77 c10 5.3ls turbo
 

Thought I'd post some pictures of my c10 turbo install on a 5.3ls, I'll update as I make progress. I finished up the 5.3ls conversion a couple months ago and decided I wanted to put a single turbo on it. Shooting for 500hp at under 10lb boost. Only mod to the engine will be the fuel injectors.

After doing so research I came up with a rough idea of how to do it. But mostly figuring this out as I go. Not in a hurry so I'm buying the parts as I go and using mostly Ebay parts. My overall objective is to keep the engine bay as clean and subtle as possible.

First purchase was the exhaust manifold, I used the Hooker single turbo exhaust manifold. It is a very tight fit but it clears. I like it because it is cast and has a factory look to it and is not terribly expensive ($300). I had interference with the original clam shell mount, but after some grinding it cleared. I suspect if I had used aftermarket motor mounts it would have cleared.

I Used 3" sch 40 fittings and a turbo T4 flange to finish the hot side pipe. ($75). The location of the turbo ends up being a compromise. I had the radiator hose, radiator, fender liner, battery, intercooler pipe routing, etc.. to deal with. At this point I just have the hot pipe tacked together, will have to pull out for final welding.

Turbo is an Ebay GT45 turbo, ($177). Drove myself nuts trying to figure out what turbo size to get. I finally hit the point where I just picked one so I could keep moving forward. I ended up with.


Compressor Trim Inducer Diamter Exducer Diamter A/R
50 69 mm 98 mm 0.66
Turbine Trim Inducer Diamter Exducer Diamter A/R
77 88 mm 77.5 mm 1.05

I did know I wanted a t4 size so if this turns out to be the wrong turbo I'll buy different one.

1st intercooler I ordered ($85) is to small, larger unit ($80) is on the way. I'm not sure from a performance standpoint if it is to small. From a looks standpoint it is. Pic is of smaller intercooler.

Re: 77 c10 5.3ls turbo
 

sub'd

Re: 77 c10 5.3ls turbo
 

Nice truck. This will be an interesting build!

Re: 77 c10 5.3ls turbo
 

Got the larger intercooler in the mail today. Fabbed up the top mount and mocked up the intercooler. It is a tight fit but a nice fit. Ran out of mig gas so had to tack the mounts with crappy welds. Will clean them up when i get a refill. Will work on bottom mount this weekend.

Re: 77 c10 5.3ls turbo
 

I like the bigger intercooler for sure. sweet build. My long term goal is an LS with a single.

Re: 77 c10 5.3ls turbo
 

I will follow along too as I am looking at doing the same at some point.

Re: 77 c10 5.3ls turbo
 

Definitely following this build

Re: 77 c10 5.3ls turbo
 

Following, looking to do my swap this winter but with ac. Good looking truck btw.

Re: 77 c10 5.3ls turbo
 

Im in

Re: 77 c10 5.3ls turbo
 

I havent made much progress because I've been in China on vacation with the family. Didn't see one square body (no surprise) i was surprised that I didnt see one light truck or any Chevys. A lot of Buick minivans, quite a few Fords and one Dodge.

Got back at it tonight. Got most of my turbo to intercooler piping routed. Went together pretty well. Need one reducer elbow to connect the intercooler piping to the MAF. MAF is 4", intercooler piping is 3". I'm thinking about having the alum pipe section the goes from intercooler to MAF tigged and powdercoated flat black. Had to notch a radiator core support bracket on the drivers side a little bit. But going into this I thought I was going to have to cut into the core support more than i've had to. Used a 4" hole saw to cut the intercooler piping holes in the support.

Determined that I will most likely have to relocate the battery because of the aircleaner location. I will be installing a bigger aircleaner down the road.

Ordered the reducer and a blow off valve.

Re: 77 c10 5.3ls turbo
 

I had not anticipated changing out the cam but after much debate I decided to. Ordered a trickflow cam tps30602001. .560 lift/216/220 duration with 114lsa with matching valve springs. The guy that will be tuning the car indicated that 80lbs injectors might be a bit big for the stock cam. Since i have a feeling this boost deal is going to be addictive i figure i might as well start off with a cam that can support 80lbs injectors. Dont want to have to do 60lbs now and then 80lbs in 12 months.

I have the wastegate, blow off valve, oil lines and a few other thing ready to go after I get the cam and springs installed. Also need to drop off hot side manifold and intercooler pupe to get some welding done.

Re: 77 c10 5.3ls turbo
 

I welded the hotside pipe myself. Hotside pipe dia. Is 3", which is too big but it looks nice. Would use 2" or 2.5" if i did it again. Apparently the smaller the pipe the quicker the turbo spools up. The exhaust manifold had a 3" exit so I continued on with 3". Will be wrapping the pipe in heat tape. The top one pipe is for the wastegate.

Re: 77 c10 5.3ls turbo
 

yep smaller the pipe = faster the gas has to move . bigger = longer fill time and then move time .

anyway you look at it tho its a ls with turbo on the budget . and most guys i have read on this tend to do 550-600hp with out trying to hard at all .

Re: 77 c10 5.3ls turbo
 

I am liking everything I’m seeing so far...!

Re: 77 c10 5.3ls turbo
 

Ill post up a couple more pics of progress and then will be quiet for a week or so. Need to get the cam swap done and have some aluminum welding done. Bung welded to timing chain cover and blow off flange welded to intercooler piping.

Ran the oil pressure line from the oil filter boss deal to the high side pressure port on the turbo. The boss deal already have a zurk fitting deal the I pulled and Used #4 AN fittings and black braided hose. The turbo oil drain line will tap into the timing chain cover. Im having a #10 bung welded on and will run #10 from turbo to bung.

Wrapped the manifold, and mounted the wastegate.

Got front off engine pulled and ready to pyll harmonic balancer.

Re: 77 c10 5.3ls turbo
 

Like it so far looking good.

Re: 77 c10 5.3ls turbo
 

Following along - doing a 5.3 swap in my 80 C10 in the spring, probably nitrous initially but maybe a turbo eventually. Looking really clean!

Re: 77 c10 5.3ls turbo
 

OK... since I do not know a whole lot about this boosted stuff, maybe you can shed some light. You are only getting exhaust to the turbo from one side of the engine and tinydb84 has a similar set up, but is getting exhaust from both sides. Obviously it is simpler to just keep everything on one side, but are you sacrificing anything in doing so?

Re: 77 c10 5.3ls turbo
 

There will be a crossover pipe coming over from the drivers side. In one of the first pictures you can see a V band flange on the rear of the turbo manifold.

Re: 77 c10 5.3ls turbo
 

Looking good. How did you decide on that cam? I am running a stock one for now but plan on upgrading after I get some miles on it.

Re: 77 c10 5.3ls turbo
 

Google was my friend. But I will say it was really confusing because there is no correct answer. But I did determined a couple things many people agreed on. I determined the LSA for a turbo should be in the 112-114 range. As much as I wanted a 108lsa for a nasty idle apparently that is not what turbos like. The lift I picked .560 appeared to be about as high as I could go using stock pushrods and valve spring retainers, I am changing springs. I'm sure someone has a different opinion on that.

Re: 77 c10 5.3ls turbo
 

Got the cam swap done, fairly easy process.

Had the #10 AN fittimg welded to the timing chain cover for the oil return line. And had the blow off valve flange welded on. Really happy with how it turned out. Hope to get the valve springs changed out this weekend and start reassembling.

Re: 77 c10 5.3ls turbo
 

Got the valve springs changed out this weekend. Still need to torque the rockers arms down but I wanted to get moving on some fun stuff today. Did the following.

Mounted up hot pipe/turbo again (hopefully the last time but i doubt it). Final install intercooler hoses, and fabbed up the start of the downpipe. Downpipe is 4" and i am going to run it on the outside of the passenger side frame rail, kinda like a fender well header. I think it should work really well. I couldnt see how a 4" pipe was going to fit inside the frame rail. Downpipe also has the wastegate exhaust tapped into it. Downpipe is stainless, but will be heat wrapped. Not proud of my welding but will take it to my buddy and have him clean it up. Will install a 4" v band at the far end of what you see here and go with 4" mild steel the rest of the exhaust.

Update - after looking at the downpipe this morning I determined I wasn't going to be happy with it. Ordered some prebent 4" elbows and will try it again.

Re: 77 c10 5.3ls turbo
 

Redid my downpipe. Much happier with it.

Re: 77 c10 5.3ls turbo
 

I like it

Re: 77 c10 5.3ls turbo
 

Sub’d. Badass upgrade to the LS!

Re: 77 c10 5.3ls turbo
 

Looks good.

Re: 77 c10 5.3ls turbo
 

Got the exhaust from the downpipe down to where the muffler will be. From here on it is just a couple pieces of straight pipe and a tip. I am going to put a y pipe before the muffler for a future cutout. Tricky route having to dodge various things. Had to notch a cab support. 4" pipe is really big and makes routing a challenge but really happy with how it turned out.

Re: 77 c10 5.3ls turbo
 

In parts gathering mode. Waiting for some exhaust pieces. Deatschwerks 78lbs injectors ($470) came in today along with the Innovate Wideband/boost gauge ($254). The Innovate gauge displays the AFR and boost on a signal gauge, which helps keep things clean.

https://innovatemotorsports.com/products/psb1.php

Walbro 450 ($98)arrived yesterday. Still need to figure out the fittings, will run 8an lines.

On the transmission front I'm having a local guy build a th400 for it, he will also be the guy that is tuning it. Going with a 2700-3000 stall converter. He has been very helpful. A link to an old article, but he continues to turns out some crazy rides.

https://www.hotrod.com/articles/ccrp...reet-machines/

I really wanted to keep the a833 tranny in it but there was nothing I could do to it that would keep it in one piece. Really nice tranny, new clutch/flywheel, complete with shifter so it has some value so I decided to pull it out before I blow it up. Priced out a 4l80e and couldn't justify the price, not planning a it being a highway cruiser. I also have 3.08 gears so it will be fine down the highway with 1:1 3rd gear. Apparently 3.08 are perfect gears for a turbo car.

I'm over my target budget of $2k, guessing I'll end at $3k not counting anything transmission related. The wideband and cam are items I didn't budget for. I also have about $200 into things I've ordered and didn't need, or messed up.

Re: 77 c10 5.3ls turbo
 

DOPE AF!:metal:

Re: 77 c10 5.3ls turbo
 

Absolutely...my thoughts exactly.

Bubba

Re: 77 c10 5.3ls turbo
 

Got the injectors installed. Finished welding up most of the exhaust. Still need to figure out the last 2 feet. Exhaust hangs down maybe an inch below the frame rail. Since im dealing with 4inch pipe im very happy with that. Exhaust consists of 3 pieces that are connected with v bands.

Waiting for the fuel line so I can get the pump and lines installed. Still need to figure out the crossover pipe (will wait untill th400 is installed) and install the wideband.

Converter came in along with the flexplate for LS to th400. Waiting for tranny guy to finish up transmission.

Re: 77 c10 5.3ls turbo
 

Got the fuel pump (Walbro 450) installed and the fuel lines. The Walbro mounted up in place of the AC delco pump I previously had, real easy install. Used 8an for the primary line and 6an for the return. Primary has an inline fuel filter I got on Amazon. Used these Russell fittings on the pickup and at the fuel rails. Real slick. I didn't use them when I first put the LS in, highly recommend them.

Hope to have the th400 back this Friday, if so I will install over the weekend.

Re: 77 c10 5.3ls turbo
 

Isnt the sending unit on these -6? I was thinking of running -8 but didn't want to try to modify the unit so I ended up going -6.

Re: 77 c10 5.3ls turbo
 

If I remember correctly the sending unit is off an 87, which has 3/8 primary and 5/16 return.

The fittings I got were for 8an and 6an lines. I was looking for an 8an fitting for the 3/8th line. I'm not sure if a 6an is an option on the 3/8 line.

Russell part# 644130 3/8th line & 644110 5/16th line.

4 Russell fittings cost $60. Have $245 into pump/filter/fittings/hoses.

Re: 77 c10 5.3ls turbo
 

did you re-flare the sending unit hard lines to work with the push connect ?

i didnt think there was the correct length left after you cut off the bulb flare for the older rubber hose .

Re: 77 c10 5.3ls turbo
 

Did no cutting on either the sending or rail lines. The fitting uses the original flares. It is not a push connect, it is a compression type fitting but unlike most compression fittings I have used in the past. Doesn't have a copper ring like other compression fittings.

Re: 77 c10 5.3ls turbo
 

I wish I knew about those fittings. I cut the tubes and brazed fittings on.

Re: 77 c10 5.3ls turbo
 

i used these with the nylon fuel line builder kit i just did . brass comp fitting to barb specific to nylon hose . cut the flare end off and works great .

reason i had asked the orignal question is those adapters looked a lot like the ones for oem style quick connect and i didnt want to see you have a fuel leak .

pics of my adapter for fuel pressure gauge sender port on an to quick connect line adapters from red horse racing products .

Re: 77 c10 5.3ls turbo
 

Also got battery mounted in truck box. Because of the turbo placement i had to move the battery. I had orginally planed on mounting in under the bed. After thinking about it i mounted it in the truck box. When i bought the truck I had planned on pulling the box. It has grown on me and now I'm keeping it. It was a truck box/slip tank combo probably original to the truck. I cut the top of the slip tank out and now I have a nice box where my battery is installed, along with future nitrous bottle and tools/small cooler, etc...

Also ordered some 15x8 steel rims with Nitto nt555 275/60/15 drag radials.

Gennie shifter for th400 came in. Really nice quality.

Did I mention Im over budget. Oh well. My wife always say whatever your budget is Im going to times that by 2. She is usally right.