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MY K3500 HX40, FTB & Other Performance Mods

DieselMike1

DieselMike1

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Messages
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Location
Missouri
This is a build thread I started on another site, thought I would share over here also. Finally starting work on my k3500, I am doing my cko hx40 install first. I got everything apart and the turbo arrived today. It is a JM turbo off of ebay, 16 cm^3 housing, that is 7 blade 86mm ex. and 10 blade 76mm in. 220201d1401745933t-my-k3500-hx40-ftb-other-performance-mods-hx40-009.jpg 220209d1401745933t-my-k3500-hx40-ftb-other-performance-mods-hx40-010.jpg
 
I got the vband cut off the turbo, and the intake cut behind the bolt. It looks like im going from 21/4" off the turbo too 21/2" on the intake, so gotta figure out how to go about that and get some silicone hoses ordred.
220241d1401746835t-my-k3500-hx40-ftb-other-performance-mods-hx40-008.jpg 220249d1401746835t-my-k3500-hx40-ftb-other-performance-mods-hx40-007.jpg
 
I temporarily bolted up the turbo to get it clocked, and get some measurements, and a general idea for how to route my intake to the k47 airbox, not gonna be much room here. I also got the oil return cut off, and need to find some oil rated hose to extend it, looks to be 3/4". For my down pipe I ordered a 3" steel, direct bolt on flange and plan to weld a 3" Pipe to it with a 3" v band to the other end to fit my D.E. down pipe. 220257d1401752248t-my-k3500-hx40-ftb-other-performance-mods-hx40-001.jpg 220265d1401752248t-my-k3500-hx40-ftb-other-performance-mods-hx40-005.jpg 220273d1401752248t-my-k3500-hx40-ftb-other-performance-mods-hx40-006.jpg
 
I sent my ECM off to Heath Diesel to get it custom programed with his Max e torque program a few days ago, called yesterday and they said they just shipped it back, so I should have it by the time I get the turbo swap completed. :hurray:
 
I had everything done except for my downpipe. I really could use some help finding someone to build me a down pipe as there's no way I can do it for 4 to 6 weeks until the hand heals, and the trucks already sitting there apart. My Brother in-law said he would put everything back together for me, if I found a D.P. I P.M. samonhed to see if his friend would build one, but he hasn't been active on here for a couple years. Any help would be appreciated.
 
I P.M. Samonhed, and he says his friend that made his and 94c1500's down pipe, will make one for me. Many thanks go out to samonhed for helping me on this.:thankyou2: Here's a photo of the down pipe he built for 94c1500. http://www.dieselplace.com/forum/members/94c1500-albums-hx40wii-picture4926-hx40-turbo-exhaust-v-band-elbow-side-side-shot-shows-off-three-sections-elbow-welded-together-more-winding-staircase-effect-made-specifically-match-outlet-gm-turbo-like-my-original-gm-turbo-used-create-base-jig-hx40-swapped-position-its-outlet-jig.jpg
 
JayTheCPA said:
Leroy can probably help with the silicon parts.

Toward the intake plumbing, while waiting for the hand to heal, here is a working example on what to put together: http://www.thetruckstop.us/forum/sh...rts-on-the-way&p=474608&viewfull=1#post474608 which is also what I did. Only thing I am still trying to figure is how to keep the battery post from rubbing the intake hose.
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That's the way I had planned on doing it, as far as the battery post goes ive got the battery mount out and am going to drill the spot welds out and cock the inside tray toward the front about an 11/2". Kind of like this: 2013-04-30_11-55-06_143_zps4b8dda87.jpg 2013-04-30_12-41-50_383_zps17a3c76e.jpg 2013-05-02_09-50-12_793_zpsfacf1531.jpg
 
It's alive! Just got everything finished up this evening, and took the truck for a test drive. The truck feels likes it just breathes a lot easier at low rpm, it pulls hard all the way to red line and runs about 20 lbs. of boost, cant comment on egt's as my pyrometer guage decided to quit working. It has a little bit of hazeing but clears up about 2100 rpm. The truck sounds awesome, and so far im satisfied with how it turned out. Ill post pictures tomorrow.:partay:
 
scottm said:
Nice work! Have you put on head studs for that much boost?
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No, with the hx40 with 16cm housing you have approximately 1 to 1 ratio or at most 1.3 on back pressure. With the stock gm turbo you have a 1 to 3 ratio on back pressure. So running 20 lbs of boost on the hx 40 is actually less pressure than the gm running 10 lbs.
 
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