G'day all, I thought I would share my turbo v6 hilux build as I have used this forum a fair bit without ever contributing. I will try step out the build so it can help others build there own. I am going to post the build in sections over time otherwise it will take too long to type/post, so bare with me.
This first post is Fabrication.
It all started with a high km (220,000km) 2006 4x4 dual cab petrol v6 hilux which I brought specifically for the purpose.
First step was to remove all the factory intake and exhaust manifolds and start to fabricate the turbo manifolds. I decided to use normal black pipe butt weld fittings to make the manifolds from. I cut the flanges off the standard exhaust. The turbo is mounted on the drivers side so I also needed a crossover pipe from the passenger side exhaust manifold to the drivers side manifold. This was made from 2” stainless tube. Here are some shots of the passenger side manifold. In hindsight I should have just brought an off the shelf passenger side set of extractors.
Off the ute and painted in exhaust paint.
On the ute trial before paint.
Here are a few pics of the drivers side exhaust manifold/turbo collector. Note where the passenger side exhaust enters the collector from beneath. Also note the external waste gate take off and turbo flange. As with most of my build its not pretty though it does the job.
Off the engine.
On the engine.
Next step was to dummy mount the turbo (Garrett gt35/40) and fabricate the dump pipe and external waste gate entry into exhaust. Care was taken to still be able to remove spark plugs with turbo, waste gate and dump pipe still in place. Care was also taken to ensure gearbox could be removed with crossover pipe and dump pipe still in place. If starting this build from scratch I would use an internal gated turbo depending on power goals, it would have made the build much easier. I think an XR6 internal gate turbo would be ideal for someone chasing modest power. I only used the gt35/40 as I had one lying around.
All Tacked up.
Fully Welded
(don’t laugh at my welds, nothing a bit of heat wrap won’t hide)
I continued the 3” dump pipe down the same place the standard drivers side exhaust goes and put a 3” cat in for legal reasons. I then just brought a 3” diesel cat back exhaust off the shelf to save myself some time. I couldn’t find a 3” petrol one. It lined up with all the standard exhaust hangers.
Next step was to build and mount the intercooler and hook up plumbing. The intercooler was a garrett core which I made end tanks for. All plumbing was 3” tig welded stainless tube. I mounted the intercooler where the winch goes on a standard Toyota bull bar.
Here is the finish product as it stands now with all plumbing and exhaust hooked up and engine cowl on.
Next post will be engine management.