Since the exhaust was now good to go, I needed some intake plumbing. I was leery of all the Chinese silicone couplers out there, so I opted for Gates couplers used for MD/HD trucks and equipment. I got simple straight couplers that I could cut to length for areas where little flex was needed:
I also needed one flexible coupling on each side, so I got a pair of ring-retained hump hoses:
Note the "Made In USA" on the hoses
I also got some constant-tension t-bolt clamps to retain the hoses.
I also needed tubing. Some of the stuff I found was ridiculously expensive. I ended up using Chinese aluminum u-bends because I could actually afford them. I made a simple bead tool to put a bead on the ends, and after some
,
,
, and
I ended up with these:
Starting at the turbo:
Through the core support:
Into and out of the intercooler:
Back through the core support:
Around the extra-wide diesel radiator, which other swappers assured me COULD NOT be done:
A hump hose mid-pipe:
And finally into the intake elbow:
I had to use regular hose clamps here because the constant tension clamps were too wide. In case your wondering, yes, it does clear the master cylinder. Barely:
There was one other minor thing I wanted before I threw the batteries in and took it for a spin. I wanted a place to tee both positive battery cables off to the starter. A piece of Delrin, a 3/8" Allen bolt, and an hour of lathe time later yielded this:
It's mounted to the front of the drivers side battery tray stand. Following that was some uninteresting and still unfinished wiring and installation of the air cleaner (which I lost the pics to somewhere
), and it was ready to drive! Yay! So, how did that go? Stay tuned to find out...