thought id share a 24v compound turbo build with yall. any and all questions/ comments/opinions are welcomed. please understand the guys budget was $800 including the turbo. parts totals including sanding discs and plasma parts but not including welding consumable. was $450.00-he bought a unknown turbo off of craigslist for 250.00

heres where the fun begins, he brought me the turbo and told me its off some old semi truck. joy haha. after a couple hours of research i figured out what it was. its a tv6141 made by detroit diesel. and that this was the biggest version of this charger. dial calipered out its 64/94/84 with a 29cm exhaust housing. .75a.r. on the intake ans 1.39 ar on the exhaust. non divided inlet.
http://s573.photobucket.com/user/frosty4227/media/IMG_20130707_164025_zpsf2bfd051.jpg.htmlhere it is next to the hx35.
http://s573.photobucket.com/user/frosty4227/media/IMG_20130611_151204_zpsc025dd54.jpg.htmlcomp wheel
btw everyone here is the truck
http://s573.photobucket.com/user/frosty4227/media/Second%20gen%20truck/ResizedImage_1353598623893_zps555f3123.jpg.html
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so after identifying the charger and finding that no flanges fit it i decide ill hand make everything. so on to the fun stuff of making room haha.
took everything out.
http://s573.photobucket.com/user/frosty4227/media/IMG_20130611_202406_zpsec4606f8.jpg.htmland started fitting up all my plumbing and seeing what i needed to do do make this weird turbo fit. had to re locate the heater hose that bolts to the manifold and also had to re locate the oil returns.
http://s573.photobucket.com/user/frosty4227/media/2013-06-15_15-05-59_883_zps423c8bf0.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/2013-06-15_15-05-38_972_zps54cee0e6.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/2013-06-15_16-43-43_667_zpscafce8a9.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/2013-06-15_16-43-50_155_zps174c9224.jpg.htmleverything was fitting up nicely. the piping was cut down in the end i just have everything as long as possible because its easier/ cheaper to cut a little more off then to add.

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so from here i started work on the custom flanges for the hot pipe. everything is cut from a larger piece to help keep the flange from warping. its 1/2" mild steel.
http://s573.photobucket.com/user/frosty4227/media/IMG_20130615_131414_zps32ed3f92.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/IMG_20130622_104757_zps9a91ad66.jpg.htmlthe square flange is for the big charger the odd one for the hx. after cutting them out i ported and polished the flanges to match the housings for a smooth flow. i ordered a 3.5" exhaust elbow and they sent me a 5"!!! so i grabbed some 3" i had laying around and used it, remember budget build. i much much would of liked to use 3.5" but it all cleaned up nicely.
http://s573.photobucket.com/user/frosty4227/media/IMG_20130623_203830_zpsa63fac96.jpg.htmli did cut, port/polish out a area for the waste gate to travel into also so he can waste off as mush as the hx potentially can.
http://s573.photobucket.com/user/frosty4227/media/IMG_20130624_152520_zps1fb72a50.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/IMG_20130624_152520_zps1fb72a50.jpg.html[URL=http://s573.photobucket.com/user/frosty4227/media/IMG_20130628_165540_zpse1da7c40.jpg.html]
http://s573.photobucket.com/user/frosty4227/media/IMG_20130624_151259_zps85a2cf2a.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/IMG_20130628_165540_zpse1da7c40.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/IMG_20130628_171833_zpsd86cb77a.jpg.html
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so from here with everything bolted up tight i needed to get back on the cold side. i put the pipes back in place to see what wack angles i created when i re positioned the big turbo so i could make a down pipe eventually without having to do body work but also still allow plenty of clearance all the way around to avoid rubbing/ vibration. so i did the math for the angles to create a smooth flowing change in direction and after a few tweaks welded it up
it looks rough but its cause alll those pieces are just flaoting so i could take a pic as a general idea.
http://s573.photobucket.com/user/frosty4227/media/IMG_20130630_014833_zpsa3a894f8.jpg.htmltacked up
http://s573.photobucket.com/user/frosty4227/media/IMG_20130630_112021_zpsd4cb252f.jpg.htmlwelded up
http://s573.photobucket.com/user/frosty4227/media/IMG_20130630_114432_zps92339b6b.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/IMG_20130630_164244_zpsdbebf1a0.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/IMG_20130630_125938_zps1f4709e8.jpg.html
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so with the cold pipe done it was time for the i/c pipe. this one came out very interesting because i could only clock the hx housing so far unless i shaved off the waste gate mounts and the customer didnt want that. so here it is
it fits around hoses and lines cleanly
http://s573.photobucket.com/user/frosty4227/media/IMG_20130702_160034_zpsc6a5011d.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/IMG_20130703_113747_zpsfb0cb8cc.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/IMG_20130703_113815_zps229171d2.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/2013-07-02_16-41-30_935_zps6e3a1fdd.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/2013-07-02_16-41-22_184_zpsbc405407.jpg.htmlthe cold pipe
http://s573.photobucket.com/user/frosty4227/media/2013-06-30_12-31-45_257_zpsf13c563a.jpg.html

 

now for the budget downpipe. and this is a legit budget down pipe. the factor cast elbow for the big charger wouldnt fit/ work but it had a strange slip flange v band clamp joint. but a 5" v band clamp is to big for it. i actually had to cut out a section of a v band clamp and weld it back together to make the circumference tight enough to actually clamp down on the v-band portion.
i cut the cast elbow at its thickest point, to help minimize any warping and hard spots. the cast was 5" od with a 1/2" thick wall equating to a 4" i.d. so from here i tig'ed on a mild steel plate to give me some mild steel to mig the exhaust piping to. the exhaust piping was mitred to achieve the proper angle needed for clearence. if it was my truck i would of bought a 5" elbow and made nice smooth flowing bends but this is not my truck and this guy didnt want to spend any more on parts. so this here is what we ended up with. it is not pretty, but it fits and works perfectly(gets his exhausted gas to his stacks.) from the dp it goes right to 5" back to the stacks.
http://s573.photobucket.com/user/frosty4227/media/IMG_20130705_134040_zps9de434ed.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/IMG_20130705_133446_zpsc1d64f66.jpg.htmlbtw cast was welded with 308 filler rod.
http://s573.photobucket.com/user/frosty4227/media/IMG_20130707_210808_zpsaa2f92f2.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/IMG_20130709_231902_zps071df01d.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/IMG_20130709_231519_zps3ae50997.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/IMG_20130707_211007_zps431a2d44.jpg.html
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now how to feed and return oil to the turbos. what i decided to do was to use the test port on the oil filter housing separate from the factory oil feed to feed the big charger and just use the factory feed for the factory charger. just used high pressure fittings and hoses.
then on the return side on the big charger i used some 1/4" plate to make a flange(accidentally deleted those pics. ill take new ones when the truck comes back) and tig welded part of the factory steel return to it and bolted it up. then cut off the factory oil feed for the hx so it was just a strait nipple and tig welded a bead around its lip to help hold the hose on. then with what was left of the factory oil return line i cut/ welded up a y pipe. everything works perfectly. no leaks and everything is being oiled properly.
here is the little y return pipe.
http://s573.photobucket.com/user/frosty4227/media/IMG_20130709_152140_zps194a9414.jpg.html
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all the gaskets put in place and everything bolted up snug. took it out for a test drive. the truck almost sounds like a common rail with how quiet it is with the compounds. the truck pulls much harder than when it had a single charger he claims(i was not in it) that he see's 50 psi(claims its still climbing) and that egts wont go over 1000. the truck has a edge comp box with the hot level 5 and 150hp injectors. 4.10 gears, six speed manual. theres my write up on this. i thought it was a very interesting build. any questions comments suggestions please ask/state away.
oh the intake for the big turbo is 4" stainless with a custom made bend up 90*
http://s573.photobucket.com/user/frosty4227/media/IMG_20130710_142444_zps9ef435b8.jpg.htmlhttp://s573.photobucket.com/user/frosty4227/media/IMG_20130711_022947_zpsbd69f8f8.jpg.html