Passenger Side Truck Manifold Crossover Pics - More pics Updated 4/2/13
03-27-2013, 11:32 AM
#1
Passenger Side Truck Manifold Crossover Pics - More pics Updated 4/2/13 I have spent a few hours now searching all over LS1Tech.com and the web for inspiration and haven't come up with much.
First a little background, I am in the process of building a '87 RX7 with a 5.3l LM7 and a 76mm On3 Turbo. The car's primary purpose is to scare the crap out of me, but I plan on drifting it a bunch, roll racing and general hoonage. Goal is a conservative 400-500whp at moderate boost levels, and the ability to crank it up from time to time on the track (highway). Car should end up weighing in around 2500lbs. so that will be more than enough to make it a handful to drive.
My dilemma:
I am trying to package the turbo setup neatly and need to place it on the pass side of the engine bay. I have been looking for pics of crossovers and merges using non-egr truck manifolds that place the turbo with the compressor inlet facing forward and the turbo back tight against the engine. I have already cut off the flanges in preparation for v-bands. I have no need for a heater so there is worry for hoses out of the side of the water pump. I MUST have a filter on the turbo as the fender liners have been cut out for steering angle clearance. The further back it sits the larger a filter I can fit.
After tons of searching I can't seem to find good pics of a merge or crossover that places the turbo close to that location. Pics of something similar would be greatly appreciated. If all goes well and parts show up I should have some pics over the weekend.
One idea I had:
1. Weld pipe directly to the pass side manifold coming straight forward up the frame rail and place the flange right where I need it including the merge. The driver's side can connect with a v-band at either end.
Similar to this:
First a little background, I am in the process of building a '87 RX7 with a 5.3l LM7 and a 76mm On3 Turbo. The car's primary purpose is to scare the crap out of me, but I plan on drifting it a bunch, roll racing and general hoonage. Goal is a conservative 400-500whp at moderate boost levels, and the ability to crank it up from time to time on the track (highway). Car should end up weighing in around 2500lbs. so that will be more than enough to make it a handful to drive.
My dilemma:
I am trying to package the turbo setup neatly and need to place it on the pass side of the engine bay. I have been looking for pics of crossovers and merges using non-egr truck manifolds that place the turbo with the compressor inlet facing forward and the turbo back tight against the engine. I have already cut off the flanges in preparation for v-bands. I have no need for a heater so there is worry for hoses out of the side of the water pump. I MUST have a filter on the turbo as the fender liners have been cut out for steering angle clearance. The further back it sits the larger a filter I can fit.
After tons of searching I can't seem to find good pics of a merge or crossover that places the turbo close to that location. Pics of something similar would be greatly appreciated. If all goes well and parts show up I should have some pics over the weekend.
One idea I had:
1. Weld pipe directly to the pass side manifold coming straight forward up the frame rail and place the flange right where I need it including the merge. The driver's side can connect with a v-band at either end.
Similar to this:
Last edited by Rogue Status; 04-02-2013 at 10:50 AM.
03-27-2013, 12:42 PM
#3
I wish I had that much room Matt! That is in fact the front mount GTO.
I think my biggest concern is the merge itself. I am worried if it is to sharp or abrupt it will create a TON of turbulence.
I need to take a page from the Sloppy Mechanics book and just go out in the garage and make magic happen . . . barefoot!
I think my biggest concern is the merge itself. I am worried if it is to sharp or abrupt it will create a TON of turbulence.
I need to take a page from the Sloppy Mechanics book and just go out in the garage and make magic happen . . . barefoot!
03-27-2013, 04:17 PM
#7
I did Matt and I am thinking about something along those lines.
I have a few obstacles however, I can only run the merge across the front of the engine, under the crank pulley due to the engine bay layout.
In addition, I would like to use what I have. I don't have the disposable income I used to and have to make do with what I have.
I have a few obstacles however, I can only run the merge across the front of the engine, under the crank pulley due to the engine bay layout.
In addition, I would like to use what I have. I don't have the disposable income I used to and have to make do with what I have.
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03-29-2013, 12:20 AM
#8
Well made some good progress tonight. V-bands should be here Saturday and I already got the piping from summit.
Ended up fabricating it how I mentioned in my first post. The merge came out far better then I expected and should be perfect for my application. I will snap some pics in the morning before I head into work. Did the best I could with a roll cart, vice grips and an angle grinder.
Ended up fabricating it how I mentioned in my first post. The merge came out far better then I expected and should be perfect for my application. I will snap some pics in the morning before I head into work. Did the best I could with a roll cart, vice grips and an angle grinder.
04-01-2013, 09:03 AM
#9
Was out in the garage both Thursday night and Friday night working on the crossover. So far I am pleased with how it has come out. Still need to add the 44mm wastegate and connect the pass side. Had plans to do this on Saturday afternoon but the USPS had other plans. Should have the V-bands today and hope to make more progress tonight.
04-01-2013, 10:47 AM
#10
Passenger side manifold has to do a very sharp U-turn to the turbo, you are going to lose a lot of exhaust velocity in that and probably drive the backpressure way up too.
It sees like you had plenty of room to route the pipes like I did on my 240sx.
It sees like you had plenty of room to route the pipes like I did on my 240sx.
04-01-2013, 11:49 AM
#11
It was a compromise for sure. There were a few reasons I put the turbo there, asthetics, space contraints, the ability to run a filter, wastegate routing, ect. The car should only weigh 2500-2700lbs so if it hits 600whp I will be more than happy. The merge was actually pretty nice and even. I will get some better pics this evening.
04-02-2013, 08:31 AM
#13
Finished the crossover last night. Everything for the driver's side is just tacked. Figured it was time to go to bed at 1:00am.
I am happy with how it came out. Clean and tight to the engine, looks exactly how I wanted it to. I am sure I sacrificed flow, performance, and spool; but hey, it is an engine out of a Tahoe with a 76mm turbo hanging off it in a Mazda that weighs half what the Tahoe did. I think it will work just fine. Not trying to set any records, just build a fun car I can drift, roll race, track days (maybe) and on occasion drag race. Enough talk, onto the pics . . .
I am happy with how it came out. Clean and tight to the engine, looks exactly how I wanted it to. I am sure I sacrificed flow, performance, and spool; but hey, it is an engine out of a Tahoe with a 76mm turbo hanging off it in a Mazda that weighs half what the Tahoe did. I think it will work just fine. Not trying to set any records, just build a fun car I can drift, roll race, track days (maybe) and on occasion drag race. Enough talk, onto the pics . . .
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Homer_Simpson (12-28-2021)
04-02-2013, 04:25 PM
#14
04-03-2013, 08:25 AM
#18
tta656:
Specs on the piping:
2.5" 16ga Mild steel from SummitRacing.com
2 x 180* J bends 5" radius
1 x 120* Individual bend 2.5" radius
1 x T4 undivided flange mild steel
2 x v-band clamps and flanges eBay.com
All said and done with shipping I have $135 into the whole crossover. I had a small chunk of ~20* left of the bends and plenty of straight. It was close but had just enough.
tired2valve:
No P/S right now. I properly de-powered the rack and will try it out with the manual steering. The car is gonna be light and mostly for drifting/hooning so manual steering should be fine. If it ends up needing P/S I will most likely go electric P/S. The manifolds are from the 5.3l, I believe it is a 2002-2004 engine as the manifolds do not have the EGR provisions.
Thanks everyone! I should be able to get the wastegate fabbed on there this weekend, get hardware to bolt the turbo on and finish welding everything. I am also going to add a brace to the pass side on the inside of the sharp bend. With the weight of the turbo I want to make sure that nothing is going to crack or bend. 3/16" thick 3" wide steel should do the trick. Going to try and make it look pretty with some "speed" holes.
One problem I have run into now is the wastegate placement. I really want to return the dump to the downpipe. My VW had an external gate and although it sounded awesome, I really want to keep the noise down. With where I have the WG positioned, it just barely touches the tensioner pulley without the belt on. With the tensioner moved to where it would sit with a belt on I have plenty of clearance. Should I worry about the plastic wheel and the belt being that close to the WG. I was thinking about switching to a machined pulley just to be safe. Thoughts?
Specs on the piping:
2.5" 16ga Mild steel from SummitRacing.com
2 x 180* J bends 5" radius
1 x 120* Individual bend 2.5" radius
1 x T4 undivided flange mild steel
2 x v-band clamps and flanges eBay.com
All said and done with shipping I have $135 into the whole crossover. I had a small chunk of ~20* left of the bends and plenty of straight. It was close but had just enough.
tired2valve:
No P/S right now. I properly de-powered the rack and will try it out with the manual steering. The car is gonna be light and mostly for drifting/hooning so manual steering should be fine. If it ends up needing P/S I will most likely go electric P/S. The manifolds are from the 5.3l, I believe it is a 2002-2004 engine as the manifolds do not have the EGR provisions.
Thanks everyone! I should be able to get the wastegate fabbed on there this weekend, get hardware to bolt the turbo on and finish welding everything. I am also going to add a brace to the pass side on the inside of the sharp bend. With the weight of the turbo I want to make sure that nothing is going to crack or bend. 3/16" thick 3" wide steel should do the trick. Going to try and make it look pretty with some "speed" holes.
One problem I have run into now is the wastegate placement. I really want to return the dump to the downpipe. My VW had an external gate and although it sounded awesome, I really want to keep the noise down. With where I have the WG positioned, it just barely touches the tensioner pulley without the belt on. With the tensioner moved to where it would sit with a belt on I have plenty of clearance. Should I worry about the plastic wheel and the belt being that close to the WG. I was thinking about switching to a machined pulley just to be safe. Thoughts?
