Offroad-Express

Hi all, I have been a member of these forums for a little while but have not done an introduction.

I have a swb safari and live near Palmerston North.



I felt like I needed some more power so started looking into turbo kits. The price made me decide to tackle it myself. Below is a few pictures of my build.


Fitted the manifold and turbo. No real dramas here.


Had to notch the engine mount to fit the oil feed line.


The turbo has a exhaust v-band fitting so it makes a 3" short radius bend fit quite nicely.


excuse my rusty welding skills.


I made the rest of the exhuast, some parts were quite tight as I wanted it to remain as high as possible around the rear diff.




It was hard to get some decent pictures of the exhaust.


Fitted the rest of the bits, the actuator bracket needed modifying to fit the rotated turbo.


Not the tidiest bracket I have ever made but it looks like it will work.

I still have a bit of work to do prior to being able to drive it, turbo water cooling, oil catch can, intake and filter etc.

great effort. You have some skills and patience. It takes time to get things just right, especially the correct clearances.

Nice looking work.

What turbo are you running? Is that an intercooler on top of the motor? What size is it?

Matt.

Thanks Guys. It certainly does take alot longer than I expected to piece it together.

The turbo I am using is a 6cm 16G Kinugawa with anti-surge cover and v band exhaust housing. I am dubious on what difference the anti-surge cover will make on a diesel but it certainly adds bling points when there is no intake pipe on.

Yeah it is a water to air intercooler. I was lucky and managed to get it off a friends truck so I didn't have to make any parts for that. What specific measurements are you after? when I am working on my truck next I will get them for you.

Did a little more today and tapped some turbo coolant fittings into the thermostat housings. I wasnt to keen in teeing into the heater hoses.



Only issue is I have is I need new bolt for the thermostat housing. The one that was in my one had been tapped into the lower section and didnt got all the way through into the water pump for some random reason.

Hopefully the hose fittings for the turbo to replace the banjo fittings turn up next week so I can make the lines.

I know those sheds
Truck looks mean

I wondered how long it would be till someone recognised those sheds.

I did some more work this arvo and made up some coolant lines, but I am not happy with the fittings I tapped in the other day so I will take them off and weld some fittings on.

Getting towards the end of the turbo build. Anyway this happened:



So i had to weld it back together.



A mate welded the coolant fittings on for me. Its far stronger than with tapped fittings.



Still have a few things left to sort out but it looks alright so far.



I am still thinking about what kind of water pump i should use for the water to air intercooler. I was thinking of using a oil cooler for the radiator part as they are relatively cheap.

Any thoughts for a pump or better radiator out there?

Ended up using a Davies Craig booster pump with a YZF250 radiator.





Ended up fitting alright, hopefully it will provide enough cooling.




Started building a airbox to eventually join to the snorkel. I think I will run a prespex lid on it.

Nice work. Is that stainless on the air box? Have you migged it?

Cheers
Matt

The YZF radiator was a brilliant idea. I would have suggested a Subaru rs turbo legacy water to air inter cooler and water pump, simply coz they are cheap and readily available. My neighbour and I are doing a very similar setup on his safari. Did you you the factory oil supply and drain lines for the turbo that are tee'd of from the alternator?

I looked for other options but the yzf radiator was pretty cheap. I used the oil feed by the engine mount its a 1/8th bspt thread snd welded a oil return on the side of the sump. I heard mixed things on using the alternator ones, for how easy it is best to make separate lines for the turbo. Post some pics up of your build on here.

Have only removed old manifold/turbo and tidied up a few bits so far. New exhaust manifold has arrived but waiting for the turbo unit to show up. This truck also has a second air con pump for inboard air to contend with, getting in the way of the intake. We have decided to continue using what we think is the factory turbo oil supply line and drain as the turbo that was removed is in great condition. Will post more pics as the bits turn up. Was your truck a factory turbo to start with ?

Is that Dave's old truck by any chance?

Nah mine wasn't turbo that's why I put new lines in.

Yeah it was dave from martons old truck. Do you know it?

kcinshaw wrote:Nah mine wasn't turbo that's why I put new lines in.

Yeah it was dave from martons old truck. Do you know it?

yep good truck that look after it lol

Thanks crash will do.

I have done a little more on the airbox but ran out of argon so no more welding until I sort that out.

Managed to get some lexan for the lid of the airbox, so wont have to take the top off to check inside. The lexan itself is really clear so hopefully it will stay that way.



It looks like an excessive number of bolts but hopefully it will pull it tight enough to get a good seal on the gasket material I have. the gasket is a rubberized cork.
Hopefully have it finshed on the weekend. I plan to also start on the snorkel aswell.

Sorry mattnan I did not see your post. Yes it is stainless and I tig welded it.

Air box is pretty much done I had to modify it a little to make it fit better.



A mate wanted some photos of the egt gauge:





Hopefully start building the snorkel over the weekend. I am going to make one from some 4" Stainless pipe. It looks tight but should hopefully fit alright with some notches.

You fitted the get after the turbo?

Nice work on the air box BTW.

Yeah fitted it after the turbo cause it arrived after I had already had the turbo fitted and the lines plumbed in. I might consider moving it later on but for now it seems alright.

looks like a good setup, Im interested to see how cool your inter cooler gets with that setup. I have a similar intercooler to that to go in mine that will be a hybrid with the Subaru water to air intercooler bits, but the way you have done yours I might just have to go along those lines. Keep us up to date with how it goes!!

The setup runs pretty good I havent had any problems with it yet. Unsure the exact difference it makes but it keeps it cool to touch. Got my first dent the other day by dropping the rear end into a rut. Once I chop the quarters it will be gone and I will have a bit more clearance.



I have done a bit more work over the weekend.

Finished the airbox up. The rubberised cork gasket worked pretty good. The filter I am using is pretty average and I will have to change it shortly I think.





I made up a snorkel it was pretty tricky to cut the guard, there was alot of checking before I cut it. I sits alright now.









I have to notch the bonent a bit in the corner to clear the snorkel but that can wait for another day.

that looks awsome dude good work on the guard, would have taken a bit of patience. you might need a few more bolts on your airbox though that lid looks like its about to fall off! haha

Lance

I just installed a 50mm suspension lift using efs shocks from 4x4bits.co.nz. they are really good to deal with and shipping was fast.

I am unsure how much to extend the bump stops. Is there a standard bump stop extension length for a 50mm lift?

Nice work dude.

kcinshaw wrote:I am unsure how much to extend the bump stops. Is there a standard bump stop extension length for a 50mm lift?

It depends on the compressed length of the shocks, you need about 50mm of uptravel left when the axle is just contacting the bumpstop so measure the length of the shock at ride height, then measure the gap between the bumpstop and diff, add 50mm. Then measure length of shock fully compressed, if the amount of travel between this measurement and ride height measurement is greater than the bumpstop gap+50mm then you shouldn't need to extend bumpstops. Hope that makes sense, it did in my head...

I have been doing a bit of work on the truck recently so I thought I put a update up.

A picture with the lift kit installed on 31s




It rides heaps better than the standard springs with KYB shocks.

I got some new tires and put them next to the truck, looks like it could be a challenge to fit them in the guards.


They ended up not been to bad, needed to trim the back of the front guards and get rid of the quarters in the rear.




I am going to have to remove the plastic flares and put something flatter on.

After some cutting I ended up with a little more clearance.


When I did the front guard there was a heap of bog and rust to work around.


My list of things to do is getting smaller. I am looking forward to getting out and testing these tires out.

I have a question for the safari owners: Is the tailgate strong enough to hold a 35" spare?

plastic garden edging from bunnings to replace the flares...

i'd say take the time to build a rear winch bar with a swing out spare wheel carrier.

You are going to make dave envious lol, you've done to it what he wanted to had the funds allowed.

I welded the rear quarters up tonight. What a terrible job. It was pretty tough to get in there with the grinder and mig torch. But at least it is all done. I just have to paint them and put some flares on. Crash, yep I am going to use garden edging.