6.5TD with a/c.... pics/info

[madcow75]

I am in the middle of doing a conversion on my, which once was a 1976CC C30 and now a K30. Origanally it was a non a/c cab but want to convert it to an a/c cab. I have a 6.2 diesel with a 6.5TD top end. Has anyone fit the 6.5td in with the a/c in their 73-87/91. I understand that it will not fit without some modification. Any modification info would be nice. Pics would be even better. I have read before an s10 a/c box needs to be grafted on? Also read a possibility of a van a/c box. But I have not really found any solid info or someone with the experience on doing this conversion. . My cab is currently striped and on a dolley ready to prep for the a/c.

[madcow75]

No ones has put a 6.5td top end on a 6.2 diesel and had to deal with the a/c accumulator box.

[joe231]

I have read all the same info. From looking at pics of the 6.5 turbo I don't know how you could mod the underhood air box to clear. The downpipe wants to occupy the same space as the stock a/c box. You could go with an aftermarket A/C setup for around $1000 or pick up a used Banks set-up for a few hundred more...
I'm picking up a 6.5 turbo set-up in the next few months, but my trucks are non a/c so I won't have that issue.
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[madcow75]

Yes I have thought of the banks sidewinder setup. But to find one... and at a resonable cost at that. Aftermarket a/c was a thought also, but still to costly for me. There must be a little cheaper route. I have thought about makeing a custom exhaust manifold or there must be a way to mod the a/c accumulator box a little. I think that I may go to the wrecking yards and look at how much different the van accumulator a/c boxes. I would think they would be a little more compact.
I don't have a tube bender so what are your thought on a square tube exhaust manifold. I could use a cutoff saw for some 45*. Or just purchase a tube bender so I could make some tube manifolds to move the turbo forward. Another thought of mine would to modify a set of military 6.2L headers which I have. Cut a hole for a turbo pipe at the front and weld back up?

[tkeduk8r]

i Helped a student of mine swap a 6.5TD into an 82 K10 this summer and fall, and yes the turbo and downpipe want to occupy the same space as the AC box....HE decided to make it a summer cruiser and delete the heater/ac altogether, cuz him bein 18, the turbo meant more I guess... I dont look at things the same way now at 38.. hahah.... again what was said above is true, the banks kit will be needed or a bit of fab work to the top end of the engine.... hope that helps...
--Mike

[madcow75]

Let me ask this does the exhaust manifold touch the a/c box? If not I might be able to move the turbo forward or toward the intake. With a little fabricating.

[joe231]

Originally Posted by madcow75

Yes I have thought of the banks sidewinder setup. But to find one... and at a resonable cost at that. Aftermarket a/c was a thought also, but still to costly for me. There must be a little cheaper route. I have thought about makeing a custom exhaust manifold or there must be a way to mod the a/c accumulator box a little. I think that I may go to the wrecking yards and look at how much different the van accumulator a/c boxes. I would think they would be a little more compact.
I don't have a tube bender so what are your thought on a square tube exhaust manifold. I could use a cutoff saw for some 45*. Or just purchase a tube bender so I could make some tube manifolds to move the turbo forward. Another thought of mine would to modify a set of military 6.2L headers which I have. Cut a hole for a turbo pipe at the front and weld back up?

What about building a square/rectangular tube spacer that bolts between the 6.5 manifold and turbo to move the turbo up and forward? I realize it will cause issues with the intake also...

I'm not familiar with the 6.5 stuff, but I wonder if you could flip the turbo assembly around 180* and bolt it back to the manifold and maybe reclock the driven side housing? That would help with both the clearance at the A/C box and maybe give enough room to snake the downpipe inside the frame?

I'm also not familiar with the hummer headers. If they are individual tubes it wouldn't work very well. There is a company online that sells pre made header flanges for the 6.2/6.5 diesels.
http://www.stans-headers.com/gm_flanges.htm
I have thought about building my own manifolds but I would have to pick up a bender as well. I would love to build a custom center mount set-up...
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[TexasDmax]

What about a vintage air set up? Then you won't have the big a/c box. It's not the cheapest way, but you get new a/c parts that will probably cool better and a cleaner firewall.

[jimbonice]

Iirc, 4bt.com has a couple conversions where an s10 a airbox has been used.
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[madcow75]

I must look for the s10 airbox conversions.

[IHguy]

I converted my 83 6.2 auto suburban to a 93 6.5 nv4500 5 speed. This is an ongoing progect for me and if my body work and paint turn out good i plan on getting the vintage air setup... I know what your going through and i ended up cutting the ac off the box and throwing some duct tape on it for now to get by with a working heater. I like the way the vintage air setup looks and more room for the turbo and exhaust with it all off the firewall.

[madcow75]

Yes mine has been an ongoing project also 1976 CC 4x4 conversion 93 6.5TD and soon to be nv4500 also. I have just recently purchased a a/c cab setup for my truck and want to convert it from a non a/c cab to a/c cab. I no the gen air is there but don't really want to purchase it. I am more into modifying what I have.

[joe231]

Originally Posted by IHguy

I converted my 83 6.2 auto suburban to a 93 6.5 nv4500 5 speed. This is an ongoing progect for me and if my body work and paint turn out good i plan on getting the vintage air setup... I know what your going through and i ended up cutting the ac off the box and throwing some duct tape on it for now to get by with a working heater. I like the way the vintage air setup looks and more room for the turbo and exhaust with it all off the firewall.

Got Pics???
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[lindstromjd]

Factory A/C is a b*tch to get it to work right. I had to hybrid a square body S-10 box into my original one by cutting, gluing, and bondo-ing. It makes for an extremely tight fit, but it works. Only problem then was that I had to use the S-10 accumulator and dryer, so I had to have custom pressure and return lines built for my truck. Still, it was cheaper than a vintage air set up.

[madcow75]

Is it possible to run a custom made spacer between the turbo and exhaust manifold to push turbo closer to the intake lets say a couple of inches. Doing this may give more clearance for the a/c accumulator box. The 6.5TD exhaust manifold itself does not touch the a/c acculator box? Just the Turbo right?

[lindstromjd]

Originally Posted by madcow75

Is it possible to run a custom made spacer between the turbo and exhaust manifold to push turbo closer to the intake lets say a couple of inches. Doing this may give more clearance for the a/c accumulator box. The 6.5TD exhaust manifold itself does not touch the a/c acculator box? Just the Turbo right?

Yeah, it's not the manifold that's the problem, it's the built-in downpipe on the 6.5 turbo. You'll need to move it forward by about 2 inches if you don't want to make your own accumulator box. Up and down won't make any difference at all.