Just a little more . . . . .

[BC847]

Call me lazy, but I made a stand so as to allow easier mock-up.

[dazedandconfused]

Looking good

[fatty]

Are you running an external gate on the secondary? Or what is that spacer for?

[DMan1198]

If you don't run a spacer with the manifold flipped up the compressor housing hits the manifold, and can't be clocked far enough to run the intercooler pipe practically.

[BC847]

Are you running an external gate on the secondary? Or what is that spacer for?

If you don't run a spacer with the manifold flipped up the compressor housing hits the manifold, and can't be clocked far enough to run the intercooler pipe practically.

I need the additional space for compressor house clocking as mentioned but, . . . .. if the internal gate turns out to not be enough, I can replace the 1" spacer, with one that has provisions for an external gate, without having a lot of reconfiguration.

Got the final mess/consumables/Argon for the TIG.

[DMan1198]

If you open up the gate ports I don't think you'll have an issue with it not flowing enough for the ve's fuelling, but that's a nice way to plan ahead.

[BC847]

If you open up the gate ports I don't think you'll have an issue with it not flowing enough for the ve's fueling, . . . . .

As assembled, the valve-plates (flappers) won't swing up, and back out of the way for accessing the ports. The WG shaft lever has a stop milled into an adjacent bolt-boss that limits rotation. The only means of taking things apart appears to be drilling out the spot-weld at the end of the WG shaft, inside the WG shaft lever. SEE IMAGE BELOW.

Kinda skert to mess with it.

It looks like I can trim said boss a little to allow the gate to open a bit more.






While the end result seems small, I got a lot of chit done today.
1 - Voted.
2 - Mated the Milwaukee PortaBand-Saw to the Band-Saw table thingy. It took a few minutes to make the blade 90* to the table, . . . . and stay there.
3 - Quickly found the top-cut, goes a different direction, from the bottom-cut, of the donut . . . . .cutting straight across using the table to hold the work. Shit!
Found it best to rotate the work against the blade thus scribing the work prior to going all the way through. These donuts are in fact 14 gauge 304SS.
4 - Used the 12" disc-sander to straighten the cut and true the end. Works NICE!
5 - So, now I've got a 3" OD / 105*ish bend. NOTE: As received, the donut's outer seam is welded. The inner seam, is not.
6 - Setup the TIG with a new 1/16" Thoriated Tungsten electrode, gas lens, no 6 cup, 15ish cfh pure Argon. 1/16" 309L filler (where needed).
7 - Mixed up some Solar Flux (allows welding SS without using a true gas purge of the backside of the weld). Much more cost effective for the scope of my needs.
8 - Ran a stringer-bead across the inner seam of the cut donut. Ehh. OK, I guess.
9 - Now, I need to swage one end of the 3" OD bend to fit the 3.5" ID of the turbine exhaust housing V-Band flange. So, I whoop-out the HD exhaust-pipe swaging kit.
10 - I promptly split the pipe at the factory weld of the outer seam. Shit!
11 - The 4' piece of 3", 14 gauge, 304SS pipe is the Mandrel-Formed variety (no welded seam), as such, it's easily swaged to 3.5" OD at one end. I cut that end off so that I've got a very short 3" OD x 3.5' OD adapter.
12 - Slid the turbo exhaust housing flange over the adapter and tack-welded it every inch around. Then completed the bead. That was a PITA as I had to keep the vast majority of the heat on the thick flange so as to make a fluidous puddle, without under-cutting the thin tubing. Suffice it to say I undercut the tubing, but it's a sound weld. UUUG-GLY! . . . but well attached.
13 - Cut out another 3" OD x 105*ish bend and welded its inner seam.
14 - Found that the exhaust-pipe swager works really well to spot-on align the butt-joint of the adapter and bend. Tack-welded said together.
15 - Completed the bead joining the 3.5" to 3" adapter to the bend. Looks like sthi. I'm over-thinking all this welding SS sthi! It appears to me that welding 14 gauge SS works best with simply running a sequential spot-weld stringer bead with no filler. I've got a Wah-Wah pedal for pulsing the TIG heat.

Tomorrow, I like to think I can fabricate the 3" OD x 2 T3 flange WYE pipe. It ought to be a hoot.

[BC847]

Well, I was successful in making the hot-pipe WYE. It's ugly as last nights Democratic party, but it ought to work.




Building something in your head, often doesn't look like the real thing . . . ..





Now, I gotta cypher exactly where the primaries are gonna sit, relative to the secondary, for the purpose of mocking up the balance of the hot-pipe (including the bellows), as well as the primaries supplemental support.

I guess I'm past the commit-line, huh?

[Remps]

I think it looks friggin sweet! I think your cummins is going to love that air. Whats the plan for the downpipe(s)? True dual exhaust? Well, as true as it gets for a single manifold that is..

[PToombs]

I think it looks good, I'd be overjoyed to have welds that good on my rig. My welds are ok, but not great.

[BC847]

Well, after spending the better part of the day going back and forth to the truck, tape measure in hand, I positioned the primaries pretty close to where they should be, relative to the secondary. This should have the lower primary's intake plumbing to clear the alternator, while staying off the truck's frame rail. The upper primary is a little lower than the secondary, so as to clear the hood (the secondary is gonna be kissing the hood's insulation (+/-).
The secondary's outlet will pass between the two primary compressor housings on its way to the IC.

. . . ... and then connected the hot-pipe ends.

NOTE: The V-Band clamps at the secondary's outlet, combined with the V-Band clamp at the hot-pipe WYE, will allow me a little rotational movement of the primaries should another round of measurements find things bumping .. . . . . . .





Once I commit to the location of the primaries, I can get on with making the secondary/primary cold-pipe stuff as well as fabricating a mount for the primaries. Easy-peasy.

[Farmboy]

Looking really good. I'll be excited to see how it all turns out for you.

[BC847]

First rough assembly. In hindsight, that WYE could have had another angle to bring the top primary a little closer to the secondary, but then I was shooting for equal splitting of the gases coming from the secondary.

Looks weird. It just seems to be a little too spread out. Maybe I'm just being too critical.

I am my worst critic.

[matthewh]

Spacing could be an issue, especially with the inner fender being close down by turbo 1 and turbo 2, but I think it's a visual thing. Once you plumb in an intercooler tube, exhaust downpipes and an intake setup it'll look right.
Honestly it does look really nice and well thought out.

[BC847]

The way I've got the primaries splayed, I believe I can use the existing CA pipe from the twins secondary to the IC.





For the turbocharger's oil supply, I'm running a 8AN stainless braided line from the engine oil cooler/regulator assembly to an aluminum manifold I've mounted under the top primary's cold-pipe. From there, three 4AN stainless braided lines run to each of the three turbos.





- The turbo oil return fittings ought to be here by Monday. They're regular T3 flange / 5/8" ID hose barbs. I'll most likely have the secondary play into the original stock/OEM turbo oil return port on the block. The primaries will play into the oil pan's return fitting.
- Waiting on the primary exhaust housing outlet flanges. Got to finish ciphering the down-pipe assembly.
- Gotta finish ciphering the primary intake ducting.
- Gotta finish ciphering/fabricating the primaries supplemental support bracket.

Won't be as long as it has been.