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Discussion Starter · #221 ·
4x Crossover doughnut gaskets from Rock Auto $44
2x stainless 4" couplers and 2x 4" Silicone elbows from Silicone intakes $80

All the parts are here except the following hardware store type misfits:

Bolts from the manifold to the turbo. Hose from the manifold to the wastegate, a hose barb into the intake manifold.

Also need 1.5" stainless tubing to make the transition from the crossover to the wastegate and the screamer pipe. THINKING about getting a stainless one now to avoid metallurgic issues trying to weld stainless to mild alumized exhaust pipe, but haven't decided.
 

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Discussion Starter · #222 ·
The machine lives with a new turbo, and it sounds very aggressive and insane with the screamer pipe. Several issues that need to be addressed yet. I can't say that it woke it up besides with noise.

The wastegate and screamer ended up hanging extremely low and is sticking way below the frame. Glad I got a second set of doughnuts, it will need to be reworked a bit.

The K47 box wouldn't fit with my current battery terminal setup pushing on the 4" silicone tubes. Need to shop terminals to get a setup that allows more clearance for the intake pipe. So I just have a bare filter gulping IAT's. Takes much longer to cool down EGT's, if at all below 300 degrees, took like 10 min of idling instead of 2 minutes. I like to turn it off at 200-250.

The wastegate had two ports on the boost side, and one needed to be plugged and the instructions had to be read line for line to find it. I found it trying to open the gate with a compressor. Previous to solving it, I ran it a bit with the wastegate not hooked up right and it would easily boost 25 plus (experimentally poking it, of course) then the PCM would do an aggressive fuel cut and made it slow as paste unless you were using half throttle.

When standing on it and the screamer pipe opened up at 10 psi it almost elicits a woo-hoo. I'd like to run about 18psi without a cut hopefully. Lots of haze at full boost that I'd like to clean up and power on the table. I might have smiled once or twice when I got the wastegate working.

I'm assuming with some dialing in it will sound significantly better and with more boost on the turbo to help make some noise during wastegate open it will sound less like a hillbilly cutout and more nasty.
 

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Discussion Starter · #223 · (Edited)
Battery terminal issue can be seen below. With that out of the way there should be clearance for the K47 airbox.

Quadstar S60 and upper intake. Had to cut the tab off the CDR tube and punched hole in the silicone with a Forstner bit and pushed the stock plastic piece into it. The intake all and all seals better than stock on all fronts. Really happy with it.

The turbo is much easier to service than the stock one. Gobs of access to get to bolts, and the adapter makes it somehow easier to bolt up the downpipe. I was just floored how easily it bolted in. No wastegate has unseen advantages. Worth the upgrade.

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Hangs really low. But, it isn't bad to service there till we get it dialed in. I was able to get the 10psi spring back in pulling it down from 15 trying to figure out my boost problem but likely won't be able to get more springs in under the truck. Will have to use clamps. Quadstar said stock pcms only allow 14.7 psi so if I go to my targeted 18 I may need a tune that ignore the MAP sensor, which is only capable of reading that high. Possible it will still sketch out even with a boost fooler as the sensor will be out of range.
644000
 

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Discussion Starter · #224 ·
The hustle is paying off. Truck has got more $ thrown at it than it has over the last 3 or 4 years. Making big strides in performance and maintenance.

Changed the oil finally since winter time. The leaking is way, way down after replacing the turbo drain. Valve covers are leaking a bit and something near the front of the engine may be leaking, but I'm not needing to lay down cardboard anymore, I don't think when I park on s clients asphalt drive.

New shoes Friday. Went with 265/75/16 Duratracs. Huge difference in the ride. I think over 50% of my ongoing ride issue could be attributed to those Cooper AT3s. I think the older set might have had as much as 60-80K miles on them. Will end up moving to 35's sooner or later, but these look great and I'm pretty happy with the performance.

Tire shop said the right upper ball joint, pitman arm, and idler arm are loose. Will replace those and hit it with an alignment soon..
 

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Discussion Starter · #225 ·
Last month was tires, this month front end....

The front end has not been touched on my truck possibly for 150k besides what I did to it. If it had been touched, most of what was there except 4 of the tie rod ends was bad, thanks to a trip to a hoist at my little brother's job and doing some jiggling. NEARLY 1K in parts on the way. Koni Heavy Track shocks, Mevotech premium steering parts, all except ball joints on the drivers side and a-arm bushings. new rear drums because the rear is warped and the rear bounces really bad when they get hot. Turning them last year didn't seem to help.

Truck makes a ton of noise going over bumps, so after making a parts list we investigated that further.

Found a trans mount bolt into the transfer case was gone. Replaced it.

Found a loose bolt or two in the front bumper. Tightened it

Ran out of time to fix anything... Found a loose bed bolt.

Found the exhaust touching the frame and the rear leaf

The grille has no bottom screws, every one of the clips that holds it to the bottom track is broken on the grille or the bottom track.

Its possible that the front shock mount has a standard bolt in the drivers side, remember breaking one and its banged/carried on ever since.

My little brother and I are hoping to knock it out fixing the front end in one night on the hoist with two people, wish us luck.
 

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Photos!!! If you can I mean...

Sent from my Pixel 2 XL using Tapatalk
 

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Discussion Starter · #227 ·
Front end update, if I get a chance a couple photos.

The front end took two people 10 hours.

Day 1

We had the following issues: the pitman arm nut was extremely tight. had an enormous wrench and another one as a "helper" and swinging with all might to remove it. Came off hard all the way with liberal application of juice etc. Could have gotten it with an impact if the stabilizer bar was removed. I injured my elbow cranking on this. I would have had to replace all the stabilizer bar mounts as the bolts were siezed from when I replaced them in 2013.

Pickle fork had to work very hard to get pitman arm off. At least an hour and multiple attempts. To get pitman arm off of steering box, had to drop drivers side stabilizer bar mount and pry it out of the way. Luckily an enourmous Mac air hammer and 150 psi shop air at our disposal, but little brother hurt his shoulder trying to remove.

The Mevotech tie rod ends came with jam nuts for the adjusting collar. The nuts would not go on the reverse thread tie rods. They say the coating is too thick on them. Wasted lots of time trying to get them on. Have to use a die to remove the coating to use the nuts (per facebook group answer). The standard thread side went on fine. Left these jam nuts off the reverse thread side. Chinese trash, all of it. IMO I would not buy any Mevotech stuff again. More on that later.

We both went home mad tired, with hurted wings, having to beg forgiveness from shop owner.

Day 2

Took off early from work to finish up truck higher than **** on painkillers.

Bothered other mechanic relentlessly for him to eat the chocolate muffin on his toolbox till he went home.

Supposedly, because the truck sat on the hoist through a working day of an active shop (luckily not in the way), it got marvelled at by the Mac guy, the Snap On guy, and a couple other reps that stopped by. The hater pipe got chuckles as well as the headlights got interest. Most people do not believe 6.5TD came in a 1500.

Ball joints went fine, standard difficulty. Was able to use the air hammer to knock out the lower ball joint (the ball joint press kit they had wasn't set up to press to remove) and boy did that feel cool. Assembly went fine, but slow.

The truck drove crappy home without the alignment. Parked it.

Day 3
Took the truck in for an alignment. Handling borderline dangerous.

Day 4
Alignment shop couldn't finish the alignment due to frozen camber bolts. Its close enough where he said I "might not" have to worry about it unless it pulls to one side too much. The steering is extremely stiff and sticky and you have to manually center it. It might need further work if it pullls to one side (camber bolts) or says stiff (faulty front end parts).

The brakes are still funky even with new drums in the back.

No joy here, but the passenger wheel isn't going to fall off, I guess. We will see how it "breaks" in.
 

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Discussion Starter · #228 · (Edited)
~ 150 miles driven. Still not driving the best, really hard to keep it on the road. Almost broke my hand when a screw snapped I was leaning on... Makes it hard to drive with how I have to fight it

Vac pump pulley sheared off for no reason 30 mins from home last week. Was able to use the 95" belt and pull the pump to delete in a friend's driveway.

Had to top off the coolant for the first time since fixing the coolant blow up last year. Worried about head gasket now.

I'm getting worn down for sure.
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Discussion Starter · #229 ·
Successfully ran 7 hours straight on a magazine delivery route. Was getting molested by an early 2000's F150 in traffic, and I shut him down pretty badly. You could almost hear his manifolds ticking in the distance over my wastegate standing open. Still have it set to 10lbs only. Otherwise I was driving for economy. I probably didn't do much better than 15/16 mpg though.

Successfully hauled this year's grape harvest in with the biggest single load ever (2400 lbs). The bins were different from a different customer and they held more than the usual 900lbs each.

Been driving it everyday to do a massive painting/staining job after work.

The front end is loosening up but still no pleasure cruise to drive on these roads around here, for sure. On the straight and flat its fine. Have not decided if I want to address the frozen camber bolts yet. Still have a slight bounce when braking that feels like its coming from the passenger front tire now. Still no word on my Koni heavy track shocks from Summit. Probably wouldn't hurt to throw pads, rotors and calipers at it.

Trying to decide if I pick up another 6.5 project truck (97 K3500 CCLB with an aluminum flatbed with a blown engine)

Or pile more money into my 1996. I have a significant amount of cash saved up that "needs" to be used, hopefully something for my mental health. Weird problem, I know.

Any input?
Automotive parking light Car Wheel Land vehicle Tire
 

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Successfully ran 7 hours straight on a magazine delivery route. Was getting molested by an early 2000's F150 in traffic, and I shut him down pretty badly. You could almost hear his manifolds ticking in the distance over my wastegate standing open. Still have it set to 10lbs only. Otherwise I was driving for economy. I probably didn't do much better than 15/16 mpg though.

Successfully hauled this year's grape harvest in with the biggest single load ever (2400 lbs). The bins were different from a different customer and they held more than the usual 900lbs each.

Been driving it everyday to do a massive painting/staining job after work.

The front end is loosening up but still no pleasure cruise to drive on these roads around here, for sure. On the straight and flat its fine. Have not decided if I want to address the frozen camber bolts yet. Still have a slight bounce when braking that feels like its coming from the passenger front tire now. Still no word on my Koni heavy track shocks from Summit. Probably wouldn't hurt to throw pads, rotors and calipers at it.

Trying to decide if I pick up another 6.5 project truck (97 K3500 CCLB with an aluminum flatbed with a blown engine)

Or pile more money into my 1996. I have a significant amount of cash saved up that "needs" to be used, hopefully something for my mental health. Weird problem, I know.

Any input? View attachment 646130
I would concentrate on the 96' and get it completely done. ( Brakes, rotors, front end, etc )
(y)
 

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Discussion Starter · #231 ·
That's sound advice, OKdually. Lots of other small things to do for sure... I could use a bigger truck for my business. My thoughts on the K3500 anyways.

I did contact Quadstar to update my tune to get full boost without a derate and fix a shifting issue and a pile more fuel.

I hadn't cleaned the truck out for months and months and finally decided to try, took an hour just to get the tangled tool bags, load straps, and extension cords extracted from the backseat.... Still not done.

Grabbing my long overdue to be updated sig to toss in here because it has info I didn't document anywhere else.

1996 GMC K1500xcab 6.5 3.73 4L80E rear bags Bought at 99k 12/13 now 138k 9/17
Repairs:
BWD OPS 1/14 Heath PMD kit 3/14 Airtex boost solenoid 6/14 Lube Specialist cooler lines and cooler, rad support mounts, Pro Comp ES9000 Shocks, rear brakes 7/14 Interstate Batts, Cooper AT3 tires, Hummer H3 rims, stepper motor 4x4, coolant flush 11/14 Stabilizer bar links, soot trap gasket 9/15 Dorman tank, sending unit/sock delete, filler neck, filler neck, hose, Leroy's Tank Barbs, SAE30R9 lines, WIX filter head and prefilter with brackets by paleyjim, intake manifold gaskets 3/16 Used transmission, dipstick tube, fluid flush, drain plug pan by paleyjim, power steering fluid flush, transfer case seals and fluid 9/16 Duraterms 11/16 Ball Joints and wheel bearing drivers side. Powerstop pads, lubed sliders 4/17 AD244, Leroy's Flight Systems PMD 9/17
Performance:
Ashland Muffler 2.5 X-over 12/13 FTB FFM by paleyjim, ported upper egr delete S-code, lower F-code, ported IP fitting, FASS DRP-02 lift pump 3/16 Transgo Shift Kit by paleyjim, Energy Susp. engine+trans mounts 9/16 Ported GM8, Diamond Eye, Quadstar tune 11/16 K47 Box, Glowshift 3-1 1/17 Leroy's Billet Crank pulley, Fluidampr. 9/17
 

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I need to get working on a high output injection pump for you. Now that you have a bigger turbo on there, we need to blow that thing up.
Or maybe I should build myself a bigger pump and give you my current one.
 
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