Seeing all these turbo projects lately has motivated me to finally get started on my own. I've had a turbo for months but just picked up a Navi motor this week.

Turbo is a 78mm with .96 A/R and a 4" v-band exhaust.
Engine... Going to build a forged bottom end. Haven't decided if I'm going to rob my current engine of it's rods or buy new ones. Going to get new pistons but haven't found a good source yet, want pistons that give a good quench and compression ratio. Going to port the heads but not sure if I'll use the stock cams or put in turbo grinds. Sullivan intake on top. Not sure if I'm going to go air-air or water-air intercooled yet.

Plan on doing all the work myself so it may take a while... but I think it's going to be fun . Selling my Kenne Bell and spare PI torque converter on eBay to give me some funds to get the project off the ground. Plus it's motivation to work faster as the truck isn't quite as fun to drive with Eaton .

Anyway here's a pic of the progress so far...

(don't let the Cobra valve covers fool ya, it's still a 5.4)

 

I just got a rude awakening on pistons.
I had to custom order some for my 4V because there were some things I wanted different namely the 3.700 bore. I wanted a different compression height (brought the piston to TDC were it belongs) lets see....small block chevy wrist pins, lateral gas ports, skirt coating etc etc.

The piston, pins and rings were somewhere around 1250.00 for the set
I'm not really smiling, still in shock but damn are they nice pieces. Oh and they were JE's.
Dale

 

Man-O-Man this is getting good!

Blown aluminum 32v 5.4L
Turbo 32v 5.4L
Turbo 5.4 16v
whipples, KB, MP, ported Eatons, TUrbos.

Step back and think about it for a second.

The 5.4L s/c was only put in the lightning! A very limited production vehicle! There are SO many suppliers lining up to develope more and more parts for a truck that isn't made anymore!

This is good!

Please keep us updated.

 

Don't forget Eric (Doweelies) he is building an aluminum (GT block) cammer with single turbo.
Dale

 

I'm glad you are doing all this R&D Dale, and I want to be the first to thank you.

 

Sweet! Nice to see another one getting started. There are going to be some sic trucks prowling the streets and surprising more than a few people.

 

Hopefully you went wet sleeve on those cylinders, otherwise I would not go more than 20psi boost. Darton makes the best 3.700" sleeves.

 

Yep...its a Darton sleeve block now.

 

Also, did you get the combustion cylinder part of the heads ceramic coated, as well as the top of the pistons? This will help with the heat generated from high boost!

 

ceruker
I don't mess around with ceramics in a blown motor. The heat can get away from you too quickly. The 4V motor will be better than the 2V in that regard but I still don't feel like experimenting with it.
I use dry lube coatings on piston skirts and bearings and some valve train components and even then I'm picky. I have had good and bad results all caused by the company doing the coating....I only buy the best I can get ahold of or its not worth doing....matter of fact if the coating isn't done really well it can do more harm than good.
Dale

 

This is pretty close to what my engine builder was telling me. I was going to do the skirts as I've been pretty impressed seeing Mahle L pistons out of vented blocks. Most of the skirts I've seen appear near new even with the high sidewall loading due to the rod angle. Problem I'm told is finding someone to do the coating as well as the OE pistons.
Sounds like we went with pretty similar piston set-ups, design wise at least, mine are from CP though without the coatings. Rings are very different than the standard 1.5 & 3 MM moly also.

Eric

 

Sweet, I knew you were leaning that way. 32 unshrouded valves will be awesome!! Still an iron block?

Eric

 

I think the rewards will be worth you efforts. Looks like you are heading in the right direction and looking at your car collection you got hodrodding in your blood. Good looking cars and girls........



Eric

I know 3 post in a row!!!

 

Thanks. I hope this project turns out okay. Feel foolish starting it as I haven't driven much with the current setup. Guess I'm just addicited to wrenching in the garage. Definitely have hotrodding in my blood .

 

The stock pistons aren't mahle, FYI. I spoke to one of the mahle OEM development engineers about that at length.