Re: Finally starting my Longhorn 4x4 conversion
 

:lol: No need to ship it in a hurry man! Believe me you wouldn't be holding me or it up. Thanks, PM coming.

Re: Finally starting my Longhorn 4x4 conversion
 

Making a little progress on the pumpkin. Starting to get turbos on this thing.

http://i181.photobucket.com/albums/x...n/IMG_0419.jpg
http://i181.photobucket.com/albums/x...n/IMG_0420.jpg
http://i181.photobucket.com/albums/x...n/IMG_0421.jpg

I took apart one of our 241DHD auto tcases, and converted it to 5 speed. I then placed it on the transmission to see what it looks like. I think it'll work fine with some work.

http://i181.photobucket.com/albums/x...n/IMG_0432.jpg
http://i181.photobucket.com/albums/x...IMG_0433-1.jpg
http://i181.photobucket.com/albums/x...n/IMG_0434.jpg
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http://i181.photobucket.com/albums/x...n/IMG_0436.jpg
http://i181.photobucket.com/albums/x...n/IMG_0437.jpg

Re: Finally starting my Longhorn 4x4 conversion
 

I'm still new to the diesel game. How much heat comes off the turbo when your egt gets high. The turbo seems a little close to the fiberglass hvac box. Love the build, wish I knew more about custom diesel building for my suburban.

Re: Finally starting my Longhorn 4x4 conversion
 

Usually while regular driving exhaust temp gases are around 500-750*. While towing they are usually from 750-1150*. (The reading is taken before the turbo in the exhaust manifold, and usually is 250* less after the turbo.) On this truck I'm going to guess it will see 1200*+ bursts when I get bigger injectors. On my F-350, which I DD and tow with constantly, the turbo exhaust housing is literally 1/4" away frm the HVAC box, and it hasn't discolored or melted yet. (I've put about 30k on it in a year too.) This pic isn't very good, I'll get a better one tomorrow. If it gets too hot for the HVAC housing, I'll put a turbo blanket on it.

Re: Finally starting my Longhorn 4x4 conversion
 

i sure am glad you are making progress because i am at a dead stop. DD blew a head gasket thursday and my jeep is having EST issues. jeez...

that t-case looks all confused, but it looks like you should be able to fit 5" tube through there pretty well.

i bet the HVAC housing doesn't even blink. a 1/4 of air is enough to really insulate the heat. if the exhaust housing on the turbo starts to glow then it might melt that sucker but if that is the case i think you have bigger problems.

looking good sir

Ryan

Re: Finally starting my Longhorn 4x4 conversion
 

TurboS? I like what you did with the T-case. Are you just going to plumb the oil pump externally for it?

Re: Finally starting my Longhorn 4x4 conversion
 

Hey hey, nice progress Ryan! glad to see you wrenching on this thing again.

Re: Finally starting my Longhorn 4x4 conversion
 

Thanks. Sorry to hear about your vehicle issues. I feel your pain. my F-350 has wanted a part a week some times. I guess it's mad I spend more money on the Longhorn now. :lol: Hopefully today I can get the primary turbo mounted and I'll show the pics of the problem area. :lol:

Re: Finally starting my Longhorn 4x4 conversion
 

I was actually thinking of trying that and putting the pick up in the drain plug port. Too bad I already sealed this case up. :lol: It was supposed to go on my brother's dodge, but he's letting me use it for now until I get our other one rebuilt for his truck.

Re: Finally starting my Longhorn 4x4 conversion
 

Thanks, I'd like to get this thing in as little pieces as possible soon. Is that possible? :mm: :lol:

Re: Finally starting my Longhorn 4x4 conversion
 

Looking good Ryan. You could also make a aluminum heat deflector with air gaps on both sides for the ac/heater..

Re: Finally starting my Longhorn 4x4 conversion
 

It is looking good man, I have been watching this build waiting for updates, you are on your way now though.

Re: Finally starting my Longhorn 4x4 conversion
 

Updates?

Re: Finally starting my Longhorn 4x4 conversion
 

Oh, well, maybe........................................ :waah:

We've got piping boys!
http://i181.photobucket.com/albums/x...n/IMG_0444.jpg
http://i181.photobucket.com/albums/x...n/IMG_0448.jpg
http://i181.photobucket.com/albums/x...n/IMG_0449.jpg
http://i181.photobucket.com/albums/x...n/IMG_0446.jpg

There is a second turbo in there. :lol:
http://i181.photobucket.com/albums/x...n/IMG_0443.jpg

I was highly disappointed today when I tried to use my 7.3psd intercooler and it was too narrow to fit around the radiator. So I improvised and flipped a 2nd gen dodge one and it fit. But now I will have to modify my hood latch because the hood latch hits the intercooler.

http://i181.photobucket.com/albums/x...n/IMG_0442.jpg
http://i181.photobucket.com/albums/x...n/IMG_0447.jpg

I got the water inlet almost done too.
http://i181.photobucket.com/albums/x...n/IMG_0445.jpg

I still have to make the oil returns, install the oil feed lines, build a support bracket for the primary turbo, weld all the piping, and build an air inlet for the primary turbo. I also have to build a down pipe and fit the exhaust. It's going to be tight! It's coming together.

Re: Finally starting my Longhorn 4x4 conversion
 

By the way, the top turbo is a HX40II and is 60mm. The bottom turbo is a HT60 and is 76mm. I'll modify the waste gate on the secondary turbo and set it to be fully opened at 25psi, which should net about 60-65psi boost total.

Re: Finally starting my Longhorn 4x4 conversion
 

Man-at-Keyboard says: "inter turbo piping no good. If one has room for LTA inter-turbo cooler, one must install such."

Hate me yet?

Re: Finally starting my Longhorn 4x4 conversion
 

Say what? :lol:

Re: Finally starting my Longhorn 4x4 conversion
 

Liquid-To-Air intercooler between the turbos...

I don't know what your final use plan for the truck is, but here is a quick little story on why you should. When I had my 96 Chevy with the 6.5L on Propane, I knew a guy who had a 12v dodge with sequential turbos. He would not tow a trailer at all. He said he couldn't keep his EGT or engine coolant temp under control with a load on the engine. Well, one day while towing a trailer in my 96 I passed him on a grade. He didn't talk to me ever again. :lol:

His truck could spank mine all over the place. but I could still tow with mine.

Cat C15s run a cooler between the charge air side of the turbos and there are a lot of off-road cummins engines (QSK60 for eg.) that run coolers between the turbos. It makes night and day difference!

Re: Finally starting my Longhorn 4x4 conversion
 

OH THAT IS FRIKING SWEET!

What kind of tubing do you use for that?

Re: Finally starting my Longhorn 4x4 conversion
 

He had 2 turbos on a Cummins in parrallel?

Air to water is not helpful in the majority of cases for multiple reasons on a street truck.

For air to water to work properly there has to be a cooling agent, IE ICE etc. Running coolant from the engine is inneficient. When you consider the air temp coming from the turbo is 750* and a stock CAC/Intercooler can drop it down to sub 200*. If the truck was going to be a competition vehicle it might warrant an air to water. But unless you are pushing over 1000HP and high boost numbers it's not needed, or if you are running a big single.

We built a compound turbo 12V that ran a 57mm charger over a 78mm charger with "435HP" injectors in it that could hardly make 1800* on the pyrometer at WOT. It would build 15psi of boost at 30mph under light throttle. EGT's can vary depending on setup, but properly setup compounds don't need an ATW setup. Air to water is great for larger single charges and helps them spool.

Not to mention the pain in the ass it is to pipe in an interstage cooler. They also are not the cheapest option available. Cheap ATW is not recommended.

Re: Finally starting my Longhorn 4x4 conversion
 

sequential... compound... sorry, bad habit. It was compound not parallel. My experience with light truck diesel with compound turbos was that dodge... and the 6.4L (don't laugh)

Being in my line of work I only get to work on unmodified diesel engines. I don't get to experience the performance side of the house... I just soak up everyone's knowledge and experience for when I decide what engine I want to run in my 70 Burb. So it is really cool to see and read your builds!

Re: Finally starting my Longhorn 4x4 conversion
 

It's a good application on heavy equipment for cooling the charge air at normal levels. But for this, I'd have to have a unlimited supply of ice and a trailer with a cooler to refill it. :lol: We've built a couple of wild compound turbo trucks that have had a lot of fuel and could still tow with out high egt's.

Re: Finally starting my Longhorn 4x4 conversion
 

Not much more progress. I had to drive down to a dodge scrap yard to get a bracket for my hydros. I also picked up a used B&W goose neck hitch for it. :metal:

I got my water outlet done. Just have to pick up an adapter for the radiator side of it.
http://i181.photobucket.com/albums/x...n/IMG_0456.jpg

I installed my injection pump so I could install my injection lines, so I could build my cold pipe from the intercooler to the engine. The injection lines fit like crap for as much as they cost!

http://i181.photobucket.com/albums/x...n/IMG_0454.jpg
http://i181.photobucket.com/albums/x...n/IMG_0455.jpg
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Re: Finally starting my Longhorn 4x4 conversion
 

Thanks. I use mandrel bent exhaust tubing. Sometimes on the turbo hot pipe I use schedule 40, but it's harder to make fit in tight areas due to the larger radius bends. Since the exhaust tubing isn't as thick as the schedule 40 pipe, I add gussets on the out side of the exhaust tubing to the flange where I can to help it keep from splitting out. Some I didn't do it too and haven't had a problem. I'm getting anxious to get this thing going! :lol:

Re: Finally starting my Longhorn 4x4 conversion
 

I need a B&W... i think i may have fond one from a guy at work that has no use for the one in his truck.

and the lines are shiny. they dont have to it well, they look nice, that is what you want right?

looking good, and i think i am a little jealous. mine is still sitting untouched as i put my ford back together...

Ryan

Re: Finally starting my Longhorn 4x4 conversion
 

Awesome!

Re: Finally starting my Longhorn 4x4 conversion
 

Very nice progress Ryan. Keep it up buddy.

Re: Finally starting my Longhorn 4x4 conversion
 

If they fit on the cylinder head as nice as they shine, it would be great. But they don't. You have to fight them to get them on. They are a PITA!

I know how you feel. This truck has been pushed out of the shop so many times I lost track. Hopefully soon it can be driven in and out. :lol:

Thanks!

Thanks. It's slow progress.

Re: Finally starting my Longhorn 4x4 conversion
 

Today I used my head and realized I had no idea where I was going to put an air conditioning compressor. So I decided I better figure it out. I had plans to put one on top of the cylinder head, but the conversion lines and upper radiator hose make it real tough. So I decided to try and put it below the lower hose and use dodge parts. Well, I had to trim the frame flanges more than I wanted to, but it's in and will work. It will be a PITA to replace once the truck is together. I'm contemplating making a bracket to put on the out side of the frame to help strengthen the area since I removed a good portion of the upper flange. My friend Adam started on the tcase cross member today and he enlarged 2 of the bolt holes so the tcase could be put on the back of the transmission.

http://i181.photobucket.com/albums/x...n/IMG_0459.jpg
http://i181.photobucket.com/albums/x...n/IMG_0458.jpg
http://i181.photobucket.com/albums/x...n/IMG_0460.jpg

Re: Finally starting my Longhorn 4x4 conversion
 

:lol:
:lol: Reminds me of an old Calvin & hobbs comic strip. In the first frame Calvin & hobbs are just walking, in the second frame Hobbs asks "Your idea never got off the ground? third frame frame just walking, Last frame Calvin says it sort of blew up in the hanger.:lol:

Re: Finally starting my Longhorn 4x4 conversion
 

:mm: :metal:

Re: Finally starting my Longhorn 4x4 conversion
 

Man, P-pumps just look so cool...

Re: Finally starting my Longhorn 4x4 conversion
 

Yes they do. :lol:

Re: Finally starting my Longhorn 4x4 conversion
 

Dude you got some game

Re: Finally starting my Longhorn 4x4 conversion
 

I had to look real close to see it! Sure is tucked in there!

Re: Finally starting my Longhorn 4x4 conversion
 

Looking good Ryan!

Re: Finally starting my Longhorn 4x4 conversion
 

Thanks man. Still have a ways to go to get to your level buddy. :lol:

Yes it is. It should look nice once all painted up. I only scratched my fire wall 3 times so far during this mock up. :mm:

Thanks Nate. Your tot rod turned out awesome!

Re: Finally starting my Longhorn 4x4 conversion
 

Thanks buddy.

Re: Finally starting my Longhorn 4x4 conversion
 

"Thanks man. Still have a ways to go to get to your level buddy.

My level?
Dude now your talking lets slammmmmmm that 4x4 and get down to my level.....LMAO**
Seriously dude you ave great game and this is a great build....can't wait to see it completed...

Re: Finally starting my Longhorn 4x4 conversion
 

Soo, I am at the EXACT same point you are, I literally tried a 7.3 intercooler yesterday evening, too narrow, then my grandpa gave me the same Dodge one you have today and it's tall as all get out!

What are you gonna do about the hood latch? I just bolted my latch up to see if it'd all clear and it ain't lookin too hot.