The truck is an '89 with EFI and a M5OD.
Not wanting to learn to program the factory ECU, I opted for a Megasquirt piggyback setup. The plan was to simply plug the MS into the factory wiring harness and clip the factory SPOUT and injector wires, but let the ECU retain control of everything else. More on that later.
The turbo I am using is from a Cummins Diesel. Its a Holset HE300, which should be from a 5+ liter engine. I purchased it on ebay, it still had the Holset green grease and purple turbine markings on it- brand new turbo for $250!
Lets see some build pictures. Some of these are huge. Sorry for the URLs, I typed this whole thing up and then got errors from the BB about 450x600 pixel requirements, rather than change every picture on my web host I just made them URLs.
I started out assembling the Megasquirt. For those familiar with MS, this is processor 1 on board V3 running the extra code.
![Image](http://i702.photobucket.com/albums/ww21/Turbo_B/Turbo300/ford_ms_assy.jpg)
and the wiring harness - in the past I have purchased wiring harnesses from DIY Auto, but this time I opted to make my own...
![Image](http://i702.photobucket.com/albums/ww21/Turbo_B/Turbo300/ford_ms_harness.jpg)
Next step made the truck undrivable on stock engine management. This engine uses something like 13lb/hr injectors stock. These are barely enough for the 150hp the engine makes when stock. My upgrade is 30lb/hr injectors off of a 90+ turbo Volvo 4cyl. (The pre-90 injectors are 29lb/hr) The math indicates that these should support a bit over 350hp.
I have seen some people who managed to mount the turbo under the intake manifold, but this one didn't stand a chance of fitting there.
![Image](http://i702.photobucket.com/albums/ww21/Turbo_B/Turbo300/ford_turbo_test.jpg)
I initially planned to just hack up a stock set of ford manifold to catalytic converter pipes. These would allow me to route the exhaust gasses up to the turbo. After starting the mock-up a friend told me he knew of a guy with a CNC mandrel bender, so we took the mock-up pipes to him and had them bent. I then tacked on the ford flanges so that the J-pipe assembly could bolt to the stock exhaust manifolds.
![Image](http://i702.photobucket.com/albums/ww21/Turbo_B/Turbo300/cnc_bends.jpg)
![Image](http://i702.photobucket.com/albums/ww21/Turbo_B/Turbo300/J_pipe.jpg)
With the turbo location, fuel, and ECU squared away I went to plumbing the charge pipes. I picked up this intercooler on eBay for under $70 shipped. Its not as good as a name brand part, but it cost about 1/10 as much as a name brand. Its over-sized for the 7-10psi I plan to run on this truck. 18" wide core, 12" tall, 3" thick!
I almost wish I had gone a little wider, but at the time of ordering I was concerned about trimming sheetmetal to route charge pipes around the radiator. As it stands, I added a 3" extension onto the ends of the IC and still had to do some trimming of sheet metal to clear the ridiculous 3" IC outlets.
![Image](http://i702.photobucket.com/albums/ww21/Turbo_B/Turbo300/fmic.jpg)
With the intercooler mounted, I mocked up the charge pipes.
![Image](http://webpages.uncc.edu/~rlfairey/turbo300/ford_tb_adapt.jpg)
![Image](http://webpages.uncc.edu/~rlfairey/turbo300/charge_pipes.jpg)
Scream BLASPHEMY !!! But I needed a cheap exhaust system larger than the 2" thing from Ford. I went to the junkyard and for $25 I came home with a complete exhaust system minus cat from a 2000ish Chevy work van. 3" inlet to the muffler and 2.75 out of the muff. I chopped up the ford muffler hangers, welded them to the chevy exhaust system and hung it under the truck! Almost looks stock.
I did have to work the pipe which leads into the muffler. Seems the Chevy didn't' have a cross member in the same place as the ford. Here are a few pictures from the downpipe fabrication and the modified muffler inlet pipe. All 3" pipe.
![Image](http://webpages.uncc.edu/~rlfairey/turbo300/DP_vice.jpg)
There is an O2 bung welded into the 90* bend coming out of the turbo. This is for the Innovate WBO2.
![Image](http://webpages.uncc.edu/~rlfairey/turbo300/down_pipe.jpg)
![Image](http://webpages.uncc.edu/~rlfairey/turbo300/dp_assemb.jpg)
The flanges are from ebay- about $27 shipped. They are 1/2 inch thick, while the machining isn't great, they are flat, and only line up properly in 1 orientation. Somebody didn't' do a good job of fitting them to the jig when drilling the holes.
![Image](http://webpages.uncc.edu/~rlfairey/turbo300/3in_flange.jpg)
Thats all for now.
The truck has been driven on 4psi for baseline tuning and shakedown. I learned a few things on the first run. The turbo spools about where I wanted - 22-2500ish rpm. This will come down with a car trailer behind it. Also, Ford didn't include an exhaust gasket between the manifold and the head. Felpro makes one. Ball and socket exhaust flanges are difficult to line up and leak if they aren't lined up properly!
20+ year old headgaskets don't like boost. The compression numbers were a little funny when I started this, now they are real funny and I have water in the oil- It never knocked! Head gasket on order and ARP studs are on order.