Bradzuzu's 99 Trooper Build All the Goodies !!

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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby bradzuzu » Sat Apr 01, 2017 8:40 pm

I ran up in did a side by side comparison of a 2000 passport heater core

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I think it would fit just fine

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Here's the one in the amigo , it almost looks like the heater box is the same (both mechanical anyway) so you could either use the whole thing or the black half or just trim the trooper box to clear ... I'll probly make a separate post/thread on it if it works out ..
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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby bradzuzu » Sat Apr 01, 2017 9:00 pm

Now for some not so rotten nasty pictures ... I had a short day Friday so I turned my attention to the control arms , 6 hours later I was tired and ready to be done but the feeling of accomplishment was worth it !!

First was somewhat easy , I sliced and diced and popped in the bosses

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I did both sets of arms and then started in on the strapping part for mine since they are the full length..

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I was fighting trying to pull the long section in and finally realized my clamp at the eye was holding it :roll:

After I loosened it up things started to work a little better :)

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The second one went a little easier too !!
91 amigo sas toy front leaf- traded off :(
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custom built buggy ffor the dirty stuff

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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby bradzuzu » Sat Apr 01, 2017 9:20 pm

Although the top section was a flatter run the first transition was ramped pretty good

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I used the vise and Pre bent both pieces , I find it's easier to work in pairs on projects like these

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The rest was nice and easy compared to the bottom run

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Starting to beef up !!

I went narrower on the end pieces for a couple reasons , one these built ones are physically bigger and two I want them to be able to twist/flex without binding up hitting metal on metal ..

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Short pieces bend right around with a few whacks with the baby sledge

I did the middle one last , don't ask me why , maybe I figured it would be the easiest

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Finally they where both complete , I'll finish up the skip welds later , I had my fill !!

Here's a side by side comparison of the factory one and my newly built one

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Notice the narrow top edge for clearance

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Glad that parts done !!
91 amigo sas toy front leaf- traded off :(
2000 amigo sas d44 wagonear 4 link
custom built buggy ffor the dirty stuff

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Intake R&R - port and polish

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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby hessmess » Sun Apr 02, 2017 10:55 pm

Those are some purdy welds!
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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby paulevans76 » Mon Apr 03, 2017 9:47 am

Nice work.
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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby DSUZU » Mon Apr 03, 2017 6:42 pm

Lookin good. (and beefy). Reminds me of adding the strapping to my Warn brush bar a year or so ago. Weld on brother! Dennis
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Previously owned: 1987 Trooper II LS, 1989 Trooper (parts only), 1994 Trooper 3.2 Auto, 1997 Rodeo 2.6 5 speed, 1993 shortbed pickup 2.3 (project - sold) 1992 Rodeo 4x4 LS (parts car, devoured by Spacecab needs) plus some 70 plus other non Isuzu vehicles over the years.

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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby shaggydoink » Tue Apr 04, 2017 2:47 pm

Absolutely incredible!! :thumbup:

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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby bradzuzu » Wed Apr 05, 2017 1:30 am

Today I finished getting the amigo ready to come apart , yesterday I shimmyed under the trooper (still on the trailer) and checked it out for differences and room for the dual transfer cases ... I notice they inverted the E brake cables how they mount up , I'm hoping the axle ends will match up with the 44 , it looks like the upper link will be close in length .. I'm thinking of a different steering box possibly , one with the arm facing forward so the box doesn't have to stuff as far forward , I'm also planning on pushing the axle forward so it won't contact the inner fender well when the suspension stuffs , I want to fix as many bugs as possible this time so I don't tear up the body ... It'll be nice working on a new platform that already sits up higher and has fender room !! I wish there where better drink holders though :)
91 amigo sas toy front leaf- traded off :(
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custom built buggy ffor the dirty stuff

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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby itsmehb » Wed Apr 05, 2017 7:40 am

I wish there where better drink holders though :)

Yep, a must have for all off road vehicles. Keeps one from spilling there favorite beverage, you know where, while transversing forest trails. HAHA
This is going to be an interesting build to follow.
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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby bradzuzu » Thu Apr 06, 2017 12:16 am

Haha it's very important out on the trails dontcha know :)

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Can't wait to see these wheels and tires under the trooper !!

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I'm thinking of revamping the turbo system , be a little cooler if it spooled at idle like the die cels and tone down the max boost , I need to see if it's in good shape ..
91 amigo sas toy front leaf- traded off :(
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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby nasty610 » Thu Apr 06, 2017 7:16 am

Probably going to need a more efficient perturbo exhaust setup. Ever though of building a twin scroll setup? You could always look into a billet wheel for the compressor as well. They decrease spool up quite a bit.
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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby shaggydoink » Thu Apr 06, 2017 9:45 am

Do you plan on doing a similar type of body cage for this Trooper?
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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby trooper4kids » Thu Apr 06, 2017 10:32 am

I love it AND I'm jealous!! Picking up the body with a trackhoe is flat out unfair!! :) The rest of us have to figure out some combo of hoists or jacks...
1995 Trooper - first Troop long time ago, sold when 3rd child arrived
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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby Cronk » Fri Apr 07, 2017 5:56 pm

Wow! I saw the random posts on Facebook, now I see what they're all about. Pretty cool!
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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby bradzuzu » Sat Apr 08, 2017 12:36 am

nasty610 wrote:Probably going to need a more efficient perturbo exhaust setup. Ever though of building a twin scroll setup? You could always look into a billet wheel for the compressor as well. They decrease spool up quite a bit.


I think I know what you're talking about , that might be an option , the big thing is to have the turbo spinning faster at idle , I think that'll help out with the leak by ... I built the exhaust system similar to a diesel setup , the lack of room has always been part of the issue ... I was able to pull the trany with the crossover pipe on still so as far as serviceability it's not built into a corner par say... I hate setups where it can't be worked on or maintenanced ..
91 amigo sas toy front leaf- traded off :(
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custom built buggy ffor the dirty stuff

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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby bradzuzu » Sat Apr 08, 2017 12:39 am

shaggydoink wrote:Do you plan on doing a similar type of body cage for this Trooper?


I think I do , I'm taking wind resistance into account this time and the fact that it has four doors that puts the vertical bars furrher apart , ideally I'd like to have a leg right between the doors but I think fingers could get smashed super easy..
91 amigo sas toy front leaf- traded off :(
2000 amigo sas d44 wagonear 4 link
custom built buggy ffor the dirty stuff

My build up page
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Intake R&R - port and polish

Sometimes trying is all you can do, but when you succeed , that's something to be proud of...
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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby bradzuzu » Sat Apr 08, 2017 12:44 am

trooper4kids wrote:I love it AND I'm jealous!! Picking up the body with a trackhoe is flat out unfair!! :) The rest of us have to figure out some combo of hoists or jacks...



I am definetly spoiled with the equipment at work :mrgreen: , if it makes you feel any better it doesn't help not to have problems with my parts though ...

I hope I made the right decision to make this jump , so far it's been allot of work !!
91 amigo sas toy front leaf- traded off :(
2000 amigo sas d44 wagonear 4 link
custom built buggy ffor the dirty stuff

My build up page
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Intake R&R - port and polish

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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby bradzuzu » Sat Apr 08, 2017 12:48 am

Cronk wrote:Wow! I saw the random posts on Facebook, now I see what they're all about. Pretty cool!


Thanks Joe we'll see how wow it goes , so far I've got a mess on my hands ... Like most projects it has to get dirty and difficult before the more enjoyable part comes into play , I think I hit that today lol ,tired and exhausted but I think I have everything torn down as far as needs to ...
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custom built buggy ffor the dirty stuff

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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby bradzuzu » Sat Apr 08, 2017 1:09 am

I wasn't sure what I was going to find today , deep down you never want to find anything but that old saying "if you play you pay" , in my case I've been pushing boost into my engines for the past few years ... my new engine has around 42,000 on it and is in need of some love ...

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Funny a motor can be dank and dirty but add shiny valve covers and it looks so much better :alien:

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It took a while but I got it torn down to see what had gone wrong

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I'm not sure if I'm sold on these multi layered gaskets or not ..

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Can you see that the gasket is ballooned ?

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I think I was more worried that the heads had cracked so in that stand point I guess I'm lucky

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The valves and seats still look good !!

My sad little pile of Ottis spunk mire, tomorrow I'll see how the block cleans up , if it's to mard up it's going to need to get surfaced too..

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Fingers crossed and a good nights sleep so I can make the best of my time tomorrow , I just don't want a repeate of this job anytime soon ...
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custom built buggy ffor the dirty stuff

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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby humming » Sat Apr 08, 2017 3:11 am

Set it up for anti-lag! Just kidding. How are you going to have it spool at idle? That's got to be the tiniest turbo ever! I'd start to worry about being in a really inefficient(and hot) zone on the compressor map at higher rpm's...

Also, what do you do for an ECM?
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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby shaggydoink » Sat Apr 08, 2017 9:14 am

Damn, that gasket looks FRIED! :shock:
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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby nasty610 » Sat Apr 08, 2017 7:57 pm

MLS gaskets are pretty standard for boosted vehicles. Was yours an OE MLS or an aftermarket from Cometic or another supplier? If it was an OE part I'm not surprised if failed. They usually have less layers and are made of thinner material.

A huge contributor to your spool problem is the way you've designed you manifold. The crossover pipe is fine but it exits into a large void where it merges with the passenger side. This causes the gases to slow down, expand and cool. Once all that happens they have to compress and speed up to go through the turbo. You'd be much better off building a passenger manifold out of ELS fittings feeding the front port of a twin scroll while the crossover pipe feeds the rear port.

http://www.superstreetonline.com/how-to ... em-design/
That's a decent explanation of twin scroll turbos. For your truck you'd want the passenger bank feeding one port and the drivers bank feeding the other. There should be several twin scroll exhaust housing for your turbo for fairly cheap. Also you'll probably want a 12-15cm housing. You'll give up some top end but the low end gains will be worth it.



humming wrote:Set it up for anti-lag! Just kidding. How are you going to have it spool at idle? That's got to be the tiniest turbo ever! I'd start to worry about being in a really inefficient(and hot) zone on the compressor map at higher rpm's...

Also, what do you do for an ECM?


I hope you're not talking about the turbo Brad is currently using. That turbo is off a 5.9l Cummins diesel. On a gas engine it will support over 500hp. There's multiple people in the Japanese car world using this turbo as well as several Holsets pushing 30-40psi. Some are running 8-10,000rpm engines with these turbos. They have a reputation of being super durable and flowing more then a comparably sized Garret/Turbonetics/whatever.

On the other hand if you're just talking about spooling it at idle that's really not very hard. All it takes is a decent perturbo exhaust and an electronically controlled waste gate. It's not going to be pushing 10+psi at idle but it would easy to have it sitting in the 5-10psi range. He may need to step down his housing size. Can't remember what he's running off the top of my head.
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Lift Coil Spring Options
Add-a-Leaf kits and Part Numbers
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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby humming » Sun Apr 09, 2017 1:32 am

yeah, I just meant that to spool at idle would require a tiny turbo, not that the turbo pictured was tiny.

So when you close the throttle, then instead of building vacuum, which then would normally open the wastegate, you just keep the wastegate closed, which then keeps the turbo spinning at least a bit.

And I guess even though you are making pressure you'll still hit a limit when the air getting through the throttle at idle chokes and can't flow anymore. The ecu will be able to keep it from getting too lean, though that's gotta use a lot more fuel at idle.

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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby nasty610 » Sun Apr 09, 2017 9:32 am

humming wrote:So when you close the throttle, then instead of building vacuum, which then would normally open the wastegate, you just keep the wastegate closed, which then keeps the turbo spinning at least a bit.


That's the basics of it. A lot of it depends on the exhaust routing preturbo. If the exhaust pulses can't generate enough energy at idle you'll never get positive boost. So monster turbo on a tiny engine and this won't work. Everything has to be somewhat in reason. Brad may not even be able to run a setup like this on a stock ECU.

humming wrote:SAnd I guess even though you are making pressure you'll still hit a limit when the air getting through the throttle at idle chokes and can't flow anymore. The ecu will be able to keep it from getting too lean, though that's gotta use a lot more fuel at idle.


This is where proper tuning comes in. Once you have a target AFR, timing and fuel tables close the computer will make adjustments to keep everything working correctly. I doubt you'd use anymore additional fuel. The ECU uses the IAC to control air into the engine so it's not like you'd be getting fuel air flow all the time.

My buddies M4 builds around 7psi at idle. If you weren't watching a gauge you'd never even know it. His exhaust doesn't even soot up much. My wife's stock Kia Optima 2.4 has more soot on the bumper.
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Add-a-Leaf kits and Part Numbers
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Re: Bradzuzu's 99 Trooper Build All the Goodies !!

Postby bradzuzu » Sun Apr 09, 2017 7:30 pm

Good discussion ... I can't say I'm disappointed in the way the engine performs or performed with the exception of the light throttle and 3-5 lbs of boost on a slight incline , it was like the pressure was there but such a light flow that the maf reading was to low ... I will no longer have to deal with the ion sensing system or the flybywire :) ... I'm also going to get an fic 8 which is designed for a frequency based maf , that in itself will be a big help !! As far as turbo spool , it would make 3 lbs starting around 1500 rpm and with a gasser that's not really bad at all ... At an idle how ever the turbo is just spinning around slowly , the internals are pretty good size and add inertia which is where the issue lies ...

Here's the two turbos sitting side by side

Image

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The smaller one is off of a 6 cylinder diesel generator I believe , its close on the impellers , I'm having both of them checked out and will see what the results will be ..

I ran that smaller one on my air cooled 2076 years ago for a couple tests and it made around 8 lbs off that engine and spoiled up at an idle ...

One of the factors I took into consideration when I built the turbo manifold was durability , that much weight bouncing around would stress a tube style manifold and crack it , I've had a couple spots crack on mine even , either related to heat cycles or to much weld ground off after building it .. I'll get some pics of it tomorrow when I get to work , it'll show how the feed from the other side links in and is directionally faced (it was the best that I could come up with) ...

The other thing about the big turbo - I changed out the vacuum pot to a 7-8 lb spring rated one after the diaphragm ruptured in the other original one (I opened it up and redid the spring tension in it to)... So even with the tension set loose I can and have hit 12 lbs around 4000 rpm and gaining , about that time the clutch slips too , I don't need quite that much torque hitting the drivetrain ... I'm going to test a different air feed style , may or may not work or help we'll see... Oh and no more ecu under the hood so more room for other options !!
91 amigo sas toy front leaf- traded off :(
2000 amigo sas d44 wagonear 4 link
custom built buggy ffor the dirty stuff

My build up page
Four link pics
Intake R&R - port and polish

Sometimes trying is all you can do, but when you succeed , that's something to be proud of...
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bradzuzu
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