I'll start off by saying I'm not a photographer so the pictures will have to do haha. Figured I'd put up some pictures of how I did it because I haven't seen many write ups for non i/c trucks.

Parts list

-BD Super B turbo kit (second gen kit)
-Hx35 discharge elbow - Cummins 3918685
-Discharge elbow clamp - Cummins 3069053
-Discharge elbow o-ring - Cummins 3883284
-1/8th pipe plug for port in elbow
-Turbo oil feed adapter - Cummins 3919687
-Grid heater gaskets - Cummins 3969988
-x2 3 inch silicone couplers - Summit Racing VPE-2714
-x4 3 inch t-bolt clamps - Summit Racing TNT-30275-300
-Air intake hose from an i/c truck or fab your own
-4 inch exhaust if you don't already have one
-Some fab work, misc. tubing and materials
If I think of anything I missed I'll add it

Baby h1c and crossover taken off


Super B and baby h1c just for comparison


New turbo mounted, the washer fluid tank was in the way, I still haven't decided where to put it so I just unhooked it for now. The turbo oil drain barely rubbed on the waste gate arm, BD suggests bending the waste gate arm, but I just put a small dimple in the oil drain tube so it wouldn't touch.


Making the new flange for the grid heater side and the finished flange



Here are the finished crossover pipe peices I made, they were made from the original 3 inch exhaust off the truck, it has been sitting outside for a quite a while so I welded them up and ran a ball type cylinder hone through them then washed them out to clean them good.


The old 3 inch turbo outlet flange cut off, also had to cut off several inches so it wouldnt hit the heater box. Then I cut the 4 inch flange off the 2nd gen dp that came in the kit and welded it on my 1st gen dp.



I also had to trim on the throttle bracket where it bolts on the grid heater to get it to clear the 3 inch crossover tube. I plan on taking it off and cleaning it up a little better eventually.


All finished up, as you can see I had to dent the pipe to get the grid heater bolts down past it, was having a hell of a time getting it dented enough, not the prettiest job but it works haha. Crossover pipe has a good inch plus of clearance to the bottom of the hood, with the insulation still in place. Originally I wasn't going to make the crossover pipe two pieces but it ended up that way when I thought it may be a pain to put everything together as one piece. Really impressed with the turbo so far, spools quick, egts are lower and definitely more controllable, haven't got on it super hard yet but have seen somewhere shy of 40 pounds of boost so far, was seeing just over 30 with the baby h1c before. I plan on putting in head studs just for peace of mind sometime soon.

 

i like the lines of it all. looks good

 

Guess this probably should have went in the performance section, wasn't paying attention. Hope someone moves it.

 

Are you able to use the stock intake or did you have to go to a bigger one? Did BD offer any kind of intake for that set up? Looks good. Thats something I would do. I like fabricating my own stuff.

 

The air intake from the air filter to the turbo or you mean the crossover tube? If you mean the air intake from the filter to the turbo, the non i/c h1c is a 3.5 inlet on the turbo. The i/c h1c and hx35/s300 turbos are 4 inch inlets. I just robbed the one off my intercooled truck when I was test driving. Kind of a pain for now but I don't really drive the 89 in the winter anyway, way too nice a truck to let salt eat up. I ordered an intake off bcdd on the 21st, still waiting on it though.

 

NO the tube from the turbo to the intake. The one you made. I didnt know if you had to go bigger on that or if a stock one would still work.

 

Ah sorry about that, yeah kinda hit me that's what you meant after I read your post again. No had to make one, baby h1c has a small rubber hose connection off the compressor outlet, super b has a vband outlet like hx35 or the i/c h1c, and no BD doesn't offer anything for the crossover either. If you thought long enough you might be able to find a way to make the stock crossover work, not sure

 

Ok Got it.. For now mine is stock non I/C except for the performance parts I put in the injection pump. Im happy with it. But who knows,Down the line I might want to upgrade the turbo to something like this. Thanks again

 

No problem, it made a huge difference in driveability if you ask me, a good used hx35 is a good upgrade too though, and a little more on the budget side. I'll probably end up with one for the 91 eventually