Turbo Build

Yo dually, I just had my first turbo mishap last night on the way home from work. Got my diesel all buttoned up over the weekend, tested it for a couple of days, and yesterday during lunch I loaded my custom street tune. Numbers were supposed to be upwards of 425+/800+ for hp/torque.

Hit my first long straight and punched it. Hot damn that truck moved out! Did it again on the next straight. Awesome.

Next straight away was long and there was nobody in front of me. Mashed the pedal to the floor, launched like mad, smiled ear to ear, and heard a loud POP! and power dropped. One of the intercooler lines popped off. Screwed things back together, loaded the economy tune, and drove home without issue.

Is there a trick to keeping the pressurized lines attached other than simply keeping them free of contaminates and tightening the clamps? I've heard of applying hairspray to the connections just before joining them as an extra precaution. Thoughts?

 

Stock factory stuff. Most of the connections use the band clamps that wrap around a lip on the tubes, but for the intercooler tubes use flexible hoses at the joints.

With those, the solid tube has an indented ring at the connection and the flexible tube it inserts into has a metal ring that drops into that indent. The clamp applies pressure to hold the two together and in place.

I'm guessing the metal ring in the flexible line might have simple worn out or broke when I was disassembling everything. It'll probably be worth suck it up and buy new ones. Cheap investment relative to everything else that's already been done.

I cleaned up the tubes and connections and reassembled everything again last night. So far it's holding well, but I haven't pushed the boost over 25 psi. I'm running a milder tune to keep the boost under 30 psi for now. I'll see how it holds together.


Your truck sounds incredible! Great work as always, and props for sticking with the project!

 

Just looked up "t-clamp" in google, and that's what I'm using. They definitely hold strong!

I'll order those new couplers in the next week. Thanks for the advice!