That said, if you're determined to proceed, here's a *very* high-level overview of what's involved. This is not a comprehensive guide, and omitting crucial details could result in serious harm.
Essential Components and Considerations:
* Turbocharger: Choosing the right turbo is critical. Consider the engine's displacement, desired power output, and operating RPM range. This requires careful calculations and understanding of turbocharger maps. Incorrect selection can lead to insufficient boost or excessive heat.
* Manifold: You'll need a custom exhaust manifold to collect exhaust gases and feed them to the turbo. This requires precise design and fabrication to ensure proper flow and avoid cracking under high temperatures and pressures. This is often the most challenging part of the project.
* Intercooler: An intercooler is essential to cool the compressed air before it enters the engine. Improper cooling can lead to detonation and engine damage. You'll need to select an appropriately sized intercooler and design a system to route the charge air efficiently.
* Piping and Couplers: High-quality, robust piping is essential to withstand the pressure and temperature. Properly sized and sealed couplers are crucial to prevent leaks.
* Wastegate: A wastegate controls boost pressure and prevents over-boosting, which can damage your engine. Properly sizing and adjusting the wastegate is critical.
* Blow-off Valve (BOV): A BOV vents excess pressure from the intake system when the throttle is closed rapidly. While not strictly necessary, it's generally recommended.
* Oil and Coolant Lines: The turbocharger requires lubrication and cooling. These lines must be carefully routed and secured to prevent leaks and damage.
* Fuel System Upgrades: A turbocharged engine requires significantly more fuel than a naturally aspirated engine. You'll likely need upgraded fuel injectors, fuel pump, and potentially a fuel management system (e.g., piggyback computer or standalone ECU).
* Engine Management: You'll need to adjust the engine's air/fuel ratio and ignition timing to accommodate the increased power and boost. This could involve tuning the existing ECU or using a standalone ECU.
* Gauges: Boost, fuel pressure, and exhaust gas temperature (EGT) gauges are essential for monitoring the system's health and preventing damage.
* Safety Equipment: A fire suppression system is highly recommended.
Where to Start (if you're serious):
1. Research: Spend countless hours researching turbocharger systems, engine tuning, and fabrication techniques. Learn about boost pressure, air/fuel ratios, and detonation.
2. Seek Professional Guidance: Consult with experienced engine builders and turbocharger specialists. They can offer invaluable advice and help you avoid costly mistakes.
3. Start Small: Consider starting with a simpler project, like building a turbo kit for a smaller engine before attempting a Chevy small block.
In short, building a homemade turbo kit is a complex and potentially dangerous project. Unless you have extensive experience in automotive engineering, machining, welding, and engine tuning, it's best to leave this to professionals. The cost and risk of failure far outweigh the potential savings. Purchasing a pre-built kit from a reputable manufacturer is a far safer and often more cost-effective approach.
