Newbie from NYC. Modifying my intake and exhaust in hopes of gaining 100+whp :D

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Maximumrisk

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Keep us updated Can't wait to see results

Sure will!,

I received the bends to do the wastegates and driver side downpipe. I am also waiting for a some 1/4" steel plate I ordered to make a little bracket/ fitting so that I can install the power steering reservoir remotely (away from the pump and the driver side header. LOL! ) with the steel piece I will also make an EGR block off plate.
Also, I ordered a battery holding bracket for my Optima battery. IF it gets here before the weekend I will tackle that as well as adding a 200amp fuse to the power line, just off the battery terminal (for safety reasons)
I will update you over the weekend
 

Gecko

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Just an idea for your EGR block off up at the intake manifold you could cut the tube and crimp the end and keep the normal fitting in there. That's what I did when I installed my SC. We tried the egr block off plate and it didn't completely block it off. I'll try and get a picture up later to show you what I mean.
 
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Maximumrisk

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Just an idea for your EGR block off up at the intake manifold you could cut the tube and crimp the end and keep the normal fitting in there. That's what I did when I installed my SC. We tried the egr block off plate and it didn't completely block it off. I'll try and get a picture up later to show you what I mean.

Some pictures would be nice ;-)
 

Gecko

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Here's the best I have right now. You can see its still the stock EGR tube. We just cut it and then crimped it shut. It allowed us to keep it mounted the same way and blocked off the way we needed. I've had no leaks from it at all.

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Maximumrisk

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Thanks for the idea!, i saw the plug, which the seller mentioned is a Chrysler offered product to delete the egr tube, and they want almost $40 for it and 30 something for the egr delete plate.
I was like, there is no way i am paying $80 (including shipping) for those two things, LOL. I am going to make my own delete plate and cut the egr tube and crimp it, like you did, or try to find a big enough vacuum cap and clamp it on.
Once again , thanks for the idea
 

Gecko

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Thanks for the idea!, i saw the plug, which the seller mentioned is a Chrysler offered product to delete the egr tube, and they want almost $40 for it and 30 something for the egr delete plate.
I was like, there is no way i am paying $80 (including shipping) for those two things, LOL. I am going to make my own delete plate and cut the egr tube and crimp it, like you did, or try to find a big enough vacuum cap and clamp it on.
Once again , thanks for the idea

Yea I bought the billet tech block off kit and just didn't like how the intake manifold plate was bolted in through the plastic manifold. So we just cut the tube. We did use their block off plate though for down on the head. Though we had to machine it down to .094 inches to fit between the mounting bracket and the head. It was quite the ordeal lol
 
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Maximumrisk

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Today I relocated the power steering reservoir. At first, I was going to tap the power steering pump to accept a 1/2npt fitting, but then I thought that any future power steering pumps would need to be tapped. So I decided to make a little adapter and would have a 1/2" npt **** which would seal using two o-rings.

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then I used a bunch of fittings to get the hoses routed away from any heat source. I installed the tank by the fuse box. Everything is working perfect. No leaks

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This hose took me 2 hours to make, if you thought regular stainless hoses were difficult to assemble, try these teflon lined, stainless hoses. Holy crap, I almost lost my sanity! LOL

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Anyways, now that that is done. I will work on the wastegates tomorrow.
 
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Maximumrisk

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Not much went on today, I just welded on the wastegates (on the header side). I was tired as hell after yesterdays ordeal and a long work week, so I called it quits early. Here are a few random pics

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Maximumrisk

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This weekend wasnt very productive as it has been raining on and off and i am doing this project in my driveway. Anywas, here is what got done: drilled the holes to mount the battery box in the back; i did not install it though as i am waiting for some grade 8 hardware that i ordered.
I also added a 200amp fuse inline to the power cable right next to the battery pole (for safety).
I got rid of the egr valve. I made a little plate to block it off at the head and cut and capped the tube going into the intake.
I was able to make the feed and return lines for the turbos.
I pulled the manifolds to install new gaskets. I have had very good luck with Remflex gaskets in turbo applications so thats what i went with again in this project.
I cut apart the coolant overflow tank from the winshield washer tank. I will be able to reuse the winshield washer tank which is a plus!. For an overflow tank i will see wat i can do later down the road.
I am waiting for sime bellows to weld to the wastegate tubes that will be going to the downpipes. I will try to finish the downpipes next weekend. next weekend i should be able to start the truck with the turbos on!
The next thing for me will be fueling and i am also thinking of ways to setup the rest of the exhaust. I am open to suggestions on that.
Anyways here are a few random pics

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Maximumrisk

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I was not able to acomplish as much as i wanted this weekend as i had some home maintenance repairs that i needed to tackle which took me most of Saturday, but i did get to complete the most time consuming part of a turbo build (for me anyways) which was routing the downpipes and recirculating the wastegates to them.
I also started to make a little bracket to hold the abs unit (not pictured) next week i should be able to start with the intercooler.
I am also considering routing water (coolant) lines to the turbos. The have provisions to be water cooled. Originally i was not going to do that, but it really helps extend the life of the turbo bearings. I will decide over the week.
Here are a few pics
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Good job, it's coming along...
 
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Maximumrisk

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Good job, it's coming along...

Thanks!. There are a lot of little things that i need to take care of: heat wrapping/shielding, painting, powder coating some parts, some wiring, fuel components, plus some other small fabrication here and there, but for the most part the hard part is done which was fabricating the hotside.
 
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Maximumrisk

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This weekend got a few things done. I bought some aluminum hex bar stock to make a custom "fitting" to go inline with the heater hoses. One to feed water to the turbos and the other to return it. I made and routed all the water lines. Also installed the turbos for good! I was able to start the truck with the turbos on, everything went well, no leaks anywhere!!. I still need to wrap the downpipes (it got dark outside). I will start on the intercooler next week weather permitting. Then there is the fuel stuff which i am leaving for last. Anyways a few pics:
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Maximumrisk

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Today finish wrapping and installing the downpipes, wastegates are in. Added some heat shielding to the inner fenders, brake booster and some of the wires. Finish installing the battery bracket. Tomorrow intercooler goes in.
I have to research the pcv situation with this intake as i would like to run an air/oil separator (aka oil catch can)

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Maximumrisk

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Mounted the intercooler today. It sits low, but will get plenty of air once i fabricate ducting for it. I did not do any of the tubing because i had other things to do.
Next update in a week
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Today, i almost completed the cold side. I need to order a few 45degree couplers to complete it as well as welding the blowoff valve flange . I am routing the turbo inlet tubing in a way that it would allow me to use the oem hood scoop to get fresh air, i just have to find a way to keep water out of the engine bay/air filters using some form of drain.
Any questions or suggestions i am all ears.
Here are a few random pics20151017_112137_zpsj7ftoypv.jpg
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usaf2006

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dag-gum... when the zombie apocalypse happens, I know what escape vehicle I'm stealing.
 
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