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View Full Version : Turbo V6 Dakota Build.



Mopar318
11-21-2008, 02:38 PM
I am building a tubular turbo header for a V6 dakota, I know alot of you on here also have dakotas so I thought I would post this on here. I am just building the header, the guy Im doing it for lives in california, so I cant really mock anything else up on my truck because of the slight differences in the trucks.
Turbocharger is Garrett GT35, utilizing a external 38mm tial wastegate.
Check out my awsome homemade collector jig! Buy it for a one time low price of $499.99!

http://i32.photobucket.com/albums/d48/Mopar318/Tona.jpg

http://i32.photobucket.com/albums/d48/Mopar318/ARCintercooler019.jpg

http://i32.photobucket.com/albums/d48/Mopar318/ARCintercooler020.jpg

BOO for stupid port shapes. Something most the import header buidling guys NEVER have to deal with.

http://i32.photobucket.com/albums/d48/Mopar318/ARCintercooler022.jpg

http://i32.photobucket.com/albums/d48/Mopar318/ARCintercooler023.jpg

black86glhs
11-21-2008, 03:02 PM
I was thinking you were talking about the six pack when you said custom jig....:clap:
Nice work.

Mopar318
11-21-2008, 06:46 PM
http://i32.photobucket.com/albums/d48/Mopar318/ARCintercooler025.jpg

Vigo
11-21-2008, 08:46 PM
keep up the pics, i wanna see where this goes. My dad's got a 96 3.9 we've had since like 97 and one day i may get around to messing with it since its pretty much extraneous nowadays.

black86glhs
11-21-2008, 11:44 PM
So the spacing on the cylinders is the same between the 5.2 and 3.9? I know the 3.9 is supposed to be be based off of it.
Not trying to imply you would build it wrong, just asking.:thumb:

GLHS592
11-22-2008, 12:20 AM
So the spacing on the cylinders is the same between the 5.2 and 3.9?

Yes it is.

Mopar318
11-22-2008, 12:35 AM
Yes they are virtually the exact same with 2 cylinder cut off the front. Same bore, same stroke, same cam lift, same valve springs, pistons, rods, etc.......

I might finish it tomarrow if it warms up a bit.

Mopar318
11-22-2008, 05:30 PM
Overall look, need to cut down the collector pipe to lower the flange, and shorten the runners, I dont like how long it is.

http://i32.photobucket.com/albums/d48/Mopar318/ARCintercooler026.jpg

http://i32.photobucket.com/albums/d48/Mopar318/ARCintercooler027.jpg

Dez
11-22-2008, 09:39 PM
Looks good, mild steel?

Mopar318
11-23-2008, 11:05 AM
Looks good, mild steel?

yes, it will be ceramic coated.

moparzrule
11-23-2008, 03:45 PM
Hard to tell, are they 1 3/4'' primaries?

Looks nice.

Mopar318
11-23-2008, 04:21 PM
They are 1-5/8" primaries into 2" then into the collector

Made some alterations
http://i32.photobucket.com/albums/d48/Mopar318/ARCintercooler030.jpg

moparzrule
11-23-2008, 04:30 PM
So you are going to run the driver side feed to the turbo from the firewall side instead of the front of the engine?

Mopar318
11-23-2008, 05:05 PM
So you are going to run the driver side feed to the turbo from the firewall side instead of the front of the engine?

Yes the crossover runs behind the engine, He is going to have an exhaust shop connect the crossover to where is y-pipe used to be, and build his downpipe. Those are things I cant mock up on my truck do to the different transmission.

Mopar318
11-24-2008, 07:19 PM
its done minus wastegate pipe.

http://i32.photobucket.com/albums/d48/Mopar318/ARCintercooler.jpg

8valves
11-24-2008, 08:03 PM
Neat stuff. How did you weld the insides of the two grouped primaries on the head? It would make it so that you wouldn't have welds lined up, but you could make the #2 (from right to left) primaries first piece longer to sit out so the weld is where the bend in #1 is to make it easier if you do another one.

Just a thought. I bet a turbo Dak would be fun. Your 318 truck would've been a blast!

Mopar318
11-24-2008, 08:13 PM
Neat stuff. How did you weld the insides of the two grouped primaries on the head? It would make it so that you wouldn't have welds lined up, but you could make the #2 (from right to left) primaries first piece longer to sit out so the weld is where the bend in #1 is to make it easier if you do another one.

Just a thought. I bet a turbo Dak would be fun. Your 318 truck would've been a blast!

Once I tacked everything I pulled the tubes and welded them all individually, then stuck them back on the flange.

On the inside I push the tube in level with the flange, Welded it with a small amount of filler and ground it flat. Its how they do all the headers from any of the other companies so I think It should work out fine, Im also going to run a bead on the out side as far in as a I can. Sometimes its hard to work with thinner tubing because its so easy to burn the carbon out of it.

8valves
11-24-2008, 09:28 PM
Once I tacked everything I pulled the tubes and welded them all individually, then stuck them back on the flange.

On the inside I push the tube in level with the flange, Welded it with a small amount of filler and ground it flat. Its how they do all the headers from any of the other companies so I think It should work out fine, Im also going to run a bead on the out side as far in as a I can. Sometimes its hard to work with thinner tubing because its so easy to burn the carbon out of it.

Ah, so you break the tacks from the flange and collector then put them back in... right on. That's all I was curious about. That's why slip fit collectors are so nice :)

Aries_Turbo
11-24-2008, 10:16 PM
you gonna make another tubular one for the other side i assume and have the exhaust shop do the connection?

they gonna cut and weld mandrel bends together?

it would be a shame to go to all that trouble for some nice headers and have some crush bent in there.

Brian

Mopar318
11-24-2008, 10:18 PM
Well its not a full slip on, Its a formed collector you have to weld the star in the middle of the tubes and then weld around the collector.

A slip on burns collector would cost more than whole header alone, and then I would want to use some 321 instead of mild to go along with it.:D

Unfortunaly, its not my money to be making the desicion.

Im still trying to figure out how the Burns slip ons are fabricated, I know they are CNC welded, but how friggin small is the welder to fit inside the tubes like that.:confused2:

mrkindweiler
11-25-2008, 03:49 AM
sup dudes, im the dude letting this guy mopar318 build that header for me!! :D

should be all together within the next 2-3 weeks...

8valves
11-25-2008, 08:11 AM
Well its not a full slip on, Its a formed collector you have to weld the star in the middle of the tubes and then weld around the collector.

A slip on burns collector would cost more than whole header alone, and then I would want to use some 321 instead of mild to go along with it.:D

Unfortunaly, its not my money to be making the desicion.

Im still trying to figure out how the Burns slip ons are fabricated, I know they are CNC welded, but how friggin small is the welder to fit inside the tubes like that.:confused2:


I use a Burns or SPD collector on every header we do, and they look hand welded to me on the outside. Very well done, but hand welded none-the-less. The inside would probably be reachable with a pencil torch, and if you pulsed it while fusion welding it I think it would turn out just the way they do seeing how tight their gaps are.

Mostly 304 though, we've only done one car with 321 headers and collectors. The cost increase doesn't seem worth it to everyone all the time.

Here's a pic of the 321 header, you can see the weld on the collector that isn't perfectly consistant, makign me think they are by hand, on the outside at least. Then one of mine for fun :)

http://i234.photobucket.com/albums/ee189/Eight_Valves/DSCF0011-3.jpg

http://i234.photobucket.com/albums/ee189/Eight_Valves/DSCF0015-3.jpg

mrkindweiler
12-23-2008, 04:14 AM
some updates... got the intercooler and the turbo manifold by mopar318 ceramic coated :partywoot:
the coated turbofold matches pretty good with the coated JBA header hmm? :D
http://i9.photobucket.com/albums/a98/Mrkindweiler/IMG_1402.jpg
http://i9.photobucket.com/albums/a98/Mrkindweiler/IMG_1210.jpg
http://i9.photobucket.com/albums/a98/Mrkindweiler/IMG_1403.jpg

intercooler
http://i9.photobucket.com/albums/a98/Mrkindweiler/IMG_1405.jpg
http://i9.photobucket.com/albums/a98/Mrkindweiler/IMG_1406.jpg

will be doing the full install this friday and saturday :)

moparzrule
12-23-2008, 07:29 AM
Good luck getting all the peanuts out of that IC! I HATE packing peanuts with a passion, mostly because people send me intake and exhaust manifolds with them. I should make an extra surcharge if you do that.

mrkindweiler
12-24-2008, 02:05 AM
Good luck getting all the peanuts out of that IC! I HATE packing peanuts with a passion, mostly because people send me intake and exhaust manifolds with them. I should make an extra surcharge if you do that.
i dont follow...:confused2:

im new to this...:amen:

moparzrule
12-24-2008, 07:44 AM
The first pic the the intercooler, the pipes are full of packing peanuts.

mrkindweiler
12-24-2008, 10:27 AM
:lol: wow, im officially a dumbass, not that i wasnt before, but wow. hahaha

Darkapollo
12-30-2008, 12:33 AM
You REALLY should make a support for the turbo. I can see that thing lasting a month or maybe two before it starts to sag and crack from heat cycles...

:remembers to save a box full of peanuts and leave it on moparzrule's porch:

moparzrule
12-30-2008, 06:52 AM
:censored:

Nemesismachine
12-31-2008, 02:17 PM
intercooler with bent tubes...? SWEET welding there, 8valves. That is art.

mrkindweiler
12-31-2008, 04:10 PM
You REALLY should make a support for the turbo. I can see that thing lasting a month or maybe two before it starts to sag and crack from heat cycles...

:remembers to save a box full of peanuts and leave it on moparzrule's porch:

definitely going to make a brace...

mrkindweiler
12-31-2008, 04:10 PM
intercooler with bent tubes...? SWEET welding there, 8valves. That is art.

stupid shipping ----ers... gonna cut off the bent part and go from there

mrkindweiler
12-31-2008, 04:14 PM
the install is on the back burner for another week or 2, blew a head gasket and so since i have to remove a head, im gonna remove both and have them ported. :eyebrows:

Mopar318
02-26-2009, 02:52 AM
intercooler with bent tubes...? SWEET welding there, 8valves. That is art.

I welded the tubes, and the tabs on the intercooler. They werent bent when I sent it and had UPS pack it. They did a crappy job of packing and now the intercooler is scrapped and a claim gave him his cash back.

Great_Archer66
02-28-2009, 08:27 AM
wow that sucks what year is the dakota?

mrkindweiler
03-02-2009, 05:19 AM
wow that sucks what year is the dakota?

1996

still on back burner until she's running right

Sadilk
09-02-2009, 11:03 AM
very cool. Let us know how the build goes.
I assume youve done your research and picked those parts based on your desired compression? and what turbo youll be using?

Vigo
09-02-2009, 02:43 PM
Im still waiting to see how this turns out as well. I have a 96 3.9 truck and another 3.9 i just took out of a parts truck waiting for a good idea to come around... :p

httrdd
09-14-2012, 03:02 PM
Do you think you can make another manifold? If not I will build one off of aftermarket headers.