Walledition-New Project: Boost/Turbo-Fuel/Return System, Build

Hey guys! Ive been on this site for a time but havnt post before, i´ll do my best to make this detailed and interesting even its a small project compared to what a lot of you guys have going on with your trucks. Please feel free to comment, advice and feedback

Project consist of:
http://i784.photobucket.com/albums/y...ps5qi7vqma.jpg
2005 rcsb stepside 6.0 LQ4, 4L80E with TransgoHD2, TR224 112, 14bolt/posi/4.10`s, Circle D MultiDisk 4C 3600-3800

This is not my daily driver but i wana be able to drive it on weekends and have a consistent bracket truck for small local racing events.

Upgrades:

PT7475
http://i784.photobucket.com/albums/y...psunqf0gz5.jpg
KBracing T4 Hotside
http://i784.photobucket.com/albums/y...ps78cyg3q0.jpg
http://i784.photobucket.com/albums/y...psjin8h7zp.jpg
http://i784.photobucket.com/albums/y...ps7ghv9ait.jpg
Custom Exhaust
http://i784.photobucket.com/albums/y...psvquaeycd.jpg
Custom Coldside
http://i784.photobucket.com/albums/y...psyvnfjkcb.jpg
Jgs 40mm wastegate
http://i784.photobucket.com/albums/y...pskqpz2ueg.jpg
Rps 50mm blow off valve
http://i784.photobucket.com/albums/y...psliawegrc.png
Truck style 80lb/hr@4bar injectors + ev6 to mini delphi
http://i784.photobucket.com/albums/y...psvjzyoloo.jpg
http://i784.photobucket.com/albums/y...pskinuyapg.jpg
Converting to return system (fuel)
http://i784.photobucket.com/albums/y...psein4vqpz.jpg

I will go into details as i move on with this project:cheers:[/QUOTE]

Hot Side:
Time to pull the headers/exhaust/intake out and start installing new uprades
http://i784.photobucket.com/albums/y...pspvwvynzm.jpg
I used 1" Cool It Thermo Tec black wrap on the turbo manifold and coated it with Cool It Thermo Tec after wrapping it, supposed to last longer and the coating looks good on any metal, in my experience the zip ties sucked big time since the system they have to ajust them doesnt let u make a tight fit so i went ahead and got regular hose clamps and just coated them after installing them for a cleaner look
http://i784.photobucket.com/albums/y...psuls3bukl.jpg
http://i784.photobucket.com/albums/y...ps3rq778f6.jpg
http://i784.photobucket.com/albums/y...psrhpbghfw.jpg
http://i784.photobucket.com/albums/y...psnnd6jzas.jpg
Stock driver side manifold sand blasted and coated with 2000f as well
http://i784.photobucket.com/albums/y...psfxahqyrv.jpg
Crossover pipe was bolted on, spot welded and fully welded after, i used 2" Cool It Thermo Tec black wrap and coated it as well
http://i784.photobucket.com/albums/y...psvwsbzkiu.jpg
Permatex 81878 Ultra Copper High-Temp RTV Silicone Gasket Maker was used to seal the driver side manifold and crossover pipe
http://i784.photobucket.com/albums/y...ps2br0rohm.jpg
wastegate installed after crossover pipe was done
http://i784.photobucket.com/albums/y...pseubs9428.jpg

Intercooler mount:
I had a hard time trying to find info on mounting a intercooler behind the grill and rout the 3" piping on the sides with a 04+ 34" radiator, thanks too "smokeshow" he gave me some tips, it can be done keeping the pcm and battery on stock location and YES its tight
http://i784.photobucket.com/albums/y...pslhupkusz.jpg
http://i784.photobucket.com/albums/y...psikuhdztd.jpg
http://i784.photobucket.com/albums/y...psgw1w5o7b.jpg
http://i784.photobucket.com/albums/y...psvascxrj0.jpg
Little welder wish made it happend lol
http://i784.photobucket.com/albums/y...psguddauaw.jpg
Passenger side:
To make room for the 3" pipe i had to take the ac gas out, weld a small extencion in and refill the ac again
http://i784.photobucket.com/albums/y...psaodwqhus.jpg
http://i784.photobucket.com/albums/y...psubnh7g5n.jpg
http://i784.photobucket.com/albums/y...ps88b1iejm.jpg
http://i784.photobucket.com/albums/y...pspi00ybei.jpg
Intercooler Piping:
http://i784.photobucket.com/albums/y...psmquv6hnc.jpg
http://i784.photobucket.com/albums/y...psglrmjtd8.jpg
http://i784.photobucket.com/albums/y...psiab0ucws.jpg
http://i784.photobucket.com/albums/y...psk1jehm4l.jpg
Welding: (First i tried mig welding, later had everything rewelded with a tig welder, looks much cleaner)
http://i784.photobucket.com/albums/y...psskj13hyi.jpg
Mig Welding
http://i784.photobucket.com/albums/y...psewxsbxir.jpg
Vs. Tig Welding
http://i784.photobucket.com/albums/y...pscn4il0qc.jpg
http://i784.photobucket.com/albums/y...psgvux9ik7.jpg
http://i784.photobucket.com/albums/y...psy8glwjkz.jpg

Cold side and ic bracket done (had it powdercoated black):
http://i784.photobucket.com/albums/y...psi7tznelp.jpg
http://i784.photobucket.com/albums/y...psaiflnhrr.jpg
http://i784.photobucket.com/albums/y...psy41jjvzp.jpg
http://i784.photobucket.com/albums/y...pszuqompfd.jpg
http://i784.photobucket.com/albums/y...psuzh1nlim.jpg
http://i784.photobucket.com/albums/y...pslhltq716.jpg
http://i784.photobucket.com/albums/y...pse56iwjij.jpg
http://i784.photobucket.com/albums/y...psy1idxxs6.jpg
http://i784.photobucket.com/albums/y...psucie8asw.jpg
http://i784.photobucket.com/albums/y...pswldxei0b.jpg
http://i784.photobucket.com/albums/y...ps195kaqyt.jpg
http://i784.photobucket.com/albums/y...pszrb0s5w6.jpg

Oil feed and return ports:
Feed i taped in this fitting:
http://i784.photobucket.com/albums/y...psvbwv3f3h.jpg
Return:
http://i784.photobucket.com/albums/y...ps7ulgeay2.jpg
http://i784.photobucket.com/albums/y...psuqgkjlig.jpg

Since i was dealing with powdercoating i had some more parts sandblasted and powdercoated to clean the engine bay
http://i784.photobucket.com/albums/y...ps93cbmqce.jpg

Good looking truck. Nice job on the turbo install. How much work went into converting to return style?

nice truck, good work, what state are you in?

Looks really clean! I just have one concern; Where you mounted the wastegate isn't ideal. The wastegate won't be nearly as efficient if it were placed downstream of both manifolds.

Quote:

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Originally Posted by Chevy-Art

Good looking truck. Nice job on the turbo install. How much work went into converting to return style?

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Sorry i never got a notice of responses im just seeing them
Thank you

Converting return style is not so bad, if u still need a list of things let me know i can help you out with pictures and details

Quote:

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Originally Posted by crusher

nice truck, good work, what state are you in?

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Thank you, im from chihuahua mexico

Quote:

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Originally Posted by shmiet

Looks really clean! I just have one concern; Where you mounted the wastegate isn't ideal. The wastegate won't be nearly as efficient if it were placed downstream of both manifolds.

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Thank you
Im not saying its the best place for a high hp combo but its a proven to work kit from kbracing, ive been using it for months now and so far im very happy with the way it works, there are actually a couple of 1000+hp setups around with that kit