Not so budget turbo install

**flagg** · 27th January 2013, 07:56 PM

So a while ago I was very much encouraged by Ben's (Isuzurover) 'budget turbo install' thread and decided I had to give it ago. Second hand stuff seemed like a bit of a gamble.. if I was going to go all and do the work to change it all over I wanted to get it right, so one thing lead to an other and I ended up going all out. (bit out of hand)

Lined up is a Borgwarner EFR6258 turbo and a Plazmaman Water to Air "800HP" intercooler (an absolute work of art, BTW).

The exhaust will be 3" mandrel with a muffler.

Did a test fit today so that I can measure up oil lines etc.. Fits well. No need for the new bonnet just yet...

Will need to different manifold studs, they are all different on the new one. A search around came up with many many different part numbers :-S

When I took off the heater pipes, I found them rusted out and full of crap.. can't be good for the engine

The plan for tomorrow is to measure up the exhaust and order the bends & muffler, get the sump off and "trim" it.

**Dougal** · 27th January 2013, 08:01 PM

Excellent. We need some results for these BW turbos. They should be the ducks nuts.
It fits very nicely with the height of the compressor outlet. Where is the W/A intercooler going to sit and what will you use for a pump and front radiator?

**flagg** · 27th January 2013, 08:25 PM

The intercooler is going from the turbo outlet across the top of the rocker cover (east-west). I have a puma bonnet to give me extra room. Will have to turn the compressor outlet a little so the outlet it pointing more upwards to give me more room, then use a 45degree 2-3" silicon hose to connect them. This should give me enough room on the other side for an S bend from the intercooler outlet to the inlet manifold.

Like this:

The heat exchanger is an ally plazmaman one, and I'm using a Bosch 25l/m pump.

**rovercare** · 27th January 2013, 10:53 PM

Nice intercooler

**flagg** · 28th January 2013, 09:15 PM

The turbo is very long which is causing be to have to do a bit of thinking. For the exhaust I can cut up a doughnut to double back and around the alt, but for the air cleaner->turbo hose there isn't much room.

The input to the turbo is ID 2in, and the exit from the air cleaner is 3. I was going to run a rubber cobra head reducer but I can't find one that does 2-3inches..

If I mod the filter housing outlet to a 2" will that choke me too much?

**garryseries3** · 28th January 2013, 09:44 PM

Originally Posted by flagg

The turbo is very long which is causing be to have to do a bit of thinking. For the exhaust I can cut up a doughnut to double back and around the alt, but for the air cleaner->turbo hose there isn't much room.

The input to the turbo is ID 2in, and the exit from the air cleaner is 3. I was going to run a rubber cobra head reducer but I can't find one that does 2-3inches..

If I mod the filter housing outlet to a 2" will that choke me too much?

Ebay UK 76mm 51mm reducers, autoperformanceonline, I have got numerous hoses from them before, check them out will about a week to arrive.
Garry

**Dougal** · 28th January 2013, 10:07 PM

Originally Posted by flagg

If I mod the filter housing outlet to a 2" will that choke me too much?

Yes. Avoid restrictions upstream of the compressor if you possibly can.

**steveG** · 29th January 2013, 09:57 AM

I've bought a few hoses from TurboXS. No problems and arrived pretty quickly from memory. Looks like they've got a 3"-2" 90deg which I think is what you're after??

90 Degree Reducing Elbows

Steve

**flagg** · 29th January 2013, 05:44 PM

Thanks.

So its OK to run silicone pre-turbo? I thought you needed something that could better handle vacum?

**Dougal** · 29th January 2013, 07:41 PM

Originally Posted by flagg

Thanks.

So its OK to run silicone pre-turbo? I thought you needed something that could better handle vacum?

How much vacuum are you expecting? Just arrange your joints so they can't suck flat and you're good.
You can get silicone joiners in a range of thicknesses. Thicker obviously won't suck in as easy. Thinner obviously can't take as much boost. A few have been caught before fitting thin silicone boots to boost pipes and popping them.

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