On 3 Performance 1500 Chevy Truck Single Turbo Build Thread, Production System
08-28-2013, 05:05 PM
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On 3 Performance 1500 Chevy Truck Single Turbo Build Thread, Production System We have been working on the truck turbo system design for some time now and I finally have some pre-production parts going back on the shop truck. We started with a 2004 Chevy 1500 and has 22x,000, old lady pamper highway miles(Im kidding its a wore out old utility truck). So we tore into it and designed a single system using the stock dr. side manifold. This is where we put a little twist on the typical system, we didnt just build a log that had the driver bank flowing into the back of it. I wanted to keep both separate and maximize flow as much as possible. What we came up with is a pretty cool looking manifold that is going to work well and unlike any other truck setup that Im aware of. Here are a few shots of what I have going on right now:
When designing this kit, we test fit all the way up to our On 3 Performance t4 flanged 88mm turbo. Although this turbo does take a few tweaks to fit the downpipe, it clears everything else. We will have options for directly exchanging the stock On 3 70mm turbo all the way up to the 78mm unit that will be released around Christmas time.
As you can see ground clearance is not an issue, none of the tubing can even been seen when looking level at the vehicle in the air
I setup the downpipe so that it will come out of the turbo, re-circulate the wastegate and step to 3.5" at that point. From there is goes down below the firewall and will run back as a 2 piece section (3pc total).
Then what we are doing is using the factory hanger and just going to tack that to the last section of the downpipe.
Each production kit will be coming this same way and terminate at this point. On our truck we are going to make a little plate for the bed and have the exhaust run from where you see out through the bed in front of the rear tire.
One other custom touch we are going to be doing on this truck instead of just having a filter is making a custom 4" air intake from the turbo into the grill at the top left corner. I havent gotten that far yet but just was getting ideas as the truck was going together last night
Part of the kit will also be the new hard upper polished radiator hose. This allowed us to eliminate the surge tank on the passenger side and give us a little more room to work with the turbo stuff. On top of that, each kit will require the user to go with an electric fan. In our case, we already had some 98-02 Camaro take off fan's and went ahead and threw those on the car.
I will continue to update this thread as we make headway and for those interested in the kits, we have a tentative release shipping date of
NOVEMBER 17, 2013
This is not set in stone but when we are expecting to have them ready to ship. As far as a price, they are going to be $1,890 for the On 3 single turbo system with the 70mm journal turbo. If you check the website, we have intercooler upgrades, injectors, turbo upgrades, etc. All of those upgrade costs are standard across the board so if you looking to go with say a 4" intercooler, 76mm turbo, one of the On 3 ceramic ball bearing units, all of that can be found on the site.
LS1TECH special, we are going to run free shipping on all order for this system up till October 31st. This is an incentive for our customers to get in on a $95 savings. November 1st, this offer is gone so dont miss out if your wanting to go turbo -
On3Performance@aol.com for any questions concerning the kit as well
I will be continuing to work on the truck and make progress over the next week or so. As I do, Ill try to take more photos and post as I do.
Just a brief break-down of the kit and how it will come:
Complete hotside, crossover, tubular manifold and downpipes, 304ss
Complete Cold side, 6061 polish aluminum 3", all bead rolled
On 3 70mm Journal turbo
On 3 44mm vbanded wastegate
On 3 50mm Blow off valve
On 3 3" core air to air intercooler
All couplers and t-bolt clamps (black)
SS vband clamps and Lap band clamps for turbo back tubing
Custom laser formed intercooler brackets and hardware
Complete oil feed/drain kit
Instruction CD for install questions
Im sure I am leaving something out but like I said Ill be building this thread as we make headway and keep everyone informed for those interested in the build or the complete On 3 Performance Chevy 1500 / 2500 pick up truck single turbo system
When designing this kit, we test fit all the way up to our On 3 Performance t4 flanged 88mm turbo. Although this turbo does take a few tweaks to fit the downpipe, it clears everything else. We will have options for directly exchanging the stock On 3 70mm turbo all the way up to the 78mm unit that will be released around Christmas time.
As you can see ground clearance is not an issue, none of the tubing can even been seen when looking level at the vehicle in the air
I setup the downpipe so that it will come out of the turbo, re-circulate the wastegate and step to 3.5" at that point. From there is goes down below the firewall and will run back as a 2 piece section (3pc total).
Then what we are doing is using the factory hanger and just going to tack that to the last section of the downpipe.
Each production kit will be coming this same way and terminate at this point. On our truck we are going to make a little plate for the bed and have the exhaust run from where you see out through the bed in front of the rear tire.
One other custom touch we are going to be doing on this truck instead of just having a filter is making a custom 4" air intake from the turbo into the grill at the top left corner. I havent gotten that far yet but just was getting ideas as the truck was going together last night
Part of the kit will also be the new hard upper polished radiator hose. This allowed us to eliminate the surge tank on the passenger side and give us a little more room to work with the turbo stuff. On top of that, each kit will require the user to go with an electric fan. In our case, we already had some 98-02 Camaro take off fan's and went ahead and threw those on the car.
I will continue to update this thread as we make headway and for those interested in the kits, we have a tentative release shipping date of
NOVEMBER 17, 2013
This is not set in stone but when we are expecting to have them ready to ship. As far as a price, they are going to be $1,890 for the On 3 single turbo system with the 70mm journal turbo. If you check the website, we have intercooler upgrades, injectors, turbo upgrades, etc. All of those upgrade costs are standard across the board so if you looking to go with say a 4" intercooler, 76mm turbo, one of the On 3 ceramic ball bearing units, all of that can be found on the site.
LS1TECH special, we are going to run free shipping on all order for this system up till October 31st. This is an incentive for our customers to get in on a $95 savings. November 1st, this offer is gone so dont miss out if your wanting to go turbo -
On3Performance@aol.com for any questions concerning the kit as well
I will be continuing to work on the truck and make progress over the next week or so. As I do, Ill try to take more photos and post as I do.
Just a brief break-down of the kit and how it will come:
Complete hotside, crossover, tubular manifold and downpipes, 304ss
Complete Cold side, 6061 polish aluminum 3", all bead rolled
On 3 70mm Journal turbo
On 3 44mm vbanded wastegate
On 3 50mm Blow off valve
On 3 3" core air to air intercooler
All couplers and t-bolt clamps (black)
SS vband clamps and Lap band clamps for turbo back tubing
Custom laser formed intercooler brackets and hardware
Complete oil feed/drain kit
Instruction CD for install questions
Im sure I am leaving something out but like I said Ill be building this thread as we make headway and keep everyone informed for those interested in the build or the complete On 3 Performance Chevy 1500 / 2500 pick up truck single turbo system
08-28-2013, 05:06 PM
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I have a lot of people asking me for better photos of the manifold. Today I got in our 78mm prototype turbo and decided to throw it on the truck to get some mileage on it. Since it was apart, I shot a few more photos to hopefully this will help clear up any questions people might have.
Also people have asked about heater line clearance, as you can also see I have made some custom stainless hard lines to clear all the hot parts without having to worry about melting a line
Also people have asked about heater line clearance, as you can also see I have made some custom stainless hard lines to clear all the hot parts without having to worry about melting a line
Last edited by On 3 Performance; 12-12-2013 at 05:09 PM.
08-28-2013, 10:42 PM
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Haha, I could be thats for sure. If you have any questions let me know. I hope to have the truck running in the next week or so that I have shown in all the photos. Only hold up at this point is that we sent the injectors out to get modified and not sure when they will be back
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08-29-2013, 03:04 PM
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I really just dont have the answer yet as I havent test fit on one of those trucks. I dont see why we couldnt make it work but I dont want to say yes till I actually get a truck here and bolt a kit on
I have not tested this either yet to this point, just the 1500 truck. Im pretty confident we shouldnt have an issue but its early on this as well. I need to really get this kit finished on the shop truck and get some product ran. Then we will actually have product on hand to test with and see what if anything needs done. I will certainly keep you posted and maybe if you wanted to work with us on testing a setup on your vehicle, we could be open to that as well
Thank you
Thank you
08-29-2013, 03:06 PM
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As far as splitting up the kits, I dont like to do that. People have issues more often then they should and then blame is easily pointed at us. I like to sell the complete systems so that we know everything that is being used, I have personally ran on my car and test fit with. Im not saying 100% that we will not offer you that when the kits stocked but as of right now, Im sticking with our complete turbo system idea. I strongly recommend going that route
08-30-2013, 01:44 AM
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Will a BW s476 bolt in place of your turbo? Also how much of a pita is it to change plugs on the passenger side with the new setup?
Last edited by Blackbird-WS6; 08-30-2013 at 06:32 AM.
08-30-2013, 09:41 AM
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I have not tested this either yet to this point, just the 1500 truck. Im pretty confident we shouldnt have an issue but its early on this as well. I need to really get this kit finished on the shop truck and get some product ran. Then we will actually have product on hand to test with and see what if anything needs done. I will certainly keep you posted and maybe if you wanted to work with us on testing a setup on your vehicle, we could be open to that as well
08-31-2013, 09:39 AM
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As for the kit it looks promising and I love the way you designed the turbo manifold it's really a slick Idea. Have you posted this on Performancetrucks.net I feel like a lot of guys would really be stoked for this kit.
In for more progress on the build and testing.
