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Got turbo issues

The project I was working on before my turbo fiasco.

What you do when you have all the equipment at work and a bit of fabrication experience. I repair and build anything on wheels for a major utility in Los Angeles.

I decided that I needed to add an ATA intercooler to the sub (before I new about and read all the posts on the A-team turbo) about a year ago, but lacked the funds( and found out there is a considerable wait anyways) to buy one.

I liked the way the speerco intercooler is tucked up a bit higher inside the frame rails and the air tubes are not in harms way from flying debris off the tires. But again, I'm a frugal (read as cheap bastard) to pay big bucks for the kit. So after reading up on Turbo Docs post with his install and all of the lovely pictures (thank you TD) I began my reverse engineering project. A supplier at work had the in for the cooler core and the rest is just aluminum sheat broke to proper dimensions.
I can see now why the kit is expensive. It is very labor intensive. As of right now I about 40 hours into the cooler alone. still got a bit to do to the core ( mounting tabs, oil drains) and that part is done. then will come the air ducting/tubing.
 

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Yup,But I like building stuff like this takes my mind off things for a while. Got my oil analysis kit today. will send it out on monday.
 
dhjunkie said:
What you do when you have all the equipment at work and a bit of fabrication experience. I repair and build anything on wheels for a major utility in Los Angeles.

I decided that I needed to add an ATA intercooler to the sub (before I new about and read all the posts on the A-team turbo) about a year ago, but lacked the funds( and found out there is a considerable wait anyways) to buy one.

I liked the way the speerco intercooler is tucked up a bit higher inside the frame rails and the air tubes are not in harms way from flying debris off the tires. But again, I'm a frugal (read as cheap bastard) to pay big bucks for the kit. So after reading up on Turbo Docs post with his install and all of the lovely pictures (thank you TD) I began my reverse engineering project. A supplier at work had the in for the cooler core and the rest is just aluminum sheat broke to proper dimensions.
I can see now why the kit is expensive. It is very labor intensive. As of right now I about 40 hours into the cooler alone. still got a bit to do to the core ( mounting tabs, oil drains) and that part is done. then will come the air ducting/tubing.
Click to expand...

Looks nice, I need to get a HF TIG so I can weld AL.
 
Best advice on tig units the higher the input voltage the better! 480v will weld lower amperage better than a 220v unit, But the new 220v units are great for home use.
 
Odlaw said:
Why mess with a hanging intercooler? WMI apparently is the way to go. IIRC, that's why TD's IC is sitting on the shelf.
Click to expand...

I must disagree... lots of guys have used the hanging ATA to good advantage... the good part about ATA is that it always works; WMI needs constant supervision - filling it up, making sure the nozzles/pump etc are clean and working, etc. Nothing insurmountable, but...

TD's custom Spearco intercooler is on the shelf because he has an ATT - and so far, hasn't needed an intercooler to keep his IATs down.
 
JiFaire said:
I must disagree... lots of guys have used the hanging ATA to good advantage... the good part about ATA is that it always works; WMI needs constant supervision - filling it up, making sure the nozzles/pump etc are clean and working, etc. Nothing insurmountable, but...

TD's custom Spearco intercooler is on the shelf because he has an ATT - and so far, hasn't needed an intercooler to keep his IATs down.
Click to expand...

X2 If I was still running GM-8 I'd still have ATA, Bill H likes WMI for everything, I didn't like having to stop and fill with water idea, Bill says plain tap is fine, so not a big issue for him, I never ran GM-8 with WMI so I have no basis to disagree with him with personal different experience either way.

but with a better turbo like ATT IMO WMI is better solution for me than ATA plus seat of pant improvement to me w/o IC on the ATT, which does pretty well without any post turbo cooling, my WMI is still yet to be installed.
 
Odlaw said:
Why mess with a hanging intercooler? WMI apparently is the way to go. IIRC, that's why TD's IC is sitting on the shelf.
Click to expand...

I considered all options even the absurd of forking out 50k on a new rig (not possible).

Why an ATA and all the complexities of fabrication and installation?
Like JiFaire said it always is working and is equiped onto every late model light truck diesel produced. Dont get me wrong about WMI set ups, they are great as a supplement. the draw back is that you do have to keep monitoring the crap out of them. Also I live in southern California (A DESERT) and anywhere I want to go, I have to climb a 5-6% grade for a minimum of 26 miles with almost a 10K toyhauler trailer. This is just to get out of the LA basin. I might as well be hooked up to Rhode Island. On these grades I see all my temps rise to un-nerving levels. To top it all off, our lovely global climate shift ( I do not believe in global warming) had been yeilding higher ambient temperatures in this desert which is just no fun at all. 1 1/2 years ago I was in the High Sierras going up the Lee Vigning Grade to Bridgeport, the air temp was 105* with a 15 mile 6% grade, it was brutal period.
Now for WMI set up I calculated that I would have to have a 20 Gallon tank just to make it up these grades, thats an extra 160lbs of water to lug for every climb. Granted it'll weigh just the weight of the system when I climb over the summit.
Do I see an ATT in the future- quite possibly, but for right now I have get a used unit to keep it a driver and finish my diagnosis of the engine before spending a goood money.
As for the ATA I am going to keep going forwad with this project. I got the hard part done, cant back out of it now.
 
Option priority change!

Well did my compression check today.......... engine IS toast! Following the GM engine books procedure of doing a compression check and all cylinders should be in the 380-400psi range.
Here are the numbers:
#1-350lb
#2-360lb
#3-380lb
#4-355lb
#5-340lb
#6- couldn’t get to, adapter too short
#7-350lb
#8-000lb it would go to about 150lb on cranking but not hold
:mad2:
Funny thing is that there is no miss at idle, no noise or funny stuff.
One thing is for sure, it's got to be replaced or rebuilt. Replacement costs are out of the question. So I'll be starting another thread soon on rebuilding hints and idiosyncrasies of this engine.
:sad:
 
My condolences about the bad news. I too am from SoCal and can totally relate to pulling major grades in the heat. Done just about all of them in Cali but not towing. I bought my truck to tow boats down Baja, but have never done it for fear of pulling some of those grades in 100 degree heat. Now we know what killed your engine.

I am on a quest to do whatever possilble, in incremental steps, to keep my enigne running within tolerable heat ranges while towing. I don't need to have the most horsepower or dream of beating a Dmax or Powerstroke off the line. I just want to safely tow without nerve wracking temps coming from my engine. That's all.
 
dhjunkie said:
I considered all options even the absurd of forking out 50k on a new rig (not possible).

Why an ATA and all the complexities of fabrication and installation?
Like JiFaire said it always is working and is equiped onto every late model light truck diesel produced. Dont get me wrong about WMI set ups, they are great as a supplement. the draw back is that you do have to keep monitoring the crap out of them. Also I live in southern California (A DESERT) and anywhere I want to go, I have to climb a 5-6% grade for a minimum of 26 miles with almost a 10K toyhauler trailer. This is just to get out of the LA basin. I might as well be hooked up to Rhode Island. On these grades I see all my temps rise to un-nerving levels. To top it all off, our lovely global climate shift ( I do not believe in global warming) had been yeilding higher ambient temperatures in this desert which is just no fun at all. 1 1/2 years ago I was in the High Sierras going up the Lee Vigning Grade to Bridgeport, the air temp was 105* with a 15 mile 6% grade, it was brutal period.
Now for WMI set up I calculated that I would have to have a 20 Gallon tank just to make it up these grades, thats an extra 160lbs of water to lug for every climb. Granted it'll weigh just the weight of the system when I climb over the summit.
Do I see an ATT in the future- quite possibly, but for right now I have get a used unit to keep it a driver and finish my diagnosis of the engine before spending a goood money.
As for the ATA I am going to keep going forwad with this project. I got the hard part done, cant back out of it now.
Click to expand...

I guess I assumed that everybody has a 4x4 farm truck... LOL my bad.
A hanging IC would last about a week on my truck.

As far as "complexities of fabrication and installation" - you must be referring to homemade - the kits I've checked out look easy to install....and even easier if you enjoy doing that sort of thing.

Jifaire/TD thanks for correcting me on TD's IC.
 
Something hard hit those turbine blades.

The turbo needs to be replaced and I would dump the sucky controls and install a turbo master along with a chip that will allow things to work in harmony.

Heath Turbo master and Heath Chip.

BUT I would yank the complete air system off and check things out to see if there are any pieces still floating around.


Missy
 
Well after a long hard look at the trucks woe's, the amount it would cost to repair/replace and the realistic logical thinking of what I put it through. I decide to have my co-worker take it to auction and sell her off. I took all of the good add-on stuff off (one of the auction houses stipulations was that vehicles had to have all the factory equipment) and will be posting it on the classified sections.
 
Not sure yet. I'm a die hard General Motors guy, so it's hard for me to look any other direction but into the D-max crowd, just not wild about the prices they want for them.
 
dhjunkie said:
Not sure yet. I'm a die hard General Motors guy, so it's hard for me to look any other direction but into the D-max crowd, just not wild about the prices they want for them.
Click to expand...
OK, here's my .02:

Consider replacing your suburban with another, later 6.5 version. Compared to the prices you're seeing on the DuraMax forums, there are some GREAT 6.5 deals out there. In addition ot more purchase bang-for-buck, the 6.5 is a very user-friendly motor to work on and parts are far cheaper than the later diesel motors. As you've seen from this list, there's a ton of info available on purchasing how-to's, cheap fixes and mileage- and engine life-enhancing mods. I bought my truck two-and-a-half years ago and I've never regretted the purchase. Between the guys on this list and the basic economy of the powertrain package, I've got a truck that I can keep for years. Plus it doesn't hurt that the 6.5 is an IDI motor and will easily burn my home made biodiesel. Dollar for dollar, you can't beat one of these vehicles.

Like I said, my .02.
 
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