Well here goes guys..... Remember no laughing!!!
Well first of all you have to decide how much boost you want to run so you know what needs to be done to the motor inside you want to run max 8to1 compression ( the less comp. the more boost...but it cost driveabilty) I've been running 11Lbs in mine for about 10yrs but I'm running TRW forged pistons with molly rings mine is about do for an overhaul after about 60,000 HARD miles ( they say with forged pistons you could run 15 to 18 lbs but I'm chicken.......)
About the hardest part to this project is fabricating the exhaust manifold ( I've built 3 so far one from the original manifold one from a set of headers to my latest from black iron pipe so far the best one) the problem with the first one is that the turbo heat makes it grow longer and it never goes back so it will get to the point where it will sag in the middle (which will cause a massive exhaust leak) and eventually break in two....The second one the problem is again the heat and the header pipe will not stand up to it (so your always patching up holes....no fun! )
So to fabricate a manifold you need a set of header flanges (available from Clifford performance in Corona Ca.) an old head to build it on 6, 45 degree elbows 4, 90 degree elbows, 4 tees 2 with one side machined off (they match up with the 2 machined elbows ) and some black iron pipe about 3 feet... the elbows should be the same size as the ports in the flanges then about 4 in of square tubing and a turbo flange.( I got most of my stuff from Turbo City in Orange Ca.) You'll need to have 2 slip joints machined to eliminate the problem we had with #1 they go between 2and 3 , 4and 5 . I used a Mig wire welder to put my manifold together ( less heat less warping VERY IMPORTANT to the flanges sealing on the head ) One other thing you'll need 2 of the 90 degree elbows machined to fit back to back to make the exit port into the turbo (that's where the square tubing will go on ) in the side of the square tubing you'll need to put a round pipe and waste gate flange to mount your waste gate on so you can adjust the boost Well that's about it for the exhaust side other than putting everything together!!
Now for the intake side... I used the offenhouser (sp)4bbl intake (I had an adapter machined for the top of the manifold but that was strictly for looks you can use the one that comes with it) then I used a small block V8 (oh V8 bad bad!!!) carb adapter I put the bonnet on the intake and the carb adapter out in front of the turbo (on a V8 this setup stacks one on top of the other so the carb stays in the same place) The 2 bolt holes on the intake where the 2 manifolds bolted together I made 2 tabs to go from there to the turbo flange which was welded to the square tubing to help support the turbo On the bottom of the Offey manifold I had the heat riser tits machined off to keep the turbo heat out of the manifold ( you want heat in the carb not the manifold.)
Well now you got a turbo hanging on the exhaust manifold and a carb hanging on the front of it well you need oil to the turbo and heat to the carb...well oil is the easy one sorta you come out of the pump with a tee where the sender goes and bring your oil around to the turbo then you need to dump it back into the oil pan I welded a fitting into the side of the oil pan well above the oil level so as to have no restrictions.
Now heat to the carb...well I wanted it as neat as possible so I drilled into the pad on the left side of the block ( right by the starter ) that goes into the water jacket and put a fitting to bring water to the carb adapter to heat the carb then from the adapter I put a fitting in the drain hole of the radiator to run the water back into the system you'll need a bracket from the block to the front of the carb adapter to help support it. The throttle cable will have to be fabricated ...I used a piece of stainless steel braided hose with Teflon on the inside and the inside of tach cable off a big rig to make one.
On the back of the turbo you don't want any restriction in the exhaust so use as big a pipe as possible I run a 4in out the back in the top of that pipe you'll need to put the other side of the waste gate flanges.