QD32 Turbo Progress

[Peacheyqd32]

Hello all,

Thought id make up a thread with my progress and some info I have found along the way.
So far I have bought 90% of the parts I need, waiting for most to arrive.

have gone with:
GBC22-350 turbo
Aeroflow 280x300x76mm intercooler to topmount
SAAS SG81803 turbo timer
Redarc G52-BET EGT, Boost and air temp gauge
Redarc G52-PWT Oil pressure, water temp, oil temp gauge
2x GS-OWT1-8 sensors
Provent copy catch can

I have made my own 2.5" 409 stainless
I have made my own exhaust manifold
I will also be making my own dump pipe with a 3" stainless bend and using a v-band to connect to the setup I started from the existing dump pipe.
Also planning on cutting the existing intake manifold and welding a 100x50x3 box section on with a 3" pipe for a silicone hose to attach to from the intercooler. I have tried to source a stock td27 intake but none of the wreckers want to sell the intake manifold separate I think this may be a good thing tho as the position of the factory turbo intake might not be in the right spot for my setup.
Ill also be buying a bonnet scoop once everything turns up and I begin to fit all the bits.
Ill just be relocating my factory air box, connecting straight to the snorkel at the guard and using a flexible hose and 67 degree 2.5" silicone bend.
Once the setup is all working and there are no issues on the hot side ill be getting the exhaust manifold, dump pipe and maybe the turbo hot side ceramic coated.

Here are a couple of photos of the progress so far. I have been test fitting some things with a TD04 turbo I have lying around.

 

[Peacheyqd32]

Couple more pics

 

[eli martin]

nice keep us updated i will be doing them same soon

 

[Peacheyqd32]

Couple update photos.

Managed to get the intercooler in the front. 2" pipe just fits between the frame and radiator.
Had to relocate the radiator overflow.
Made up a plate under the intercooler to hopefully force some air through instead of pushing out the bottom.

 

[Peacheyqd32]

Have the car running now.

Seeing 12psi at the manifold
About half a turn on the pump and everything looks happy.
Oil temp sitting under 80degrees
Water temp doesn't go over 88 degrees
Egt iv had up to 650 from 0-110kph
Egt at 100kph is about 400-450
Intake air temp last night was 35 and went up to 50 after the 110 pull.
Going to tweek my plate under the intercooler to hopefully catch some more air.

Clutch started slipping as soon as it comes on boost anything past half a turn.
Getting npc to machine my flywheel and put a 10" td42 clutch on it.
Ill then turn up the boost to 20-25 and turn the fuel up some more.

 

[Vidusha]

Nice work!

Are you running the stock injector pump and airbox?

Getting an intercooler on mine soon to up the boost but wondering if getting a boost compensator on my stock pump and a bigger airbox would be worthwhile upgrades.

 

[Peacheyqd32]

Nice work!

Are you running the stock injector pump and airbox?

Getting an intercooler on mine soon to up the boost but wondering if getting a boost compensator on my stock pump and a bigger airbox would be worthwhile upgrades.

Yeh still the stock pump and air box.
Was going to remove the air filter for a quick run to see if there was any noticeable difference.
Also going drop off a muffler or both to see how that goes with noise. Its so quiet atm. They are all on vbands so its a 2min job.

Plan is to get the clutch replaced in 2 weeks.
Mount my adjustable waste gate.
Boost up to 20psi.
Pump up to a full turn.
See how that goes.

If im confident with the tune ill leave it. I may get a diesel specialist to tune it with proper afr equipment. Will eventually get the pump rebuilt with a compensator put on. Thats going to cost about $2300 so im holding off on that. Also contemplating replacing the injectors as i can get them for under $600. They are usually being replaced at 200k with the pump as well. Mines at 205k now.

 

[Vidusha]

Sounds like a good plan - I reckon i'll have to stick to around 10psi and see if i'm happy with that power level before looking at dumping money into upgraded clutches.

Were the exedy hd clutches not enough for the 20psi mark or are you planning to push for more in the future?

Two mufflers would make the ute really quiet, I had just one 10 or 12" offset/centre muffler put on mine and it sounds great, not obnoxiously loud or droning but still a decent note coming out of it.

 

[Peacheyqd32]

Going to the beach this weekend on current setup. See how the clutch holds up there.

Planning on going more than 20psi. Just going to see how the pump goes. Probably need the boost compensated pump past that. May go to 25. May go to 30. The turbo is rated for 300hp which ill never get to but it will take more than the motor can handle

I like doing the job once properly. Not keen on spending $500 on a clutch to then have to spend $1000 later anyway. Im not planning on getting rid of this car for a long time.

Just test drove without the air filter, sounds good. Tested with dump pipe only and sounds obnoxious.

Going to remove the 1st 10" highflow muffler and leave the one on the rear i think.

 

[Peacheyqd32]

Slowely working through all the small bits.
Tidying up the wiring.

 

[Peacheyqd32]

beach drive went great.

couldnt get EGT over 650 on the beach so I can lean on the fuel a little more.
Fuel economy went from about 14L/100 to 12.5L/100 on a 60K drive.
will test fuel economy a bit more this weekend.

Oil temp on the beach got about to a bit over 90 degrees, oil pressure on the turbo line went down from 21 to 18psi at idle with the higher temps (was getting min 21psi on the oil feed port before turbo was fitted). min oil pressure on the qd32 manual is 11psi so well within safe temps but looking into running a aeroflow oil cooler, just not sure where I can mount the thing yet. not sure if running fully synthetic will help with oil pressure at higher temps but will do a little more research into that soon.

boost on the highway at 100kph was a touch under 10psi, air intake temp was sitting at 50degrees. havent really got intake temps much higher than that.

the extra power is definantly noticeable and highway driving is sooo much better now. cant wait to turn it up some more.

 

[eli martin]

beach drive went great.

couldnt get EGT over 650 on the beach so I can lean on the fuel a little more.
Fuel economy went from about 14L/100 to 12.5L/100 on a 60K drive.
will test fuel economy a bit more this weekend.

Oil temp on the beach got about to a bit over 90 degrees, oil pressure on the turbo line went down from 21 to 18psi at idle with the higher temps (was getting min 21psi on the oil feed port before turbo was fitted). min oil pressure on the qd32 manual is 11psi so well within safe temps but looking into running a aeroflow oil cooler, just not sure where I can mount the thing yet. not sure if running fully synthetic will help with oil pressure at higher temps but will do a little more research into that soon.

boost on the highway at 100kph was a touch under 10psi, air intake temp was sitting at 50degrees. havent really got intake temps much higher than that.

the extra power is definantly noticeable and highway driving is sooo much better now. cant wait to turn it up some more.

so what egt do u think is safe because i have been told 600 for long periods will melt it

 

[Peacheyqd32]

so what egt do u think is safe because i have been told 600 for long periods will melt it

600 with a sensor post turbo would be right. Mines pre turbo so there is about 200degree difference. Mine will read higher, but more accurately and faster. Post sensor will be slightly delayed and drops in temp by time it reaches sensor.

Mine in factory form (no turbo) with egt sensor on the manifold was getting up to 750. Which is about right for consistent max temp from what iv read.

 

[tweak'e]

the problem with post turbo sensor is its a guess what the temp drop is, especially with custom or variable turbo setups.

 

[Peacheyqd32]

Went camping the weekend before last.
100km drive out towards Aratula, filled up in Brisbane to the filler and then filled up at Aratula and averaged 10.3L/100km which was awesome.
4wdriving was great. the extra power was handy in low range as well!
clutch still hasn't slipped again since I turned up the fuel that one time.
I have removed the clutch and taken to NPC to get the work done on the flywheel. the new clutch is an organic 10" replacement (stock is 10" but very weak spring design)
new clutch will be able to handle 600nm
I still had a factory Nissan clutch in mine at 200,000km

 

[Vidusha]

How are you finding the turbo and how's the boost early on?

I've got the Schwitzer S1BG that came as part of the denco turbo kit but it struggles to get to even 10psi. It's alright on the highway but not much power overall.

 

[Peacheyqd32]

Im back to 14psi till i sort my fuel pump out. Seeing 14 at 2000ish rpm.
When it was on 18psi i was seeing 12psi at 1500rpm. Maybe had a little extra fuel down low which helped.
Im now pulling a 2t trailer up a hill faster than i could before the turbo without the trailer.
So yeh heaps more power.

 

[Vidusha]

Sounds like the turbo is a great fit, it's not too expensive either which is a plus. Will have to put one on order soon.

I've tried finding why my turbo isn't working properly and have ruled everything out except for a crack in the turbine housing - so I guess we can call this a forced upgrade.

How's the clutch going by the way? I've found an extreme outback one that's rated to 560nm so thinking that may be the one to go with if getting the flywheel machined is more costly.

 

[Peacheyqd32]

Clutch is going great. No slipping at all.

This is the clutch i got, its an exedy. They machined new alignment holes for the new pins and new holes for the bolts.

Not sure if npc modified the clutch plate at all, forgot to ask

 

[QD32Pig]

How are you finding the turbo and how's the boost early on?

I've got the Schwitzer S1BG that came as part of the denco turbo kit but it struggles to get to even 10psi. It's alright on the highway but not much power overall.

ive got the Schwitzer on my qd32 aswell and its a slug, has a 7.5psi spring in it and it tops out at 9psi at 3 grand, makes 1-3psi at 1-1500rpm which is ok, 2000 its making around 5-7, and by 3000 its overboosting but its only an extra 1.5psi so no biggy, not winning any races thats for sure, i think its probably making less than 120hp. im thinking about putting a boost tee on it and seeing what the schwitzer will make but i think shes pretty much out of huff and puff at 10psi might squeeze 12-14psi at 3 grand but i doubt the low rpm boost is going to change, might need to dump a bit more fuel in aswell