2003 Toxic Tacoma

[ToxicGumbo]

You can do this Jeff!

Thanks! Your solution looks really elegant. I don't have a welder (or access to a proper electrical outlet even I rented one from a place down the street) and as you can tell from my hacky approach, just about everything has to be bolt-on. I'll likely work on cobbling together stainless steel brackets out of hardware store parts and possibly switch the fan for something slimmer.

IE, cutting it away to make room for plumbing if required. That was the only mod I had to do to the front panel in my truck to fit my GTR intercooler up.

Ah! Okay, fair enough. I'm completely game for cutting sheet metal. Any thoughts on intercooler piping? 2.5in for the main runs would be ideal for clearance, but it's hard to tell whether those "universal kits" are the way to go. There aren't any Tacoma-specific kits in production and no one in town carries performance parts. If I can find a business that sells aluminum piping of that size, I have a large cutoff bench saw and can flange the ends by hand.

Also, thanks to Fred for some suggestions regarding getting my dash tach to work and for properly setting up the wideband. I've made changes to my Jaguar for the wideband sensor and will scope both the tach and IGF lines tomorrow to look for a similar signal (the former likely being a tapped version of the latter so that the stock ECU can determine RPM). Here's a useful document on Toyota's ignition system which appears to compliment his statements.


-Jeff

[Fred]

I don't have a welder

You should fix this! Instead of an extension you could then buy a genset to run it :-D

I'll likely work on cobbling together stainless steel brackets out of hardware store parts and possibly switch the fan for something slimmer.

These things MUST be rubber mounted. Don't ever solid mount an IC or radiator. Why s/s? What about 1/4" alloy flat bar? Easy to work with, strong, light, etc.

Any thoughts on intercooler piping? 2.5in for the main runs would be ideal for clearance, but it's hard to tell whether those "universal kits" are the way to go. There aren't any Tacoma-specific kits in production and no one in town carries performance parts. If I can find a business that sells aluminum piping of that size, I have a large cutoff bench saw and can flange the ends by hand.

Thoughts:

1) Throttle entry vs Turbo exit vs Intercooler entry/exit = your correct sizing(s). Tapering up out of the turbo is OK. Otherwise it should stay pretty constant throughout. Measure OD and ID of all four and post up :-)
2) Universal kit = a possible OK supply of parts. Kits are not required.... no kit for my ute, nor my beetle, nor the hotel. Kit's are lame. Buy materials (even if in a kit) and make your plumbing work as it should.
3) Nice and short.
4) Power goal = IC pipe size. 2.5 is probably good for you.
5) Good on ya for suggesting cut/dice/flange
6) Mostly pipe, short pieces of silicone
7) Proper T-clamps, not cheap hose clamps. I use s/s bands, steel bolts. (5-10 bucks each, but worth it)

Also, thanks to Fred for some suggestions regarding getting my dash tach to work and for properly setting up the wideband.

You're most welcome :-)

Fred.

[masterkorp]

About the turbo, have you ever considered a Variable geometry turbo ?
They're great for truck aplications, you can start with a mechanical control system for simplicity of the setup.

[Matthijs]

I think turboing a non-turbo car is already a big enough challange. Let alone to manage the VGT part.

[masterkorp]

Not that much more, if you start with a simple mechanical controller, once you drive one of those its amazing.
I would only not consider one is in the plan to run high EGTs

[Hentai]

Not that much more, if you start with a simple mechanical controller, once you drive one of those its amazing.
I would only not consider one is in the plan to run high EGTs

gas motors have a lot higher opreatings egt's than diesels do. at cruise I am 700c, idle is 450c

[Hentai]

Nice, some progress on the Jeff mobile

Thanks!

What turbo you planing to use?

Picked up a used TD05HR 16G from an Evo off eBay. Looks to be in good shape.

Finding space for the intercooler is going to be a challenge. I think I can fit it vertically between the winch and hood level at the front, but it'll likely push out or eliminate the front grill. Part of me has been considering fabbing a long tube header and mounting the turbo and intercooler under the truck bed with a modest air chute and electric fans, but I'm more likely to go with the traditional front placement.

Losing the grill will look pretty awful. I don't want to lose the winch though as it was just replaced under warranty with a slightly improved model. And below the winch won't work since there's a small skid plate and support bar as part of the bumper design. Will figure something out.



-Jeff

so you are gonna custom make a exhaust manifold?

[ToxicGumbo]

so you are gonna custom make a exhaust manifold?

Yes. I don't see any other choice. Though Tacomas may be common in the US, they have very few options for forced induction (and what's on the fab market is pretty lame and outrageously priced). I bought pre-cut flanges for both the block and turbo sides and will determine the shape soon.

-Jeff

[masterkorp]

Well, get a TIG welder, probably the best decision ever

[Fred]

No way would I get a TIG before a MIG. MIG is very utilitarian, TIG is very specialist. MIG is fast to fab mild steel stuff. TIG is slow to fab anything. Getting a MIG for making his mild-steel manifold, though, fine idea! Just needs to find a 240V feed in his kitchen to power it :-D