6.2 hummer exhaust manifold on 1009

[richingalveston]

I am putting my banks turbo on my 1009 and I am looking to make a better cross over. I am trying to see if anyone has put a 6.2 hummer exhaust passenger side on the drivers side of their cucv

The stock cucv passenger side can be flipped to drivers side for a front output on the drivers side. However, it hits the power steering pump. I have a PSC tankless PS pump so there is more room but not quite enough. The manifold is just to long. IF it were shorter and could turn down sooner it will work.

Looking at images of the hummer passenger side, I want to flip it to the drivers side on my 1009. It looks like I can then 90 out of the manifold down and over to the banks manifold where the input is next to the fuel pump.

I do not believe this will work with a standard Hydro pump but with the remote reservoir, I have a lot of room for the exhaust if I can find a manifold that works.

Looks like: http://www.ebay.com/itm/6-2-6-5-Die...ash=item3f5e27135f:g:I10AAOSwvgdW4D0B&vxp=mtr

the connection to the cross over looks different and I am not sure what type of clamp is used to connect the cross over.

I believe this manifold with a banks manifold will allow for very simple front cross over on the cucv for turbo add.
I also have the ORD high clearance cross member so the cross member is under the motor mounts and not in the way of the exhaust elbo

Any thoughts.

 

[richingalveston]

Well I guess I will be the test subject. The manifold with shipping was $100. If it works it will be well spent.
due to work it may be a while before I can actually do any work on the truck so don't expect any updates soon.

Rich

 

[Ilikemtb999]

Looks like maybe just a v band clamp. Much better than a 3 bolt and a donut gasket.

 

[Jozseph]

I am putting my banks turbo on my 1009 and I am looking to make a better cross over. I am trying to see if anyone has put a 6.2 hummer exhaust passenger side on the drivers side of their cucv

The stock cucv passenger side can be flipped to drivers side for a front output on the drivers side. However, it hits the power steering pump. I have a PSC tankless PS pump so there is more room but not quite enough. The manifold is just to long. IF it were shorter and could turn down sooner it will work.

Looking at images of the hummer passenger side, I want to flip it to the drivers side on my 1009. It looks like I can then 90 out of the manifold down and over to the banks manifold where the input is next to the fuel pump.

I do not believe this will work with a standard Hydro pump but with the remote reservoir, I have a lot of room for the exhaust if I can find a manifold that works.

Looks like: http://www.ebay.com/itm/6-2-6-5-Die...ash=item3f5e27135f:g:I10AAOSwvgdW4D0B&vxp=mtr

the connection to the cross over looks different and I am not sure what type of clamp is used to connect the cross over.

I believe this manifold with a banks manifold will allow for very simple front cross over on the cucv for turbo add.
I also have the ORD high clearance cross member so the cross member is under the motor mounts and not in the way of the exhaust elbo

Any thoughts.

Rich, fwiw have you reviewed the article "500hp 6.5L Diesel Race Engine"

http://www.trucktrend.com/cool-trucks/1006dp-500hp-65l-diesel-race-engine

There is a good idea how the turbos where mounted.

"The single-most important performance improvement featured in this engine is the custom tube-style headers and non-wastegated Garrett turbochargers. The headers were built of heavy-wall, drawn-over-mandrel (DOM), 1.625-inch o.d. 1.45-inch i.d tubing. The four tubes were routed into a simple, four-tube collector, which mounts the turbocharger. The turbochargers were custom-engineered by BD Diesel Performance's John Todd. These turbos were designed to operate at high efficiency with an output of 30 psi boost at maximum engine speed. That boost falls to 22 psi at the shift recovery rpm."

Regards

 

[richingalveston]

thats really cool but probably puts up to much boost for my 6.2.
So far I have found zero threads where someone was able to make a front cross over on a 6.2 when adding the turbo. I found a few threads where people tell you that you cannot use the 6.2 passenger side on the driverside because it is to long but no threads where a custom manifold was produced.

I could not find anyone to make me a custom one even if i could afford it so i started searching all the 6.2 and 6.5 manifolds i could find and it appears the hummer 6.5 is what I need.
I bought it and already have it at home but it will be a few weeks before I am there to work on the truck.

A front drivers side manifold output would fix the biggest problem and only problem I have found with the banks kit. It bolts in great but the cross over is pretty nasty when you built your rig with minimal lift. Not much room to get it past the front axle.

Rich

 

[NovacaineFix]

Watching to see for future ideas, best of luck

 

[Jozseph]

Another Idea, this is on a Detroit 6v92 / 8v92 Turbo Charger Exhaust Inlet Connector;



Regards

Joseph

 

[Jozseph]

.....[SNIP} "I could not find anyone to make me a custom one even if i could afford .....{SNIP]
Rich

Rich, Speak to Stan's Headers, they manufacture entire systems and also sell individual components / parts; http://www.stans-headers.com

Regards

 

[richingalveston]

A header will not work for what I am doing. I need a manifold. Most manifolds are cast. I have not found any Manifold makers. There are lots of header people out there but no one that cast custom manifolds that I know of. Not something that is economical when having one made. when they cast something it is normally because they are making thousands of them.

I do not know anyone who makes welded manifolds. I think I have the problem solved. I already have the manifold at home waiting on me.

Thanks
Rich

 

[richingalveston]

I managed to get home for a day and play with my new parts. I installed the hummer manifold on the truck and it is tight but I beleive I can make it work.
From the back of the pump I have 3.25 inches to the flange of the manifold. The center line of the output fitting and the center line of the manifold almost line up. The manifold is slightly lower than the pump connection which helps. I may be able to run a smaller belt which will raise the pump output higher. The manifold needs a real tight 90 which I have found several on the internet. the manifold 90's down and and the pump output needs to angle up so i am fairly sure I can make it work with 90's in opposite directions. It will be close and may require a heat shield.

I took some pictures but for some reason they did not save properly and I can not recover them. I will take some new ones on my next trip home.

I will have to change the stock hydro pump output line. The stock one has a large sweeping bend turning to the radiator and then eventual up and out toward the fender. I am sure this is done for reasons. Vibration and strain protection on the fitting I assume. With the stock line in place I have 2 inches to elbow down.

The new line will need an immediate 90 as tight to the back of the pump as I can get. I am thinking a banjo fitting might work but the pump fitting is an flare with 0=ring style and I am not sure what I can get to work.

My homework this week is finding a 90, or the parts to weld up for the 90. The ID of the manifold is 1.75 inches. The v band flange is 2.5 inches.
I also need to find fittings and build a new high pressure hose for the line that goes from the pump to the brake hydro boost.

I might have to have an elbow machined but I can make this work.

At last resort I could modify the pump brackets and move it out 2 inches and they lines would bypass each other so, one way or the other it can work.

 

[richingalveston]

I ordered this elbow for the first try on making the cross over. I think this will leave me enough room on the pump connection.

http://www.himni-racing.com/index.p...ucts_id=2137&zenid=tn7gi5m5qs1o654o5f0sbr34s0

This is the tightest radius elbow with v-band flange already built that I could find so If it does not work, I may look into repositioning the pump. there is plenty of room to move it out and up but hopefully I will not have to do this.

May be a week or two before I know how it fits, work is always in the way of progress.

rich

 

[richingalveston]

https://www.amazon.com/gp/product/B00VMSQ724/ref=od_aui_detailpages00?ie=UTF8&psc=1

This is a banjo fitting I have purchased to change the port to an an-6 fitting where I will be using braided stainless high pressure lines.
The two line set is about $140 and these fittings are $32. The exhaust elbow was $230 with shipping.
So far it looks like all the pieces will fit.

still collecting parts
Rich

 

[corelokt]

Oval exhaust tubing?

 

[richingalveston]

I am starting from a round manifold with 2.5 inch v-band clamp flange. The only tight spot is at the manifold connection. I have to elbow first before I could transition to oval. I would not need the oval anywhere else in the cross member.
I considered it but found no benefit.

I believe the elbow I purchased and the banjo fitting with braided high pressure lines is going to work. I have to get home to try it out. May get to be there this Sunday.

I will post pics on my next visit.

Rich

 

[richingalveston]

Got to work on the truck Saturday, I was like a kid in the candy store with all my new parts. I had a let down when the elbow I purchased came the wrong size. I purchased a 2.5 inch and they sent a 3 inch. A positive side to it was the 3 inch would barely fit, it did touch the banjo fitting. The banjo fitting allows 2 3/8 inch between it and the manifold flange. This will be just enough room, I believe there will be a 1/4 to 1/2 inch gap between the exhaust and banjo fitting on the pump once the correct elbow is installed. The fitting is also above the center line of the manifold opening with the belts installed and tightened.

It is a straight shot down with only the trans cooler lines kinda in the way, I am removing them and putting braided lines from tranny to new cooler on the passenger side so these will be out of the way. I don not know if this will work with stock cross member and stock pump, I believe it will but the cross over will have to have some additional bends and it will be an even tighter fit. I am confident that the front cross over will work, it is now just a matter of building the correct elbow and then the rest of the cross over.

I have a PSC high volume tankless pump and the ORD high clearance cross over with the competition motor mounts. With all the stock stuff in place I am not sure it will work, with the parts I am using I believe it will be a very nice short cross over.

Thanks,
Rich

 

[glaser06]

Ok, dumb question time. What's wrong with the banks crossover kit? I ask because I just installed it and will be firing it up in the next hour...

Sent from atop the porcelain throne.

 

[richingalveston]

I am not aware of a banks cross over kit that comes with a new drivers side manifold. All use the stock manifold which exits behind the front axle. I have built my rig with very tight tolerances and there is not enough room to get past the axle.

I am trying to build a cross over that is in front of the axle. I have the banks passenger manifold and I am trying to use the HMMVW manifold so that I keep all of the exhaust cross over piping in front of the axle. With this manifold the cross over runs directly under the harmonic balancer and front oil pan. I wont have to remove it to work on the starter like most cross over kits.

Thanks,
Rich

 

[glaser06]

So that wouldn't work at all?

Sent from atop the porcelain throne.

 

[richingalveston]

My best chance to make that work is with some oval pipe about 1.5 inches thick for the 6 inch section above the axle. And I would have to move my Hydraulic assist cylinder and things would probably still touch at full flex.

I have cross over - high steer with hydro assist. My tie rod, hydro cylinder and steering link are in line with each other (one behind the other front to back) above the leaf springs. I have the ORD high clearance cross member and their motor mounts. When either side reaches full flex I have about an inch before the tie rods touch the oil pan, cross member, or frame.

I really need a front output manifold on the drivers side.

 

[glaser06]

Gotcha. There's 4" above my axle to the bottom of crossover pipe (stock, no lift) , didn't take into account flex and your crossover steering though.

I have also seen a modified version of the 2wd crossover where it goes behind the motor, but that usually ends up being a mess.

Sent from atop the porcelain throne.