My turbo 5.3 and 4l80e wagon build

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View attachment 81841 that one worked. This is the passenger side with the wastegate and dump pipe attached.
So you welded that stainless with a flux core? I know it can be done but just wasn't sure with a budget flux core welder. I'm using a cheaper Lincoln mig that works great, just wasnt sure how it would work with stainless
 
So you welded that stainless with a flux core? I know it can be done but just wasn't sure with a budget flux core welder. I'm using a cheaper Lincoln mig that works great, just wasnt sure how it would work with stainless

I've done lots of flux core welding on stainless exhaust systems. The whole TIG and back-purge sh*t is just to sell you expensive things you don't need. Do you think the OEMs are doing anything other than basic robot MIG welding the exhaust on your car? Nope. Slap it together and send it.
 
Alright folks. Hotside is pretty much done. Still need to drill my hole for the wastegate and build the down pipe but the most difficult part is out of the way.

Also got my Wideband in, so decided to build a panel out of ABS and mount the gauge. I left space on the other side for a boost gauge.
 

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Update:
Completed quite a bit over the last few weeks. Got the Walbro 400 lph with the 94 Astro sending unit dropped in the tank and the lines run. Running 6 AN feed and using the stock feed as the return. Managed to get it started to test everything but can't get it to idle. Still have some things to sort in the tune.

Sent my injectors off to Eric Derr of Derr Injector service to get them flow tested. I sent him 16 decapped Truck Delphi injectors. He will clean them and flow them and make a set of 8 that flow the closest to each other.

Also got my new Circle D 3200 converter in for the 4L80 and got my front clip set back on to check everything clearance wise. Kind of wish I would have waited to finish the hotside until the front was back on. Ran into some clearance issues. But I'm going to make it work. Moved the radiator foward while still retaining the hood latch. Going to have to get some slimmer fans. Was originally going to use f body fans but they are just too big. So I sold those and am on the search for some thinner ones. Thinking of going with some late 90s Intrepid fans.

Anyway, sorry for the ramble. But here are some pics of some of that progress. Hope some of you are still sticking around!
 

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Just seeing this. Man is there alot of room when the inner fenders are out. I left a both of them in and it definitely made for more of a packaging challenge. But I'm glad I did though FWIW.

I read back a couple of pages and seen the flex section discussion. I've had good luck with the Summit brand pieces and I've also used the Vibrant flex's and they work great as well. I've had them installed for a couple of years with no issues. I'm a firm believer in using flex joints. Before I started using them I fixed cracked pipes and headers too often - it got old after the 4th or 5th time apart and together. I'm at the point now with these hot side designs that I can remove every piece individually without having to remove another piece. FWIW, I didn't do that on the 1st couple of builds. What a PITA to remove the turbo, downpipe, WG, etc to change plugs and wires on one bank.
 
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