I wouldn't try building one without a lathe, there's are too many spacers and other parts that are needed.

 

I lathe is a must. It requires a lot of good machine work or else a lot of crazy riggin!

 

I have not really started on mine as of yet. But I will say that pretty much with anything you build a Lathe and a Mill is always nice to have but it is not a must. Things just take allot longer to do. A person can make many things with a good drill Press and a good Hack Saw along with assorted files. And of course some decent measuring tools. And of course a Welder.

As for Welders I have found you do not have to go Nuts. But welding is something one has to learn to do well. For most things a small ARC Welder will do fine. Or even an Oxy/Acetylene welding kit. As with the Oxy/Acetylene you can not only weld things but also Cut and heat and bend steel if need be. But everything is dependent on what you wish to learn or find acceptable to spend funds on.

Heck for myself If I could afford it I would get a Foot Operated,water cooled,slow start TIG welder but now I am dreaming.
Dang I almost jumped up on a Soap Box. I will stop.

 

After resealing the exhaust manifold and flanges up to the turbo, I am getting no less than 37 mpg on my Ranger with 2203DI engine. I have gotten up to 41 mpg.

 

That is about what we figured usedkubotaman's S-10 should get in the 40-45 MPG range with the Kubota V2203 DI. As an S-10 Single cab might be about 800 LBS lighter than a Ford Ranger plus his S-10 is 2 Wheel Drive.

This is also why I included the information in this thread and a New one of the IDI VS DI.

But I will add that while I was looking into this information I noticed that the IDI Design of combustion would be a better way to go if one chooses to run straight Vegetable Oil due to the mixing in the pre chamber.

 

What truck are you running? Is it an extra cab, 4x4, what rear gear? Maybe throw a pic of it up on your thread. My little truck is about as light as you can get, 96 S-10 regular cab with a 3.08 rear end. You're getting great mileage!

 

Got a question.... Did some test driving with the new trubo today the k03-005 runs great! I can boost 20lbs in1st 2nd 3rd anf 4th but in 5th I can only get to about 15lbs with around 1250 egt.... Any sugestions? Also, I melted another PVC intercooler pipe today. My ends keep shrinking when I tighten the clamps on..... Not sure what to think about either problem. Got 2 weeks till the truck has to make the trip to Oklahoma about 6 hours straight through.... Little worried!

 

I'm running the K03-029 which I believe is the same as your 005. I build about 16psi tops but it's lower because I'm running a IDI engine. My EGT's are way low, I can run the longest, steepest hill, at full throttle and only get just over 1000. What kind of intercooler are you running? Is it big enough? I would think you need to move away from the plastic pipe over to metal, just not sure the PVC is going to tolerate the heat. You r boost is probably lower in 5th because you aren't turning as many RPM's.

 

Why wont it turn the same rpms though? even if you keep it floored it never gets up there

 

I think that your engine probably is incapable of producing enough torque in 5th to build enough RPM to boost all the way up. In essence, you may be lugging the engine. The turbo relies on two main things to build boost. It needs thermal energy from the exhaust, but it also needs volume. The faster the engine turns, the more exhaust volume is created. At 1250 RPM, you might not have enough exhaust flow to fully boost the Turbo. This is just a thought. I will admit that I have not read all 20 pages yet, and I may be repeating what someone else has said. I have followed this thread in the past but not for the past several months. I am going to get back up to speed soon. Good luck!