Project: Tow-Rat (Lil' Blue)

[6DoF]

the pie-cut and straight cut stencils were awesome, highly recommend. the pie cut made quick work of adding some angle and tightening up the bend. it was a 10deg print, but i cut on the sharpie lines so probably more like 12-14 actual. the straight cut needed some tube for alignment, can't just cut off a sliver with it hanging off the end. before i started cutting back the start of the pipe i made multiple marks. ended up trimming it 3x, made it easy easy when already marked.

[6DoF]

i hate how my exhaust welds look, they are always nasty ... not going anywhere, but ugly. good thing it's getting painted and fully wrapped for that SEMA look

i am super excited this is together, and it's crazy sturdy when assembled. wish i had more room to make this pipe more racecar, but she should be fine. it's tight, but it's big at 3.5". should also have good room that i can get the 4" down pipe past the tire easy without rubbing it at full lock too. cross your fingers for me the outlet flange shows up soon.

[Dieselwrencher]

Awesome work! I love doing turbo piping but it is a lot of work. Would you sell some of those cut jigs? Those would be really handy.

[57FleetsideC4]

Amazing work!! Well beyond my skill level. That will make some serious power. Steve

[6DoF]

Originally Posted by Dieselwrencher

Awesome work! I love doing turbo piping but it is a lot of work. Would you sell some of those cut jigs? Those would be really handy.

i mean ... no ... but i'll give ya some.

know anyone with a printer and just want the files or wanna pay shipping on some? the problem is ya have to print a different one for every radius bend and pipe size. but once you have the file built, it's easy enough to change a few dimensions in the CAD and re-print. i'm also thinking about making them split with an adjustable screw, the bends warp differently thru them.

[6DoF]

was at the in-laws over the weekend, but still got some stuff done.

- Manifold turbo is officially installed (measured for oil lines)
- installed dash to windshield trim
- got sensor bungs on the hot pipe
- the wife cleaned the inside really good
- started fab of the intercooler mount
- installed seatbelts

i really like how the seatbelts came out. should be way better than just a lap belt or retrofitting a 3-point. also pretty comfy with no cutting into my neck or pulling bad.

[Dieselwrencher]

I don't know anyone with a 3D printer. I have been kicking around the idea of getting one though. Those seat belt mounting plates turned out nice. I much rather would have the belts like you have versus an over the shoulder lately.

[6DoF]

hot pipe in paint, fully wrapped, and installed with the s475. i really like the one boot cold side connection. turbo oil lines are ordered, so i really need to get on mounting that charge cooler!

no it will not have a hood stack

[6DoF]

wrapped up the intake this weekend, that's officially sealed and tight. other than once the front clip is on i'll just need to figure out an air filter. so i figured what angle the intake stack needed to be, then in 3D i cut a model of 3.5" pipe and measured the arch length around the miter. i then made an ellipse of the same arch length that fit inside the intake mounting holes and had some plate cut. chopped some pipe, squished it, and I'm super happy with the transition.

i did add some weld bead around the top edge of the pipe to keep the coupler n clamp from slipping off.

i don't particularly like the look of the cooler on top of the engine. it's a nice compact packaging though, it's free space under the hood that isn't used for anything else, and the air path is really good. hard to argue with all that.

[6DoF]

then moved on to the down pipe where thing got close, but they fit! 4" down pipe snaked

even pre-added some sensor bungs if i ever want them.

[regan wilson]

That looks nice. Where did you get the cooler? Does it have it's own cooling system?

[6DoF]

Originally Posted by regan wilson

That looks nice. Where did you get the cooler? Does it have it's own cooling system?

FrozenBoost.com ... everything so far from them seams really nice.

the 2 radiators n the back under the bed are for charge cooling water.

[regan wilson]

Originally Posted by 6DoF

FrozenBoost.com ... everything so far from them seams really nice.

the 2 radiators n the back under the bed are for charge cooling water.

Cool. I couldn't remember what the setup in the rear was for. Something like that would be nice for my C-50. It's not like you have to pull the valve cover on a Cummins very often.

[6DoF]

Originally Posted by regan wilson

Cool. I couldn't remember what the setup in the rear was for. Something like that would be nice for my C-50. It's not like you have to pull the valve cover on a Cummins very often.

i was a little worried about bleeding injectors with it there, but i can easily get all of them actually. i was also worried that they only give you one mounting bolt on the front and one on the back, but the boots are as much mounting it as the bolts are! it's really solid in there.

there's a lot of ppl skeptical about the water to air. from ppl running engine coolant thru the cooler to poor water cooling that lets it heat soak, etc. i guess we'll see hopefully soon enough. i specifically sized the radiator to be slightly bigger than the core of the charge cooler, in theory the system should be able to ditch more heat than it can take in. plus at some point it'll also have an aluminum reservoir in the bed that would shed even more heat.

[regan wilson]

Do you have the part numbers? Thanks

[6DoF]

Originally Posted by regan wilson

Do you have the part numbers? Thanks

sure thing!

https://www.frozenboost.com/air_wate...ers-p-218.html

Water to Air Intercooler, 16"x12.25"x4.5", O/S I/O (Type 18)

you can get different size cores with lots of different inlet/outlet directions.

[6DoF]

this is the water chiller i used

https://www.frozenboost.com/water-to...er-p-1026.html

Water to Air Intercooler Radiator - 26x7x3.5 (Type 101)

[regan wilson]

Thanks I'll save that information.

[6DoF]

door parts finally came!! it's officially "dry'd in"

not sure if it's just the re-pop parts or what, but these doors are a pain in the junk to assemble. completely different problems left to right.

[6DoF]

IT RUNS AGAIN!!

exhaust is fully wrapped and re-installed, and my turbo drain -10an hose showed up a day early!

fired that thing off last night and everything seams good. both turbo's spin and were getting oil at least exhaust sounds pretty decent, only one new leak at a fuel line that might have just been a loose fitting.

idle is really high with the new huge injectors though, and just turning down the idle screw wasn't enough to get a stable low idle. now it's time i figured out the P7100 tuning and started turning screws.

[Rickysnickers]

Um, video of it running or it didn't happen

[6DoF]

Originally Posted by Rickysnickers

Um, video of it running or it didn't happen

yeah yeah yeah ...

took a crappy vid last night, idles really high and over smokey. let me play with the screws and springs n see if i can't get it back clean to take an exhaust note vid. i feel like i might have gotten the new gov springs too tight.

[6DoF]

Originally Posted by Rickysnickers

Um, video of it running or it didn't happen

boom

https://i.imgur.com/TANeZKe.mp4

[Rickysnickers]

Originally Posted by 6dof

boom

https://i.imgur.com/tanezke.mp4

nice!!!!!!

[6DoF]

did a lot more staring at things over the weekend and trying stuff, then trying again til i finally got what i liked. new shut-down cable is in! it's actually a locking cable, but could just be a basic choke cable it if i wanted now. no springs, just pull on, push off, lock if ya want. probably lock-on to make sure it maintains full fuel ability.

re-did the throttle cable to delete the 2nd gen TPS and extra unnecessary linkages. just need a new throttle return spring and mount to really make that prime.

got the radiator installed and fully piped! i'm not a huge fan of the upper hose, but not the end of the world either. if there's ever an issue i already found steam ports made to cut into silicone hoses.

took the pump AFC apart to hopefully start to dial in the fueling a bit and smoke out the shop way less ... crap, i should charge the batteries after all the starting ... key now is going to be getting things ready at the bare min to drive it. gauges, wiring, fix air leaks in bag lines, etc. then i can start work on the bed and other cosmetics knowing worst case she's viable.