turbo charging my x

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ok here is the question i have a 51t turbo off a 6.5 liter chevy diesel i rebuilt it for my xterra. i need to make a header and turbo collector for it. so what im thinking is to use 3/8 mild steel for the flanges and double aluminized exhaust pipe for the tubes. its going to be the prototype so it needs to be cheap for trial and error but i want it to last. so i can save to make them out of stainless later down the road. any suggestions?
Reply:Originally Posted by assassin_worksok here is the question i have a 51t turbo off a 6.5 liter chevy diesel i rebuilt it for my xterra. i need to make a header and turbo collector for it. so what im thinking is to use 3/8 mild steel for the flanges and double aluminized exhaust pipe for the tubes. its going to be the prototype so it needs to be cheap for trial and error but i want it to last. so i can save to make them out of stainless later down the road. any suggestions?
Reply:Its going to be a prototype but you want it to last?Just make it right the first time, you'll be glad you did.Have we all gone mad?
Reply:use mild steel pipe weld els. they are cheap and easy to source.
Reply:Personally i think you have way to much turbo for that application but what do i know.Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:yes i want it to last the design or the prototype the reason is i want to run it for a couple mo dyno it and run a cfm flow meter on it to get the most out of it. in order to reduce as much turbo lag as possible. the other thing is that its an xterra and there aint much room. too much well it is a hybrid in the turbo family it is a t3 compressor with a t2 turbine so it serves as a good candidate.
Reply:unless this is a full on turbo'd engine, you won't need a "header" per say.  All you need is a way to direct the exhaust into the turbo.  Headers can be fun to build, but using a regular flange & cast iron "el's" would work just as well & be easier to build.Less expensive way to do it, flip your exhaust manifold around, get the largest exhaust pipe bent to the turbo & have fun.  The turbo works best when there is a load on it, so the extra heat from a more restrictive manifold will get it up to speed faster.As someone above mentioned, that turbo is way too big for this engine.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:serious yall think its to much .its only a t3 and its  3.3 V6 lol iv seen nissan GT R  running twin t6 turbos and yes i would like it to look clean and make a  full blown turbo engine soon
Reply:The turbo map will be way off.  I.E. large exhaust turbine, small intake turbine, takes longer to spool up.  You need to measure the size of the exhaust impeller & intake impeller, then figure out the size of the castings.Go to www.turboforums.com, register (it's free) and do some research.  There are links posted there to turbo manufacturers that will explain the A/R, what a 57mm vs 63mm are, & flow maps for different turbos.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:ok correction its a t3 turbine with a t4 compressor This is an 6.5 Diesel turbocharger good for 350-400hp.Spec's on the Turbo are :Brand: Borgwarner / IHIModel: 51T-32Size: T3/T04ECompressor A/R: 0.7Compressor trim: 46Turbine A/R: 0.6Turbine trim: stage IIFlange type: standard T3
Reply:Originally Posted by MarkBall2The turbo map will be way off.  I.E. large exhaust turbine, small intake turbine, takes longer to spool up.  You need to measure the size of the exhaust impeller & intake impeller, then figure out the size of the castings.Go to www.turboforums.com, register (it's free) and do some research.  There are links posted there to turbo manufacturers that will explain the A/R, what a 57mm vs 63mm are, & flow maps for different turbos.
Reply:As far as turbo sizing goes, it is really hard to say without trial and error how that turbo will work.  I have a feeling that it may be close to what you are looking for.  Trucks want full boost as low as possible, you may not have the boost response at the low rpm that the original truck may have, but it should be entirely acceptable if not really good.  With a t3 .6 ar hot side, you are probably going to choke the engine on the top end, but should be able to break 400 hp.  I would guess that full boost may be available as low as 3200 rpm, but that is just a guess on my part.  I tried to look up the map for that turbo on squirrel performance and it wasn't there.  They have a neat turbo calculator that plots your boost map.  The only real potential problem that I see is that the compressor may wind up in surge on the bottom end.  It's really hard to say without seening a map.As a point of reference, on 3 liter supra engines, a gt-3582r, with a t3, .63 ar hotside, can produce near 500 hp and hit full boost around 3300.  That turbo is a pretty common upgrade for trucks.  Turbo application is all science with only a little bit of art. The xterra is a v-6 and I could see making the header/manifold as being a total pain and could hurt your performance because of the long runs involved combined with lower inlet velocities to the turbo.  I think that the best way to do this for you would be to fabricate the runs from the factory cast iron (i am assuming that's what's there) manifolds to the turbo.  Try to make the runs equal so that the cylinder banks are running at the same loads.  You don't want significant pressure differences between banks because one side may wind up lean with a good overall air fuel, resulting in poor performance and potential engine damage.Good luck.  This sounds like a cool project.Rene
Reply:I found the to4e map on sqirrel performance.  I think you can make 375 hp.  Surge is not going to be a problem.  The turbo is too small to make big hp numbers.  The max flow is around 42-44 lbs of air per minute.  It's acually a pretty small turbo.375 is my official prediction.  That's to the crank.  About 330 rwhp.Rene
Reply:thanks if i make +10hp over factory im happy i love big diesels and that large turbo sound i want more sound than anything. lol so yeah dont want lots of hp just a little extra the engine is bone stock so i probably wont ever go over 7psi boost.
Reply:I just ran the numbers through their calculator and it looks like you can make about 350 crank horsepower at about 7 psi.  I think that it's going to surprise you a bit.  if what you really want is sound, get a fake blow off valve .  You never mentioned if this is an internal wastegate turbo or external.  Remember to leave yourself some space for the gate if it is external.  Don't even think of running without one because you will definitely pop an engine.  Good luck again.Rene
Reply:Originally Posted by assassin_worksok correction its a t3 turbine with a t4 compressor This is an 6.5 Diesel turbocharger good for 350-400hp.Spec's on the Turbo are :Brand: Borgwarner / IHIModel: 51T-32Size: T3/T04ECompressor A/R: 0.7Compressor trim: 46Turbine A/R: 0.6Turbine trim: stage IIFlange type: standard T3
Reply:thanks yall it is an internal waist gate and i prefer the real thing over the fake **** i rather have it all power and sound or nothing at all lol,,,, a turbo engine at idle is a sweet sound but one spooling up is priceless