EASY TWIN TURBO LS ENGINE PLUMBING HACKS!!!

welcome back to finnegan's garage thank you for hanging out with us once again especially you guys and girls that went to fsmgarage.com this month to get merch you bought hats hoodies stickers everything you need to go out in the world and not be naked and i appreciate that because every dollar you spend goes right back into the project vehicles and our poor financial decisions this video is all about working with aluminum we're going to show you how to pi-cut tubing and make the tightest bends you've ever seen in a turbo system we're also going to work on our 21 foot eliminator daytona jet boat we're going to teach you all kinds of cool things how to build seat mounts how to finish the cold side tubing the science of jet drives and how we're going to make a brand new one work in our 21 foot eliminator daytona jet boat project that's right that's the five-seater one that's going to take four knuckleheads and me really fast across lakes all right yeah oh see right as you can back he's like yeah i'll go i'll go you know you are i know i'm going to be like game over but with room for your friends and uh in the jet nozzle and i'm facing down sold it to my wife under the guys that it's her boat they'll take you one time with a bunch of passengers be like all right y'all get out and make the boat slow that is a thing i've done that before i've literally gone 80 miles an hour that sucks everybody got all right now we're going 95 because the weight penalty in boats is way harder than it is for cars you would kick us out oh you're damn right if it meant winning you would kick us out yeah i mean i'd give you a cold beverage and a life preserver but i'd definitely kick you out i mean i'd come back for you after i won the race but yeah you guys won can you swipe what yes can you swim what me yeah of course i can without a life preserver i've had to jump in the water and pull you and game over back to shore before i just can't remember whether you were you know what i didn't know i can't remember if you had additional floatation or whether you could are you treadwell what are you trying to say maybe you can't swim i don't know i'm with a project you're trying to say stay tuned continue this here is a two and a half inch diameter mandrel bend tube made of aluminum we got this from motion race works and this is really easy to work with when you're plumbing your turbo system or just building an air intake but what do you do when that 90 degree bend is way too big and takes up way too much space for your specific application well you take a straight piece of tubing pie cut it and end up with this jewel the tightest 90 you can possibly make out of that tube look at that look how much smaller that is compared to this and that's what we had to do to finish the charge tubing on our eliminator daytona jet boat last episode everybody was commenting you guys need to move the turbos switch them from left to right put the charge tubes discharging up top it's going to be amazing we had a plan the whole time and maybe we didn't communicate it very well but our plan was to leave it exactly the way it was and make it as compact as we possibly could and i'm going to show you how and why right now and then i'm going to show you how to make this at home with some pretty simple tools okay let's talk about turbo placement in the last video dave and i talked about where we wanted these and we we talked about how we wanted them tucked into the motor we wanted them lower than the intake and we talked about flipping them left to right and having the turbo outlets come up high um we tried it we didn't show it on the video but we did try that and ultimately we settled with the turbos like this and with the discharge down low meanwhile everyone on the internet was like no no the nelson racing logo is upside down and it's it would be better if it was up top because you could go right into the throttle body and what i don't think anyone could see in the video is that you can't do that and the reason why is we've moved the turbos forward the discharge is now here so if you flip this around it's going to run right into the side of the intake it's not going to be an easy transition into the throttle body nor will it be a very attractive transition to the throttle body so what we've done is run them this way we're going to tee them together and then come into this 90 degree fitting that you can get from motion race works the other thing we're going to do is after staring at this even more we realized we can move the turbos even further forward making this whole thing even more compact so right now nuber and i are going to take the turbos off shorten the 90s by an inch and a quarter lengthwise and move the turbos even further forward which gives us a little more room down here to merge the two and a half inch outlets from the turbos into the four inch 90 going into the throttle body so there's the reason why they look the way they do i know they're upside down but for our purposes this is the best way forward this is all in the name of keeping a walkway open on each side of the boat so people can get on and off because when this boat sits in the water it sits like this and it's a pretty tall boat for a 21 foot boat it's not easy to climb up over the side of this when you're in the water with a life vest on and so i wanted to set it up so that if we're out floating in the middle of the lake or the river we can climb up the back of the boat and get in the other thing people are asking me about is why did we go with a log style manifold instead of an actual header um well to be honest this isn't a max effort race deal here where you know i do believe a true header design probably makes more power this is very compact and very efficient in terms of build time we were able to put this together mock this up in a few hours it was easy a header would complicate that a header would also make this whole deal wider so that's why we went with these the other question people had is why aren't we water jacketing the exhaust time more than anything it will take way more time to build a water jacketed exhaust and i don't think it's absolutely necessary in here we'll have to build heat shields yes to protect the fiberglass but this isn't going to have an engine hatch covering anything up here um the motor you know you buy one of these intakes you want the world to see it so there'll be no hatch covering this deal this is a hot rod boat so no hatch no water cooled exhaust this is where the turbos are going to go except they're going to go a little further forward and we're going to continue on with the build all right newbern we know what happens when you try to cut a mandrel bend in the middle of the bend right right because even though it's mandrel bent it's pretty good as far as tolerances the truth is what you're doing is you're stretching the tubing when you bend it and the diameter changes so if you cut in the middle of these bends you end up with tubing that's not exactly round and if you try to cut it at severe angles to make pie cuts to make an even smaller deal you end up with tubing that's darn impossible to weld back together so yeah it takes a lot of massaging to get it back round and to match up again so right so for the people at home school them on how they're gonna take a straight piece of tubing and turn it into that right there because that's pretty amazing so i didn't know that the pie cuts weren't out of bins already i'd never knew they were out of straight pieces of you know tubing so i googled the first guy popped up was the fab forums on youtube kyle voss yeah yeah dude i mean smart dude he nailed it he made it very easy for me to understand how to do it and uh basically this tool here marks the center of your tube and this is for roll bars and it goes up to like i think two inch tubing yeah this is the centuriol tool kit we got last year that we used for the c10 roll cage let me get you a marker hold on one second so step one is to take your tubing and you want to mark the center line of it of both sides because that's your reference point later on when you're putting all these pie cuts back together see that nifty little line right there that's the line we drew down the middle of this tube on both sides and you used that right yep so basically i spaced this up in a way that gives me an inch and a quarter to the tip of that marker and i would hold the tube steady and just run it down it like that on both sides i made sure to hold this you know the tube steady and went to both sides marked it now i have a mark on each side and that's important because when you put this in the saw you have to mark make sure this is center and then you make your cut then you flip this over to your other mark make sure it's center and make your make another cut and then that gives you all of these right so we're our goal here is to make a 90 degree bend for what we're trying to do and there's a couple different ways you can do that a couple different tools you can use if you have a horizontal band saw that works great for straight tubing or if you have a really great chop saw this is all reliable we've had this for years we bought it from tricktools.com the fine slugger it's about 500 saw the benefit of using this saw is the blade doesn't deflect hardly at all it's not an abrasive chop saw so the blade doesn't deflect it leaves almost no slag that's a fresh cut right there right yep so it makes pie cutting tubing like this which basically what you're doing is you're cutting it in one direction then you're going to rotate the tube over and cut it in another direction you can make cuts that require almost no deburring no cleanup afterwards and they're very very straight because we're not using an abrasive chop saw i don't have a horizontal band saw here to do this but that would work very well these are untouched i did not clean these this is how i came off that saw right and so look at the fit up there's there's no gap there which means welding this after the fact is going to be pretty easy so for the folks at home what's the math here so i basically you set your your saw at nine degrees and when you make one cut and rotate the tube over and cut it again it makes a total of 18 degrees five of those is 90. you can make a tighter smaller radius for like a total of nine degrees but then you gotta split that and it takes what 18 of those to make a 90. right so let's not confuse the folks at home so this piece right here is cut on a nine degree angle on each side side so that's a total of 18 degrees when you stack five of these together you end up with a 90. a really tight 90 degree bend and once you have a really tight 90 degree bend show them what we can do with this dave dude take it over the boat let's show them sure why we were doing this we talked earlier we were telling you guys there was a reason that we weren't flipping the turbos over and we weren't going to have the charge tubes up here and that's because if you flip this over the charge tube ends up here and it runs right into the throttle body not easy to plumb however if you put a 90 here and you get yourself a really tight pie cut 90 degree deal there look at that suddenly we have one of the most compact cleanly plumbed turbo setups i've ever seen in a jet boat yeah and it's all thanks to that little beast right there yeah i love it so right now he's going to cut some show you the cuts yep and then we're going to tig weld those together and make two more little pieces to go in between and the cold side minus the fact that there's no blow-off valve on it will be done all right so this one's already cut at this particular angle here and so which is what that's at a nine degree angle and the way i figured that out was this other nifty tool you have right so step one is to set your saw at nine degrees which is what dave's done right there so once this is at nine degrees and you make one cut you need to do the same on the other side that's the so against the two marks so you rotate the tubing and flip it over and i totally guessed at the spacing on where to put the blade on this i did all of those at half of an inch off the edge so basically i'm going to put it right there mark this at half i'm going to center my blade on that piece or on that mark i'm gonna center the blade on that mark right there okay snug this guy up verify that i'm on the center of my mark there which should be an inch and a quarter but just dead on one more little snug and he's just barely snugging the clamp because it's aluminum if you squeeze it too hard you'll compress it and it won't come back ready yeah dude look at that that's all it's there yeah one little chip to break off but look the tubing stayed around breaks off and essentially with this blade in the saw it cuts as fast as you want it to the harder you push the faster it goes to the material and it's incredible how clean and how precise and how straight that is and then you just take it over here and line up the marks and boom done now you just tig weld it together [Music] it's my first pie cut ever dave's first pie cut killer job cutting it by the way the fit up was just money took a couple of tries to figure out the weld settings um using a miller dynasty 280 dx i was pulsing it um this was about it's o67 tubing with the pulse i was doing it about 92 amps um 0.7 pulses per second and this is the result it penetrated really well and we'll go back in there with a cartridge roll and flatten all that out but this is not going to break and again that is a much tighter radius than we would have gotten out of a mandrel bend so like if i line this up right here you can see there's where the tube would have gone this is where it's gonna go for us and with this transition we will go from two and a half to three and then from three to four right into our icon throttle body and elbow check this out the pie cuts were necessary for us to make a ridiculously compact cold side here so that's going to go there this is going to go about there after a little finessing of our y fitting right there we can probably tweak that down just a little bit do some trimming on this and this and then this will all fit together and again this is why we are running the discharge outlets to the bottom not the top if they came out the top they'd run right into the intake and the throttle body so this is uh what we believe to be the cleanest way to do this dude i can take a quarter of an inch off of this piece right here because it's straight up about half of an inch yup raise this whole thing up dude i think we're gonna be super close yeah i love it let's do it we're close to finishing this then we can start eyeballing exhaust tips where the wastegates are gonna go a lot of fun things all right so you think we can tack that on there and then just trim this or trim this and then fit it again and then tack it well this this particular piece this side of it's not cut very straight but like i said that may help us so let's get it up on there and kind of rotate it a couple of times and see where it alright the least amount of gap and uh we'll put some marks on it and attack it sweet it's gonna work good all right so yeah what i would do at this point is weld these two pieces together these two yeah okay and then you can uh yeah because there's really no there's not much left to these to change right but there's a there's a good bit left in this guy yeah to modify it's gonna work though yeah let's do it so i can weld the rest of this then probably yes yeah i don't see that changing there's not a lot of material there to actually trim back without a change in diameter so you're good there i'm gonna i'm gonna round this because it's not it's kind of oval shaped right now so i'm gonna round this put it in the bandsaw and cut it at a slight angle okay and i think that'll put us in the ballpark so this was a matter of just kind of finessing this a little bit here and there right on this is a motion raceworks dual seal connector and uh i was feeling froggy so i just welded the inside of it instead of trying to fill the big gap on the outside never done that before hopefully it works we'll find out [Music] [Music] all right so what you're looking at here is the jet drive out of game over which has been freshly rebuilt and this is the new jet drive for the unnamed boat this is wifey's whip um this will go in the red daytona this will go back in game over there are some subtle differences between the two which is why we're making this video and uh let's start with game over's jet drive all right this is what's called a dominator jet drive that's a brand that the american turbine company owns it is what i want to say here so today [Laughter] so it's a dominator jet drive um you can buy these from american turbine or any other retailers this is a race jet drive it has been fully blueprinted inside and out it was just rebuilt by the guys at marine performance design in costa mesa california because we had broken the inside of the bowl so let's let's talk about what these are so this is the suction housing or intake this is where the water comes in this is the bowl the impeller is inside of here this is a nozzle adapter and this is the nozzle now this one looks different when this one because it has this valve on top of it this is a pressure relief valve this one will eventually get one i just don't have it yet the other differences between the two of these other than the fact that one is silver and one is black is that this one is new and these parts are thicker and they've been treated to a process that makes them stronger so all these pieces are made out of cast aluminum these two pieces have been stuck in a high temp oven with pure argon forced into the oven under extreme pressure it's called hot isotropic isotopic pressure something it's called a hip process basically what it does is you heat up the aluminum parts you force argon in under extreme pressures and it forces out all of the air pockets from the cast aluminum basically eliminates the porosity of making all of this stuff way stronger than it would be normally so not only is for example this suction housing twice as thick as this one but it's inherently stronger thanks to the hip process which is pretty cool physically it looks different physically it looks different because the guys at big league racing in california which is the outfit that machined and blueprinted and assembled this one also cnc the bowl to lighten it so that's these scallops here this one is stock this one's been extensively lightened um according to the internet i'm not sure i have no idea because i'm not a scientist um seeing seeing this actually can make it stronger somehow i don't know if it takes out stress risers or what but you know i'm not a scientist but i've drank beer with them before and they tell me something i tend to believe it you know works for me so you've got dominator suction housing dominator bowl place diverter droop snoot which is an adapter that adapts the bowl to your nozzle and then this is a place to router nozzle which is that thing that we've shown you before that goes up and down and shoots a rooster tail and sets the attitude of the boat this has a similar function goes up and down but it has something i've never seen or worked with before and that as these fingers right in here they kind of look like a jet engine and they kind of move like one so this has an air bladder surrounding it and when you put air to it these fingers squeeze down making the exit of the jet drive smaller increasing the pressure when you take the air away it opens back up making the exit larger increasing the flow the idea here is squeeze it down for the whole shot open it up once the boat is moving from maximum flow and i'm told it works never used it but we're going to try it out on this boat this is by henry morris so this nozzle looks a lot like that one functions very similar to it except it has that feature right there that you won't find on another nozzle out there so yeah the other thing this jet drive has that this one doesn't is this item this is called a jet away two this is a ratcheting mechanism you grab these handles and you can move this forward and backwards and it will disconnect the input shaft to the jet drive from the drive shaft to the engine does two things it allows you to disconnect the jet drive and run the engine when the boat's on the trailer without the jet drive moving which is good um it'll also when this is connected and you're going really fast if the engine ever locks up it allows the impeller inside of the jet drive to freewheel and that gives you a margin of safety you wouldn't otherwise have so the way a jet boat works is water comes in the bottom of the boat goes into the jet drive right here goes in here the impeller is spinning the impeller squeezes the water out the back of the boat if the engine ever locks up because there's no transmission here the engine stops turning the impeller stops turning but the boat's still moving fast and all that water goes in there hits the impeller lifts the back of the boat out of the water slams the nose of the boat down and you crash so this can help that game over's jet drive really good the new jet drive also really good but significantly stronger and has the ability to have a quote unquote neutral here with the ratchet and also has that nozzle from henry morris that we've never tried before but should help this thing whole shot better i don't know we'll find out this summer so that's going back in game over this is going to go in this boat so as i said before the suction housing is redesigned it is way thicker way stronger so in addition to the hip process everything is burlier the spine right here is four times thicker than the spine of the original jet drive see how thin that is so the original spine is about four thousandths of an inch thick this is over an inch thick right here and also the bearing support right here as you can see is much wider [Music] from here to here and has a rib that comes all the way down here if you look at this one much narrower no support coming down other than right here this was all changed because these jet drives were developing cracks in high horsepower situations or applications where not only did you have high horsepower but you had a boat jumping in out of the water that water coming in you know loading and unloading would just hammer these parts and break them so this thing heavier but way stronger than this one ready so i've taped the gasket in place so that hopefully it doesn't slide while we're sliding this in [Music] oh wow all right that was really smooth i got this if you want to try and line some holes up [Music] damn it [Music] i was just [Music] going forward with it to try to get it [Music] what other brands are there this has the dominator like is there are they interchangeable with the intake of the boat like yeah so that's a marine performance design low profile intake and most all of the jet drives out there will bolt onto it whether they align very well or whether the contours inside fit very well it just depends but um it all started in the late 60s with the berkeley pump company that's what's in mine right you have a berkeley okay and then over the years there's been jacuzzi panther jet legend um there was uh dominator american turban um god what was dave's company i had one of these i had one in my boat like there was another one i can't remember it but uh there's been a bunch of them over the years this is the most popular for racing this is cool we got you you down here filming mikey roll reversal so excited is that on your phone yeah oh god no it's not on his android what are you talking about my android tells us all about life look at that finnigan's hairy arm as long as you upload it in hd it'll look good you know what you need to shut your mouth okay you probably let that go can you grab a half inch twist half inch wrench and you know the longest engine in the top [Music] i need one more bolt over here pop off somebody close dude i don't want to body work the boat no i don't know how to do that make it look good well it would be possible to fiberglass and annotation in there but then you got to match the gel coat i don't want to do that i'm hoping that if we have to we can shorten the pop off fix anything with flex tape flex step flex seal flex seal flex tape you guys look like twins what [Music] every time you put something on do you feel excited oh yeah i'm so excited for summer i'm so excited to give people rides in this thing after they sign the 12-page waiver that's important yeah we're gonna put up like a machine on the boat we'll just print it out just push a button print it out of the boat sign it we can name the vote implied consent but that would all depend on what you implied and what you're consenting to or no means no yeah cotton [Music] okay so the theory here is for the whole shot you want a small diameter and then on the top end you want to open this up for more volume right well there's these rings that go in here and these rings effectively limit how big this can go so if i put air to it it's going to shrink down smaller than any other nozzle on the market so that shrinks down under three inches i think like 2.7 inches so it'll squeeze the water increase the pressure hopefully hope the whole shot and then when you take the air away it will open up to whatever this ring size is and these rings are available in a bunch of different sizes from henry this one is three inches sixty thousandths and it comes in steps all the way up to three inches plus a quarter so 3.250 here's one 3.140 3.200 basically you can squeeze this down to like 2.7 inches and then open it up once you're done hole shotting as big as three and a quarter inch for max flow so this is going to be fun to play with how does that the question i ask is is the water coming out of here is that what is this going to open the pressure back up because the bladder shuts it right so to go bigger than that would it you see what i'm saying there's an air bladder around this when you put air to it it squeezes it for the whole shot right then you take the air away it opens up naturally but then you also have the water coming through here to squeeze it right further apart this is so cool and this is the three right here i don't know what one we have in here i'd have to go through the time this is three one two five so three and an eighth exit diameter which is a pretty common size um and let me show you this so so game over has a similar setup but you cannot adjust it on the fly these are inserts that you can change here and you can buy these from place diverter they're all different sizes so this is 3.080 uh here we go there's three and a sixteenth three and an eighth here's another three and a sixteenth you can change these right but they're fixed so you have to find a happy medium between an insert that gives you a good hole shot and maximum top speed once it's in there unless it falls out nothing changes henry's nozzle gives you all the advantages of a really small insert but then a really big insert later on when you're running so the theory is squeeze it down to increase pressure during the whole shot when you don't have a lot of volume going into the jet drive and then once the boat is moving and you have that 130 mile an hour water coming in here you open it up to increase the volume coming out of it and reduce the pressure i'm so excited to try this if you've noticed from previous videos the seats were already mounted in the boat they were bolted to pieces of angle aluminum this is quarter inch thick 6061 it's neither attractive nor lightweight so we're going to fix both those problems right here today step number one we could use a sharpie to mark our lines you know obviously that's semi-permanent works good you can get it in fine tip or fat tip but we want a little bit more precision with this deal so we covered the whole thing in dikem which is a steel blue colored machinist layout fluid and that gives us the ability to then use a scribe to put very sharp lines in here but you can see that's our layout and all we're doing here is marking areas where we want to remove material from this aluminum to make it lighter and a little more attractive looking so this is the top side where the seat's going to bolt to there will be two of these one on each side of the stringer the seat will sit on top and when it's all done this is the end result we're basically going to machine some windows in this on both sides the side that bolts to the stringer and the side the seat sits on top of and again it looks cooler and it's significantly lighter so scribe the lines in you can use a circle template or a coin or a washer to get your nice rounded corners there whatever you feel like and then you've got a lot of options for how to take the material out we're going to use the old bridgeport mill because we have it and it works really well um full disclosure i am not a machinist i've never been to school for it odds are good while i'm doing this you're going to see stuff that is either dangerous or inaccurate or not the right way to do it but uh i don't know any better and i'm not dead yet so we'll continue to do this until you guys in the comment section say hey idiot this is a better way to do it and you show me how um because unfortunately i don't have a lot of time to go watch instructional videos on how to do this particular job better and also if you ever tried to google how to machine a window into aluminum l brackets weird stuff comes up it has nothing to do with this um so i did look i just couldn't find anything that was very helpful so we'll continue doing it the way i've always been doing it right or wrong [Music] so [Music] so [Music] we are zeroed out here's the stock bracket two pounds right on the money and after about 45 minutes of machining 1.23 pounds so we've shaved three quarters of a pound off of this thing which may not sound like much but there's four brackets right so that's one and a half pounds three pounds right no three quarters of a pound one and a half pounds times two yeah we saved three pounds out of our seat brackets that still doesn't sound like much right but if you do this to everything you make for your race car your boat or whatever it all adds up and it's free horsepower it's free elapsed time it's you know it's not free you got to buy the tools and it's your time how much you know how valuable is your time but still like i didn't have to go buy a lithium battery or titanium stuff i just took material out of a part that didn't need to be there and consequently the boat's gonna go faster it's gonna be quicker so there you have it i think i did the math right three pounds yeah yeah i did i did just keep telling myself i did if i did it wrong you'll tell me in the comments that's pretty good though did you almost like it almost took half the weight off of it yeah almost and it was way more honestly that was way more than i thought it would be and you probably could take more out of it you know that slot you could have a smaller slot here you know yeah you could have drew this up here like like that and then come across and did something like that this one could have been wider like there's things i could have done but i didn't want to lose all the strength this will work all right there we go now of course we're going to speed through all the machining processes because again not a machinist probably doing this wrong so who am i to tell you to do it the way i'm doing it that's probably not safe so but the important part is lighter look at that not quite done but real close we still need to put a blow-off valve in there and we still need wastegates on the hot side but the basic layout of our twin turbo setup is finished and i could be totally wrong about this but in terms of jet boats i think this is the most compact setup like out there it was super easy thanks to stainless headers for the log manifolds that really made placing the turbos really easy uh share fab for the awesome reducers to go from the t4 flange two or three inch tubing motion race works for the icon throttle body which really made plumbing this thing easy and then kyle voss for his excellent tutorial on youtube for how to pie cut straight tubing so that we could make that really tight bend right there next up is to blow the whole thing apart we've got to put oil returns from the turbos into our oil pan uh button up a couple things on the motor mounts and then after that it's wiring plumbing and more fun stuff on the daytona so stick around we'll have more content here shortly on fittings garage [Music] foreign [Music] you

Channel: Finnegan's Garage

Views: 250,003

Keywords: roadkill, mike finnegan, david freiburger, discovery channel, motor trend, jet boat, ls, lsx, ls1, ls2, ls3, twin turbo, turbos, supercharger, pie cuts, tig welding, miller welders, dynasty 280dx

Id: B6F7PbfXkbo

Length: 41min 19sec (2479 seconds)

Published: Sun Mar 13 2022