HomemadeTurbo - DIY Turbo Forum

Well this is a project I did about a year ago with my old bud Mike G, anyhow here are a few pics from the project.

Using a bone stock Ford Ranger baseline 2.3l 4 banger.

https://www.homemadeturbo.com/2006/danger/pic1.JPG

We thought, hey.. lets use a old school tbird turbo manifold and turbo setup on this engine.. They are both 2.3's right? It should work right?

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turbo was ripped apart to make sure it was ok

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Stock downpipe housing used

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a modified stock Saab internal wastegate was used (5.5-6psi)

https://www.homemadeturbo.com/2006/danger/pic7.jpg

Unit installed, as you can see the heater core box was removed for a test fit, we knew this was going to be a issue.

https://www.homemadeturbo.com/2006/danger/pic8.jpg

Downpipe 2.5in came out decent

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fabbing up some exhaust with the nigmaster

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Mikeg about to burn down the building

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Me welding up the exhaust system, all 2.5in mandrel with a huge 36in resonator.

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came out pretty good, other than the resonator having some internal rattles

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more exhaust.. it sounded really good too, pretty burly for a ranger.

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ahhh, The oil pan that everywhere we looked said "You HAVE to take the engine out!" yea right, after taking the motor mount bolts out and jacking the engine up to the sky it came out.. it wasn't like butter but it did come out.

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Standard OP, brass fitting with the JB weld, its the simple solution for cast aluminum pans.

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Oil return all done, I did a shitty weld on the return flange, and JB weld was added later!

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Oil feed was a tuner toys fitting with 1 adapter. It was a little bit of a ---- to install, not the easiest spot to get at.

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The intercooler.. this is actually stage 2 on this picture. I think its a Audi or Saab IC, but it has plastic end tanks. Mikeg went to the boat store and got some plastic/rubber adhesive... and well it didn't work out to well at all. It blew out on the first sign of boost. So, back to old faithful JB FTW!

https://www.homemadeturbo.com/2006/danger/pic21.JPG

Intercooler fit pretty decent behind the stock grill, some mods with the hood latch had to be done, (safety catch removed)

https://www.homemadeturbo.com/2006/danger/pic22.JPG

IC pipes 2in ready to get painted

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Painted ready to go with a DSM 1g BOV

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stage 1 of the heater box mod, it was just heated and molded so the downpipe wouldn't touch it. It was later redone with sheet metal and it looks very nice. I don't have pics of it though.

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Intake Pipe with Air filter

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Intercooler pipes installed

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Getting ready for the first ripper PLX wideband/boost gauge and OBD2 Scanner

It ran ok, it was defiantly on the lean side, since we didn't have any engine management.

https://www.homemadeturbo.com/2006/danger/CIMG1471.JPG

We slapped in a Adjustable FMU, it was ok.. But it didn't seem to make much a difference. Fuel pressure was jumping in the high 90's but it just didn't pull like it should, and a new noise started from the turbo. The compressor wheel was starting to make contact with the compressor housing.

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I talked mike into a CDM t3/t4 since I have had such great luck with them.

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all ready to go in, keep in mind a CDM 5 bolt exhaust housing is not the same as a real Garrett 5 bolt, it sets the turbo in a slightly different angle/position. the downpipe had to be changed. We also used the new 9psi gate.

https://www.homemadeturbo.com/2006/danger/CIMG1428.JPG

We had a huge problem with blow by, we asked around on some Ford forums, and this is the fix, a Tbird turbo PCV valve and a Brake Booster check valve. Worked great. (also a ---- to install)

https://www.homemadeturbo.com/2006/danger/CIMG1469.JPG

the dsm 1g bov was removed because it was crushed to the extreme, a volvo bov was installed then recirc'd back into the intake air tube.

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new boost gauge installed

https://www.homemadeturbo.com/2006/danger/CIMG1476.JPG

http://www.snipertuning.com/new/prod...21-1-large.jpg

This is when mike stepped up. He bought the Sniper Special forces Tuning package. It's basically software with some very basic menus and you re-flash your stock ecu. It has lots of different options.

Range of adjustability
-Compression ratio -Low / High fan settings -Engine idle speed -Passive Anti Theft -Fuel Octane rating -Headers / exhaust -H / x pipe -Rear oxygen sensor delete
-Trans shift points-Trans shift firmness-Engine rev limiter-Engine speed limiter -Tire height / speedo correction-Gear ratio / speedo correction
-Air Fuel Ratio adjustments (richen/lean) -Spark advance (+/-) -Supercharger (Roots & Centrifugal) -Turbocharger -Nitrous (wet & dry) -Injector size -Returnless fuel pressure setting -Mass Air brand / calibration -Intercooler type -Fuel pump type

We ended up installing a set of Ford 42lb /hr injectors with a stock honda resistor box. No matter how many times we tried to adjust the fuel settings we could never get the fuel where it needed to be at. at the top end.. sure it would be rich, but the turbo spooled pretty fast and we could never get the lean spots out of it. Mike contacted sniper several times but never found a solution. We had several problems when using this software at first, in fact we even fried a ecu haha.

https://www.homemadeturbo.com/2007/dyno/CIMG1558.JPG

On the dyno

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15.0-16.0~ AFR's Hot damn // 10psi 159hp / 172tq

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Engine shot w/ the t3/t4 & heater box mod

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Danger Ranger

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This project is dedicated to Kenny Schoelles who passed away last year. In high school Kenny had a ranger and we always called it the "Danger Ranger" He was a very close friend of ours and he will be greatly missed.

Kenny Schoelles 1981-2005