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Offline JohnW

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Turbo swap 1980 Runabout
« on: August 24, 2014, 08:52:48 AM »
I've been working on this since last November when my drivetrain pretty much wore out.













Freshly painted pan and block, new oil pump, new pickup, all new seals & gaskets, new Esslinger exhaust valves cause my old ones weren't looking good.





I'll post up some more of my progress later today when I get back.
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Offline JohnW

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Re: Turbo swap 1980 Runabout
« Reply #1 on: August 24, 2014, 04:56:09 PM »










The Explorer 8.8 (3.73 LS with 11" discs!) needed some cutting and hammering to fit. The pinion is offset just under 2" to the right. If you plugged the speed sensor hole and cut off the protecting tabs you could probably avoid modding the end of the transmission tunnel. I'm using the speed sensor with a Dakota Digital calibration box and a Nissan 240sx gauge cluster cut to fit. Landrum springs installed and it sits about 2" lower.

The Aerostar driveshaft is too long with the Explorer 8.8. With an 8" it would have been a perfect fit. I found a place that will shorten and balance aluminum driveshafts for only $97 though.

The first pair of springs I ordered actually weren't a pair. One must have been old stock or mispackaged because there was a 1" difference in length on the front half of the spring. And the color was a little off plus the bushings were made in Mexico vs USA. Pit Stop USA immediately sent out a new pair of springs after I showed them what was wrong and paid return shipping on the first 'pair.' Unfortunately I didn't figure this out until I installed the whole rear end and had to pry stuff in place - and one wheel sat too far forward. I thought I measured correctly for the leaf perches...

Thanks to Pit Stop USA for making it right ASAP. They couldn't understand how this error was possible at first but their customer service was great.









Turbo Coupe T5 with a Camaro tailhousing and shift fork assembly to fit the stock shifter hole. I made a tubular transmission crossmember to fit the angled mount. One of the tailhousing bolt holes stripped out so I hammered a Geo Metro 10mm wheel stud from the inside. Easy $2 fix.





Tubular radiator support that bolts in, welded in subframe connectors through the floor.





89 Turbo Caravan heater motor for downpipe clearance, bolt holes line up. I cut the shaft down and ground a new flat spot in it.





Got a bunch of goodies from a friend for a bit less than half of retail. Tial 38mm wastegate, Tial BOV, Integrated Engineering surge tank with Bosch 044 pump, Aeromotive FPR with a gauge, Turbo XS dual stage boost controller, plus an open dump tube for the wastegate I'm going to have to modify to fit. I have a Big R fuel rail coming in the mail.

Next step is ordering AN hose and fittings to plumb the surge tank and some Cunifer 3/8" line to run to the main tank and I'll need a rear mounted pump to feed the surge tank. Also working on finishing up the wiring and making the intake clear the hood.
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Offline russosborne

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Re: Turbo swap 1980 Runabout
« Reply #2 on: August 24, 2014, 05:23:39 PM »
Did you make that radiator support? Nice. You might want to consider making them for sale.
Everything you have done looks great!
Russ
In Glendale, Arizona

RIP Casey, Mallory, Abby, and Sadie. We miss you.

79 Pinto ESS fully caged fun car. In progress. 8inch 4.10 gears. 351C and a T5 waiting to go in.
74 Pinto Wagon.  To be or Not to be a Pinchero, that is the question.

Offline JohnW

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Re: Turbo swap 1980 Runabout
« Reply #3 on: August 24, 2014, 05:50:33 PM »
Making them for sale would involve having to take my front end apart, haha. I could make a jig though.  It'll only fit the 79-90 anyways. 1.25x1/8" box tubing. Bolts into the lower valance holes in the bottom and 2 I drilled up top. The stock one was bent and flimsy and I had a universal Jegs radiator and Greddy intercooler I needed to mount.

Thanks man. I'm really trying to do everything right, it's my daily driver that I plan to have for a long time. Most of this is stuff I've never done before so it's a constant learning experience.
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Offline 65ShelbyClone

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Re: Turbo swap 1980 Runabout
« Reply #4 on: September 06, 2014, 08:45:42 PM »
I'm curious about how the IHI turbo is going to behave on the top-mount header. They are known for spooling fast already.
'72 Runabout - 2.3T, T5, MegaSquirt-II, 8", 5-lugs, big brakes.
'68 Mustang - Built roller 302, Toploader, 9", etc.

Offline JohnW

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Re: Turbo swap 1980 Runabout
« Reply #5 on: September 06, 2014, 09:22:31 PM »
I am too. I'd rather have the .60/.63 T3 but the IHI was free and in good shape. I also have an aluminum flywheel, will have an aluminum driveshaft, and 3.73s with 24" tires. I feel like it might be a little too responsive.







Now I have the surge tank plumbed to the Big R fuel rail and Aeromotive FPR. Hoping to get it to fire soon. I'm going to install the wiring tomorrow and try to rig it up.
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Offline Srt

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Re: Turbo swap 1980 Runabout
« Reply #6 on: September 08, 2014, 03:02:22 AM »
too responsive is a gas for a while.  but you never know until you try it!


get it together, get it running and run it hard.
the only substitute for cubic inches is BOOST!!!

Offline JohnW

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Re: Turbo swap 1980 Runabout
« Reply #7 on: September 08, 2014, 07:50:46 AM »
I'm planning on beating on it hard. I found out the Bosch pump doesn't seem to be working and I'm missing part of the ignition wiring. Going to need to straighten those out then hopefully it fires.
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