all the right parts to pull it off.Take your time as rushing can lead to costly errors.I would really consider getting some bigger exhaust as that 2" will choke it hard.Even a crush bent 3" would work well and be cheap at a generic muffler shop.Keep the updates coming.
Go with the 1/2 drain as well.Sounds like you have a good plan and have all the right parts to pull it off.Take your time as rushing can lead to costly errors.I would really consider getting some bigger exhaust as that 2" will choke it hard.Even a crush bent 3" would work well and be cheap at a generic muffler shop.Keep the updates coming.
04-16-2006, 12:46 AM
#57
0.5 BAR
Thread Starter
Join Date: Mar 2006
Posts: 50
04-16-2006, 01:36 AM
#58
Guest
Posts: n/a
Re: custom turbo for LX450
Originally Posted by dusty
link to my build
http://forum.ih8mud.com/showthread.php?t=88793
http://forum.ih8mud.com/showthread.php?t=88793
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