My turbo 5.3 and 4l80e wagon build

[79longroof]

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.

Yeah it just wasn't fitting without that fender in place lol. I should be able to cut a little out of it and put it back in though. They do take up a TON of space.

I'm definitely glad I installed the flex section. I can remove the whole hotside with the turbo connected (mind you it's cumbersome as hell) because of the flex joint. My buddy didn't think I would be able to lift it all past the manifold studs but with a little bend it comes off just fine!

 

[michmalibuman]

Good read, keep up the good work. 😎

 

[Turbolq4]

The intrepid fans work well. They came in several different cars and some have flat motor designs instead of the one that sticks out. I have a 05 ish crown vic interceptor fan on a stock 3 core elcamino radiator. It's set to high when it comes on and hasn't had any issue with overheating. We get lots of 90+ degree days here too.

 

[64nailhead]

In the picture below I would add two of the clamps in the other picture I attached about 6-12" from the base of your turbo flange. That way you can pull off the pipes, the manifolds , and the turbo separately. It really makes thing easier. Like working on front of engine components. If you can pull the one large pipe with the flex, then that all becomes extremely accessible.

My two cents - good luck - Jim

 

[64nailhead]

The intrepid fans work well. They came in several different cars and some have flat motor designs instead of the one that sticks out.

The Intrepid fans are quite popular, but I believe they are the same fans as the 4th gen cam fans, just installed in a different mount. The 4th gen fans and shroud conveniently are a direct fit in the core support and can be mounted directly in front of the radiator which is out of site. They have worked for us for more than 2 years. Unfortunately, the stock rad wouldn't get it done for us, but an All Star perf triple pass does. On the dyno with repeated runs I can get it to 215-220, but sub 210 on the street or strip.

 

[nawlins-tim]

I used the astro sender on my LS swap( not finished yet). The difference is that I sprung for a strip of that Holley Hydramat. Kinda pricey but I really does suk some fuel. If you are not sumping your tank maybe it is something you can look into. They make one that attaches directly to that Walbro pump like a factory screen filter.

 

[Turbolq4]

The Intrepid fans are quite popular, but I believe they are the same fans as the 4th gen cam fans, just installed in a different mount. The 4th gen fans and shroud conveniently are a direct fit in the core support and can be mounted directly in front of the radiator which is out of site. They have worked for us for more than 2 years. Unfortunately, the stock rad wouldn't get it done for us, but an All Star perf triple pass does. On the dyno with repeated runs I can get it to 215-220, but sub 210 on the street or strip.

The stock rad from my Camino is a three core brass setup. The stocker from my Malibu is a tiny thing by comparison. Same outside dimentions, just a single core. The fan comes on at 215. Only been to 220 once even after beating it. Typically 195-205. I didn't even clean it out, just stuffed it in there. It's pretty dirty inside now. I've noticed that these ls engines foul up coolant. Could be that I'm lifting the heads and contaminating it too. It doesn't leak and the level stays the same (ls9 head gaskets!!) So as long as it can maintain the temp im going to stick with it.

 

[79longroof]

The Intrepid fans are quite popular, but I believe they are the same fans as the 4th gen cam fans, just installed in a different mount. The 4th gen fans and shroud conveniently are a direct fit in the core support and can be mounted directly in front of the radiator which is out of site. They have worked for us for more than 2 years. Unfortunately, the stock rad wouldn't get it done for us, but an All Star perf triple pass does. On the dyno with repeated runs I can get it to 215-220, but sub 210 on the street or strip.

I had the 4th gen fans and they were simply too big depth wise. Everything I've seen on the Intrepid fans showed they were only like 3 inches or so deep with the thinner motors.

 

[79longroof]

In the picture below I would add two of the clamps in the other picture I attached about 6-12" from the base of your turbo flange. That way you can pull off the pipes, the manifolds , and the turbo separately. It really makes thing easier. Like working on front of engine components. If you can pull the one large pipe with the flex, then that all becomes extremely accessible.

My two cents - good luck - Jim

I considered putting v-bands on the manifolds but don't have a tig and can't tig weld and just wanted to get it together. I'll probably get tired of it eventually and have them added but for now they'll do. I appreciate the advice though!

 

[64nailhead]

I considered putting v-bands on the manifolds but don't have a tig and can't tig weld and just wanted to get it together. I'll probably get tired of it eventually and have them added but for now they'll do. I appreciate the advice though!

I mig all of my own pipes. Everything pre-turbo is 16 gauge mild steel usually from Jegs (cheapest) and the stainless clamps are from Summit., Yes I mig stainless clamps onto steel pipe with copper wire lol (I have some sloppy in me as well - lol.) The local slops tell me to post my stuff on their FB page, but I never do. I will say that I tried aluminized pipe ALOT (too much) before I gave up on it pre-turbo. Using aluminized forced me to keep up on my welding skills.

My basis for the 'accessibility' ideas is that if the motor has to come out for whatever reason, then I want it on the stand in well under 3hrs without instituting an act of Congress. Hopefully our current motor doesn't have to come out for blowing up regularly, but previously I've had motors that needed regular removal. And fighting with anything to remove them generally pissed me off enough to engineer something so as to eliminate the aggravation.

Aside from that regarding the fans/cooling system, I'm a true proponent of using whatever works on the cheap. Our fans are directly out of the boneyard, the radiator isn't but it's a sub $200 unit. Some will cringe at a $200 rad, but many will tell you that without $400+ Griffin you're cooling system is no good. It makes me chuckle. Basically, if the Intrepid fans work, then use them. They are cheap to buy, maintain, etc.

Aside from that - I do not want to muddy up your build thread. I like it and FWIW I've been looking for a wagon for about 6 months to build as a sleeper much like yours. Where are you located?