Outer Limits 4x4 Board

Hi guys ,

Thought I would share with you all my TB42 Turbo Build project for those whom are interested and maybe even get a few ideas and some help from you guys along the way.

Building The Top mount TB42 manifold

To make this project economical I am building several manifolds for other people that have expressed interest, I will be posing pictures as soon as i figure out how to do that ( the pictures not the manifold )

What Ive learnt so far ...
Longer equal length pipes before the collector provide more displacement for gas expansion after exiting the combustion chamber gasses are still expanding which means more to drive the turbine, insulated pipes dissipate less heat meaning gases continue expansion rather than start contraction as in a cast manifold which dissipates lots of heat, narrow pipes for provide higher velocity but can restrict top end rpms a balance of just the right size is needed and smooth polished surface for less turbulent flow, idealy after a good flowing header with not to much back pressure at top RPM's while still having a fast velocity at low rpms.
Almost sounds difficult ey'

Where its at .
T3 Turbo sit waiting to be mounted onto manifold other parts yet to be purchased.

After several hours of messing with CAD I have finally finished the tb42 head plate design and tested with some printed cutouts against my OLD tb42 Head which i will be using to bolt up on while welding.
The CAD files off to the Laser Cutters I hope to get down there and get a picture of them cutting the plates .

Have filled some pipes with sand for similar results to mandrel bending and done a few test bends on my 16 ton pipe bender which bends up to 3inch and they look great.
The bends will be cut and welded together into the final shape.

New Tig AC/DC welder for the job, with a variable pulse width and frequency and amps adjustments works so much better than using the Mig for this kind of thing, so I will have to make a few things now to pay for it.

Have gone with a Vband exhaust connection for the dump pipe and external waste gate hookup into a stainless 3inch exhaust.

Not sure how to fit in an intercooler in, know i want one just cant see where its going to fit, but with a big angle grinder and a no fear im sure I can get one in the front somewhere, but anyone with some pictures of these installed would be of interest to me.

should be more of these projects as they are cool.

You will need to have a photobucket account to load pictures. It is free. It is very easy to use.

Looking forward to seeing your project unfold.

Sounds very similar to my GQ Shorty, top mount ball bearing hybrid turbo TB42 running straight LPG. Puts out a lazy 300 rwhp at 10psi and around 460 at 25 psi .... all figures running 33 muddies

Mine's intercooled as well which helps. You should look into beefing up your spark system.

Good luck with the build.

Simo63 wrote:Sounds very similar to my GQ Shorty, top mount ball bearing hybrid turbo TB42 running straight LPG. Puts out a lazy 300 rwhp at 10psi .

must have more than a turbo to get that sort of power at 10psi... wats ur secret

Shootout mode.

Tuflux308 wrote:

Simo63 wrote:Sounds very similar to my GQ Shorty, top mount ball bearing hybrid turbo TB42 running straight LPG. Puts out a lazy 300 rwhp at 10psi .

must have more than a turbo to get that sort of power at 10psi... wats ur secret

Hmmm maybe you're onto something there

im also doing this coversion soon to my 93 gq patrol have the turbo its a t3/t4 57 trim, i ported the wastegate out as it was about the size of a 5 cent piece.

according to online calculators it should be on full boost by 1500rpm and flow to redline.

what will be required to "beef up" the ignition system? mines the fuel inejcted model also running on lpg, things like coil?

ICE have a module and coil that will surpass any power output you are likely to acheive. He has them on 9 000 rpm V8's on alcohol, and on engines in the USA engine masters competition.

You should be thinking of valve spribgs also.

Joel

naif wrote:im also doing this coversion soon to my 93 gq patrol have the turbo its a t3/t4 57 trim, i ported the wastegate out as it was about the size of a 5 cent piece.

according to online calculators it should be on full boost by 1500rpm and flow to redline.

what will be required to "beef up" the ignition system? mines the fuel inejcted model also running on lpg, things like coil?

I use an MSD, seems to work very well.

Making the TB42 headplates the later cutting business part of the job.

Using CAD I made up manifold templates and printed them out cut them from the paper and checked them against the head , made adjustments and reprinted here you see ( hope this works ) the tb42 head with paper templates.



After this process was complete sent off the files for samples to be cut at the laser cutters .
Here the metal samples have arrived from the laser cutters test them against the head too just in case the printer was not that accurate.


Ok so now for the pipe size , grabbing a bit of test pipe I gave it a bit of technical adjustment ( belted it with a hammer ) to see how the diameter of the pipe would match the size of the port for a nice fit.



OK so the head plates are all looking great so the laser cutter will now get the ok to cut the plates from stainless steel 12mm plate, I was going to go with the mild steel but hey all stainless is nicer but i have to see what they say the cost is going to be.

more to come

when will you know a price on the flange plates? would you be willing to sell one? otherwise tis chop chop to my hitech headers which id rather not do.

completely standard other than a stinger i think it was ecu. made 270 at the rears with 33s and a too small a turbo on 10psi

with injectors and a gt35 intercooler etc. he is expecting alot more.

may i ask why gas?
and what is the economy like on gas as its shit on petrol?

Simo63 wrote:

Tuflux308 wrote:

Simo63 wrote:Sounds very similar to my GQ Shorty, top mount ball bearing hybrid turbo TB42 running straight LPG. Puts out a lazy 300 rwhp at 10psi .

must have more than a turbo to get that sort of power at 10psi... wats ur secret

Hmmm maybe you're onto something there

ha yeah im thiking dodgy dyno

its 220kw. possible at the rear wheels

chunderlicious wrote:completely standard other than a stinger i think it was ecu. made 270 at the rears with 33s and a too small a turbo on 10psi

with injectors and a gt35 intercooler etc. he is expecting alot more.

may i ask why gas?
and what is the economy like on gas as its shit on petrol?

I'm not sure about others but for my GQ, LPG has a couple of advantages. Firstly a higher octane but secondly it's just simpler than either running a carby into the Turbo as that creates a few issues itself or the other alternative was to inject it. Simpler to run LPG.

I can't quote economy figures as I don't drive it around the roads and it's not really relevant for me so I don't count. I will add that I didn't fit the LPG and I've been advised by the fitter that the LPG valves in the tank were modified to flow more. A friend is currently fitting LPG to his 4.5 Petrol GU and it's running lean. The same fitter has told him to modify or replace the valves in the tank so it flows more gas. Maybe someone who knows more about LPG than I do can explain that a bit further. Otherwise I can ask the fitter for a more detailed explanation.

Just trying to help.

Tuflux308 wrote:ha yeah im thiking dodgy dyno

You're thiking or thinking dodgy dyno??? Hmmmm ..... Well I guess you could be right however I think that's unlikely as the dyno belongs to Chapmans Autos in Cooroy who do plenty of dyno work for people around the Sunshine Coast. In fact it's quite a large part of their business and they are recognised specialists in the area of performance tuning. I can say that from personal experience you usually have to wait a week or two before you can book your vehicle to use it. I would hope that the dyno is reflecting an accurate figure because that's what I pay for when I use it just like all the other customers.

But the truth probably lies in the fact that there are a few other tuning secrets built into the car to achieve those power figures. Like I said it's a custom hybrid turbo, the LPG helps, the MSD helps, the Cam, the manifold and the intercooler all contribute as well. So yeah you're right, it's not a bolt on setup purchased from Safari

naif wrote:when will you know a price on the flange plates? would you be willing to sell one? otherwise tis chop chop to my hitech headers which id rather not do.

Anyone else interested in a Set ?

$80.00 will cover mild steel versions I have not got pricing on stainless ones yet they may be a bit more depends on the cost difference.

Notice the lovely curves on the bracing between each flange you can tell its engineer was Italian

Well Guys it took me 4 hours in CAD to make up these Header plates so anyone wanting a set I can get the laser cutters to make a couple more individualy is more expensive as they have minimum setup charges, but doing more makes them cheaper for me so i am happy to do it.

Tuflux308 wrote:ha yeah im thiking dodgy dyno

You're thiking or thinking dodgy dyno??? Hmmmm ..... Well I guess you could be right however I think that's unlikely as the dyno belongs to Chapmans Autos in Cooroy who do plenty of dyno work for people around the Sunshine Coast. In fact it's quite a large part of their business and they are recognised specialists in the area of performance tuning. I can say that from personal experience you usually have to wait a week or two before you can book your vehicle to use it. I would hope that the dyno is reflecting an accurate figure because that's what I pay for when I use it just like all the other customers.

But the truth probably lies in the fact that there are a few other tuning secrets built into the car to achieve those power figures. Like I said it's a custom hybrid turbo, the LPG helps, the MSD helps, the Cam, the manifold and the intercooler all contribute as well. So yeah you're right, it's not a bolt on setup purchased from Safari [/quote]

1MadEngineer wrote: the turbo conversion was done by us, then the efi was tuned at chapmans and they got 260hp at the rear wheels, we then got it tested on a trusted dyno and it had 240hp, then retuned and got 270hp tubo only, then added a 150hp NOS fogger. only use it at ~75 hp atm. I will get some photos over the weekend.

sorry bout the spelling i have to push the n really hard to make it work, i have a straight gas turbo tb42 with twin converters, front mount cooler, Gt35 turbo, ice ignition, extractor manifold, valve springs and know alot more tb42 and 45 turbo engines, some that are $$$$, they make great power. But i think some places are inflating their power figures and it makes it hard for the honest ones

Tuflux308 wrote:sorry bout the spelling i have to push the n really hard to make it work,

Maybe we should put in and get you a new keyboard Or give me your address and I'll post you a 2nd hand one I have laying around

Tuflux308 wrote: But i think some places are inflating their power figures and it makes it hard for the honest ones

I would hope that isn't the case but I suspect and accept that different dynos give different readings for sure. Interesting to hear what 1madengineer had to say about the same dyno. Maybe it isn't as accurate as it could be.

Tuflux308 wrote: i have a straight gas turbo tb42 with twin converters, front mount cooler, Gt35 turbo, ice ignition, extractor manifold, valve springs and know alot more tb42 and 45 turbo engines, some that are $$$$, they make great power.

Yes you are correct. Turboing a TB42 (or TB45 for that matter) is well worth the effort as they respond very well and produce a more than satisfactory amount of horse power regardless of the exact figures or any discrepancies in dyno readings.

Those 12 mm header plates sound like a good idea as there is nothing worse than having a manifold that leaks all the damn time. Anyone looking to do such a build should latch onto the $80 ones being offered as that sounds very cheap to me.

Baalsgate wrote: To make this project economical I am building several manifolds for other people that have expressed interest, I will be posing pictures as soon as i figure out how to do that ( the pictures not the manifold )

how many of these manifolds are you planning to build?
im very keen in getting my hands on one!

It may not be the dyno operator at fault (but it can be), if you actually want to know the real power figures get onto a dyno that is tested and calibrated to a standard. There are standards for dynos just not all dyno manufacturers choose to adhere to any. If you want to know the actual power get on a Dynamic Test Systems, Mainline or Dynologic as they comply with an SAE, some more current than others, but all will be more accurate than a dyno dynamics, especially in shootout mode.

The truth is out there!

Cheers

Joel

So, TB42 exhaust manifold fit's TD42???


How many are you planning on making? and what would you charge???

monkeycritter wrote:So, TB42 exhaust manifold fit's TD42???
?

yes and yes

^--This Way Up--^ wrote:

Baalsgate wrote: To make this project economical I am building several manifolds for other people that have expressed interest, I will be posing pictures as soon as i figure out how to do that ( the pictures not the manifold )

how many of these manifolds are you planning to build?
im very keen in getting my hands on one!

At the moment I am making 5 i am making 3 various configurations for myself to try things out like :
1 . a twin turbo manifold setup for two smaller turbos ( more testing )
2 . A small profile Short tube version ( easier welding ) testing purposes
3. Long tube set for ideal performance

The other 2 manifolds for other people that have payed upfront to have a manifold built for them whom are also getting other items .

I am willing to make more if the orders are quick, its fairly fun using the tig welder so if i can make a few dollars to cover my Argon I'll be happy.

The manifolds are going to be $485 each that will include wrapping with thermal insulation header tape as even while its pretty stainless steel with maybe the exception of some of my welding, ( narr my welding is fairly good, I have just bought a new Tig welder so it should be very good ) reducing under hood temperatures and heat staying in the manifold is beneficial

Any one interested ??

I also have a couple of 3 inch exhausts if any one is interested be quick only $300 including muffler, im just fitting mine today pictures soon.

I also have a couple of 2.5 inch exhausts $100 only the tail section to the muffler but that is the tricky bit to bend if your DIY all the rest is mostly straight .

thanks for the questions

PGS 4WD wrote:It may not be the dyno operator at fault (but it can be), if you actually want to know the real power figures get onto a dyno that is tested and calibrated to a standard. There are standards for dynos just not all dyno manufacturers choose to adhere to any. If you want to know the actual power get on a Dynamic Test Systems, Mainline or Dynologic as they comply with an SAE, some more current than others, but all will be more accurate than a dyno dynamics, especially in shootout mode.

The truth is out there!

Cheers

Joel

Thanks Joel. Maybe we could ask the dyno operator for some sort of calibration certificate.

Can anyone else help out with real costings?

So far we've got $485 manifold, $300 3" exhaust, what's a T3 worth, front mount intercooler, BOV, plumbing, MSD (or similar), etc? What else have i forgotten?

How would TB42e with T3 run without MSD? Without intercooler?

I'm thinking i may be able to turn what's always been a dream into reality

Simo63 wrote:You're thiking or thinking dodgy dyno??? Hmmmm ..... Well I guess you could be right however I think that's unlikely as the dyno belongs to Chapmans Autos in Cooroy who do plenty of dyno work for people around the Sunshine Coast. In fact it's quite a large part of their business and they are recognised specialists in the area of performance tuning. I can say that from personal experience you usually have to wait a week or two before you can book your vehicle to use it. I would hope that the dyno is reflecting an accurate figure because that's what I pay for when I use it just like all the other customers.

... it could become a popular place that always hands how high figure dyno sheets. Wonder if there really are places that do the dodge like that?
... some people would be happier to have a dyno sheet showing them their large $ investment makes massive HP so they have wank value to show mates on paper....

'moit.... my fooly sik civic makes 300kw with just the milo tin zaust, and a pod .... check the dyno sheet'...

Oh dear! Was going to get one of these beaties, but the minister for finance and war wasn't happy with the speeding ticket I just got.

DOH!

Looks like I need to get that secret kitty going again?

GQ Bear wrote:Can anyone else help out with real costings?

So far we've got $485 manifold, $300 3" exhaust, what's a T3 worth, front mount intercooler, BOV, plumbing, MSD (or similar), etc? What else have i forgotten?

How would TB42e with T3 run without MSD? Without intercooler?

I'm thinking i may be able to turn what's always been a dream into reality

i'm thinking similar shorty would probably wheel stand too much though t3 is worth anywhere from 50 to 1500 depending on specs. i've got an r33 turbo which has a t3 flange. paid 250 for it in good nick. could get something like adam's dads which is just a chinese one from ebay which is about the same new but i think they've blown two.

you'd probably also need to upgrade your gas system if you're going straight gas or want to keep dual fuel with standard computer. something else to think about.

intercooler is cheap off ebay for about 170. then some dodgy little brackets and some flexy intercooler piping from a truck wreckers and thats sorted. not a whole lot else apart from that i don't reckon. set of burnout wheels and tyres?

hokey wrote:

GQ Bear wrote:Can anyone else help out with real costings?

So far we've got $485 manifold, $300 3" exhaust, what's a T3 worth, front mount intercooler, BOV, plumbing, MSD (or similar), etc? What else have i forgotten?

How would TB42e with T3 run without MSD? Without intercooler?

I'm thinking i may be able to turn what's always been a dream into reality

i'm thinking similar shorty would probably wheel stand too much though t3 is worth anywhere from 50 to 1500 depending on specs. I've got an r33 turbo which has a t3 flange. paid 250 for it in good nick. could get something like Adam's dads which is just a Chinese one from eBay which is about the same new but i think they've blown two.

you'd probably also need to upgrade your gas system if you're going straight gas or want to keep dual fuel with standard computer. something else to think about.

intercooler is cheap off ebay for about 170. then some dodgy little brackets and some flexy intercooler piping from a truck wreckers and that's sorted. not a whole lot else apart from that i don't reckon. set of burnout wheels and tyres?

hey all. we are onto our 2nd ebay turbo. the 1st one was second hand and previous owner had abused it :( the 2nd one is going great. and know 3-4 people that run them to.

t3/t4 off ebay 299-350 of ebay.ours is going strong . personally go a single sided bar + plate cooler as they cool heaps better they go for 250-450 off ebay

blow off valve costed $70 and 40 for adapter plate. they go for 200+ in shops

hosing ? all we did is bought a vl turbo inter cooling pipe kit for 200 off ebay. came with all hosing and etc etc

msd ignition = nfi

bear. we had to run a cooler with our setup. and we run just a boost retarded dizzy(nissan one reset for turbo) dad payed 140 fdor his to be done

Still a way off, but not such a distant dream now