Outer Limits 4x4 Board

well the GQ is finally on its way out, it has done 340ish turbo at 10psi. would expect more BUT it got hot coming home a year ago with mud in the rad and after it cooled I had to limp it to the nearest servo so prolly my fault.

basically I figure I can bore it out a little and put bigger pistons in, is this possibel? I have heard 4.5ltr is possible but only third hand so I am not sure, is there enough metal there, what pistons are around? will prolly go to about 14psi and an intercooler, also implication like fuel pump, head work etc

thoughts, sugestions, links and anything else would be good.

Bogged, if you dont know dont post to say you dont figgin know

Cheers Guys

Well, looking at the petrol versions, a TB45 is a TB42 with an extra 3.5mm of bore diameter. In other words, same stroke, fatter pistons.

Diesel is going to be different but I thought the information might be helpful while you're in the research stage. It suggests to me that you should be able to bore out the TD42 block a bit with no dramas.

Jason

chimpboy wrote:Well, looking at the petrol versions, a TB45 is a TB42 with an extra 3.5mm of bore diameter. In other words, same stroke, fatter pistons.

Diesel is going to be different but I thought the information might be helpful while you're in the research stage. It suggests to me that you should be able to bore out the TD42 block a bit with no dramas.

Jason

Thanks, I understood the TB42 could go to 4.5, but with the diesel having higher comp what are the implication and are there any pistons avaiable for deisel in this size?

personally i dont think you can bore them out at all. Spoke to a few engine rebuilders.

However you can do some head work and also change the cam so you can get more revs out of the motor.

Ultimately you need to work out what you want from the motor is it going to be reliable new motor or you want something with balls and less engine life.

let me know which way you go as i can give you more information if you want more power say 150kw + at the rear wheels ........

morkz wrote:personally i dont think you can bore them out at all. Spoke to a few engine rebuilders.

However you can do some head work and also change the cam so you can get more revs out of the motor.

Ultimately you need to work out what you want from the motor is it going to be reliable new motor or you want something with balls and less engine life.

let me know which way you go as i can give you more information if you want more power say 150kw + at the rear wheels ........

comp work champ, any info would be much appreciated

JPC is the go

Like this...
http://autospeed.drive.com.au/cms/A_072 ... ticle.html

bogged wrote:JPC is the go

Like this...
http://autospeed.drive.com.au/cms/A_072 ... ticle.html

be if I had a TB42

bogged wrote:JPC is the go

Like this...
http://autospeed.drive.com.au/cms/A_072 ... ticle.html

Any idea what that setup would cost? I can't read the whole article, wouldn't mind a pic of the engine bay if you could send me one.

In any case this seems like a strong contender to put against a V8 transplant.

Jason

chimpboy wrote:

bogged wrote:JPC is the go

Like this...
http://autospeed.drive.com.au/cms/A_072 ... ticle.html

Any idea what that setup would cost? I can't read the whole article, wouldn't mind a pic of the engine bay if you could send me one.

In any case this seems like a strong contender to put against a V8 transplant.

Jason

The pics on the site dont apear top link to a larger pic, so I cant do it for you, but a decent turbo or super charger set up would cost in excess of $8k

bogged wrote:JPC is the go

Like this...
http://autospeed.drive.com.au/cms/A_072 ... ticle.html

Thats marks very first turbo petrol which i think someone else bought in the 4wd industry......

Either way tiny,

What you need for your motor is just to ballance it no need to blue print it u can put a cam in to make it rev longer but not necessary.

Turbo,
well u need larger turbo say ball bearing setup that flows alot more air these can range from $1500 - 2000
intercooler either PWR water - air type or frontmount hybrid style
pump work will need boost compensator and pump modded to flow more fuel.
air setup 4" snorkle make your high flowing air box...

they are the main things to consider

morkz wrote:

bogged wrote:JPC is the go

Like this...
http://autospeed.drive.com.au/cms/A_072 ... ticle.html

Thats marks very first turbo petrol which i think someone else bought in the 4wd industry......

Either way tiny,

What you need for your motor is just to ballance it no need to blue print it u can put a cam in to make it rev longer but not necessary.

Turbo,
well u need larger turbo say ball bearing setup that flows alot more air these can range from $1500 - 2000
intercooler either PWR water - air type or frontmount hybrid style
pump work will need boost compensator and pump modded to flow more fuel.
air setup 4" snorkle make your high flowing air box...

they are the main things to consider

cheers,

I may stick with the current turbo and put a new bearing in it, maybe get a bigger snail or change the vanes (not sure what is in the current set up as it was done before I bought it although I am sure west end will have details if I give him the old reg number)

main thing is to get it stripped down to find out what needs to be done internally, but I would say a hone and rings and maybe pistons??? will see how they look. will put a bigger rad in at the same time I think.

will get a price on all the gear and will post up as I do it all

The complete article:

-----

Mark Johnson (of Johnson's Performance Centre) has built the ultimate escape machine. Forget about hang-gliding, jet skiing and motorbike riding - here is the very best in outdoor adventure you can experience. A 160kW at-the-wheels turbocharged Maverick with enough off-road capability to climb a cliff! After a hard week of toiling away under the bonnet of customers' cars, Mark likes nothing better than to head out behind the wheel of his short wheelbase Ford Maverick. But certainly this ain't no ordinary Maverick. Yep, this sucker's got around double the standard horsepower and can soar 6 feet through the air...

Yee-Ha!

Mark must be a dedicated man. Coz when he's not consumed with working on customers' cars, he'll be off climbing into the engine bay of his own Mav. There's no rest. During his so-called "breaks" and "days off", Mark has set about giving the Maverick a hike in power that'd see even the true monster truck guys raising their eyebrows. Starting off with the stock 4.2-litre (TB42) petrol in-line six, Mark decided to turbocharge it to the point where the standard CR could just still cope.

To the side of the straight six's head is now a custom exhaust manifold that feeds the 4.2's waste into a sizeable JPC-spec T3/4 turbocharger. After the turbine, the gasses get chucked out the back via a 3-inch mandrel system with a Lukey 'box. Of course, it's got a growl that's completely unlike your everyday road-going off-roader... Running up to 10 psi boost pressure, the turbo blows into a monstrous custom water-to-air intercooler that swallows up the whole left side of the engine bay. This system uses a Davies Craig 12V electric water pump (run at full speed) and also a Toyota Tarago engine radiator. A conventional VN Commodore V8 airbox is used.

Another odd twist is that this sky-scraping Ford also runs a modified-to-suit-boost Gas Research LP gas system. This is a move that, Mark says, came about because it reduces running costs, increases fuel octane and gives the potential for an extended range (when combined with the yet-to-come dual fuel arrangement). Interestingly, the standard Gas Research relief valve (which usually just vents pressure build-ups pre-carb) has been configured as a throttle closed blow-off valve. Mark tells us it works great, but it is a little noisy.

And now we come to that amazing suspension. No, Mark certainly hasn't gone out an' bought lowered King springs and Koni shocks for his turbocharged weapon! Instead, Old Man Emu suspension (with around 7-8 inches of rebound travel!) helps to make the cabin only accessible to those with a spring in their step... The swaybars have also been "binned" to give maximum travel. The wheels'n tyres? Try a chunky set of 36x1250 Super Swampers inflated onto 15x8 Sunnies. And, in addition to these, the front and rear differentials are also equipped with ARB centre locks, which make this thing just about impossible to get bogged. But - just to make sure there's no excuses for Mark not showing up for work on Monday - there's a 10,000lb Warn winch on the ARB bull bar to haul the rig out of any "awkward" situations. Mark can also tackle those deep river crossings thanks to the intake snorkel on the A-pillar. It doesn't bear thinking about what'd happen without that snorkel!

Of course, owning a rig like this opens up a whole new world of getting-your-rocks-off. Not only can you "scare the shit out of people on public roads", you can have an absolute wicked time burning over sand hills, slippin' through thick mud and roaring up un-tamed hills at speeds that are, well, insane. It's highly addictive.

Come Friday night, it's not unusual for Mark to squirt the mud off the mighty Maverick and head for - well, anywhere that his nose takes him! "You name it, we've been there," he laughs. "It's really great to get away from the rat-race and run wild." And he often takes passengers along for the rough-ride too - though he does find that most people are a little soft. "They all want to get out...". Of late, Mark's even been thinking about getting extra-serious and entering the turbo'd Ford into Competition Time Trials (which are a timed run over any given piece of rough terrain). "But you need big kahunas for that!" tells Mark.

Lucky for Mark (and his poor passengers!) the Mav's got a pair of grippy front seats that were kindly donated by a late model Rexy. And what is it like to get to sit in the passenger's seat, you ask? Well - I gotta say - I've ridden in lots of cars, but none plasters a smile on your face like the Mav. Mark shows little concern for obstacles - as noted when we launched over the gutter on the way back from our photo location. Then - hauling arse around a long-sweeping bend in the road - those big Super Swampers roll under and squirm around like you wouldn't believe. But that's all part of the fun! The rocking of the chassis, the terrific rumble from the tyres, the blaring crackle of the CB - it all gives a truly spectacular and unique experience. And that's not to mention the fact that it accelerates like one of JPC's other breathed-on hotties....

Yes - sorry Mark, it's nothing personal - but I can now understand why some people would want to get out!

Contact:
JPC (Johnson's Performance Centre)
+61 3 9465 2244

the smaller pics don't get any larger either, unfortunately

TINY pm our kiwi friend GQ TROL.

He and his mate have done some fairly gnarly work on a few td42's in nz. I don't think they punched them out though - in saying that I could be very wrong, just cam alterations and beefier internals.

JemmyBubbles wrote:TINY pm our kiwi friend GQ TROL.

He and his mate have done some fairly gnarly work on a few td42's in nz. I don't think they punched them out though - in saying that I could be very wrong, just cam alterations and beefier internals.

cheers, proly not realy looking for bottom end stuff, rather if possibel replace the required stuff with bigger if around, if not set it back up as is.

bassically the turbo bearing is on its way out and compression is way down ie when I did the clutch I could turn the engine over by hand from the flywheel either way with 10psi there is enough power there but if I can get more for no more real cost then I would be stoooooopid not to do it while it is out and being done, but I am not interested in spending 10g on working it

If you have a TD42 they have liners and its a dry set up easy to pull out and refit so everything can remain standard

duncan wrote:If you have a TD42 they have liners and its a dry set up easy to pull out and refit so everything can remain standard

so provided the pistons are ok, liners, rings and gaskets.... should be easy

not sure if my turbo is roller bearing, but is it possible to convert when I change it if it isnt??

cheers

TD42 is easy to re-build, but expensive. I built a Cyl liner remover to remove the liners on mine--old ones were very difficult to remove, but new ones went in easy. I used standard liners with standard pistons--this gave me the correct piston clearance. The liners themselves are about 1mm thick from memory. Have plenty of pics of my rebuild if you need some to look at..

Nick

Tiny wrote:

bogged wrote:JPC is the go

Like this...
http://autospeed.drive.com.au/cms/A_072 ... ticle.html

be if I had a TB42

yea I was thinkin with all the cheap Petrols round at moment with dudes doing V8's you could buy one and build it on the bench while still driving the TD around, then just swap when ready

Woop wrote:TD42 is easy to re-build, but expensive. I built a Cyl liner remover to remove the liners on mine--old ones were very difficult to remove, but new ones went in easy. I used standard liners with standard pistons--this gave me the correct piston clearance. The liners themselves are about 1mm thick from memory. Have plenty of pics of my rebuild if you need some to look at..

Nick

pics would be good, post here or email, whate ever is easy for you

cheers

will start with this my gq had 300 000 km's on it when i got it. got big ballbearing turbo off of smaller petrol motor stuffed in 13 psi had to force feed injector pump with in tank pump out of efi gq as cheap boost compensator. now has over 400 000 km's still going has seen wrong side of 4000 rpm a shit load of times still going. oh and on intercooler coming at least i have been saying that for 12 months now .

Tiny wrote:pics would be good, post here or email, whate ever is easy for you

cheers

Nick had a good thread on his rebuild, but cant find it.
if he sends me the photos, I'll up em and sort it out

Tiny,
Along the lines of where Morkz and Jeremy are coming from, we've built a few turboed TD42's for comp work and have largely left the engine as is. Haven't found the need to use oversize pistons (others may be able to offer first-hand experience though), because if you start with the right engine, they can dish out the HP no worries.

Balancing is worthwhile, but can be expensive if you have to pay someone else to do it. Cleaning up the ports is a good idea of you're chasing every last bit of performance. Decompressing engine slightly will allow you to run higher boost more reliably. Cam suitable for the turbo seems like a good idea, but we couldn't find a grinder who knew what he was doing, so we removed the turbo one (cos it was shite) and replaced it with the bog standard one. We might look at this again in the future though.

Turbo - If you want to stick with the turbo you've got for the time being, get the bearing replaced with oversized ones at the very least. But turbo work can be expensive, so you might be best to cut your losses, and get a new ball bearing one? Bigger air intake, 4" as Morkz suggests.

Fuel pump - Bigger plunger element is definitely worthwhile. Increase your fuel delivery by 100-150%. This gives the single biggest performance improvement after the turbo. I would never race a diesel powered rig without a bigger fuel pump....EVER!

Intercooler - Don't know, we haven't done it but everyone else seems to have. Water to air looks good due to the high engine speed / low vehicle speed we experience 4wding, versus an air to air system. You'll get plenty of conflicting opinions on that.

LPG Fumigation - It definitely works, but reliable kits can be expensive. Look at bringing in a Pro-Shot or Bully Dog kit. If it’s a "crash & burn" truck, I would do this before intercooling. If you're doing it for performance only, then hang on and enjoy the ride, but expect some reduced engine life.

Best thing you can do is talk to people who have been there and done that. Filter out the bollocks from the facts and build a truck that suits your needs and meets your expectations.

Have fun dude.

GQ TROL wrote:Tiny,
Along the lines of where Morkz and Jeremy are coming from, we've built a few turboed TD42's for comp work and have largely left the engine as is. Haven't found the need to use oversize pistons (others may be able to offer first-hand experience though), because if you start with the right engine, they can dish out the HP no worries.

Balancing is worthwhile, but can be expensive if you have to pay someone else to do it. Cleaning up the ports is a good idea of you're chasing every last bit of performance. Decompressing engine slightly will allow you to run higher boost more reliably. Cam suitable for the turbo seems like a good idea, but we couldn't find a grinder who knew what he was doing, so we removed the turbo one (cos it was shite) and replaced it with the bog standard one. We might look at this again in the future though.

Turbo - If you want to stick with the turbo you've got for the time being, get the bearing replaced with oversized ones at the very least. But turbo work can be expensive, so you might be best to cut your losses, and get a new ball bearing one? Bigger air intake, 4" as Morkz suggests.

Fuel pump - Bigger plunger element is definitely worthwhile. Increase your fuel delivery by 100-150%. This gives the single biggest performance improvement after the turbo. I would never race a diesel powered rig without a bigger fuel pump....EVER!

Intercooler - Don't know, we haven't done it but everyone else seems to have. Water to air looks good due to the high engine speed / low vehicle speed we experience 4wding, versus an air to air system. You'll get plenty of conflicting opinions on that.

LPG Fumigation - It definitely works, but reliable kits can be expensive. Look at bringing in a Pro-Shot or Bully Dog kit. If it’s a "crash & burn" truck, I would do this before intercooling. If you're doing it for performance only, then hang on and enjoy the ride, but expect some reduced engine life.

Best thing you can do is talk to people who have been there and done that. Filter out the bollocks from the facts and build a truck that suits your needs and meets your expectations.

Have fun dude.

Thanks alot, I am wary of the water to air due to diesel and water dont mix...mabe me being a girly man but hey, I want reliable at the end of the day.

My trusty Nav Daz has a relo who is an owner in garret so I may have access to a decent turbo at a very good price so I am considering very hard getting a new turbo

Will post up what I end up doing anyway.