Kid turbo this is fascinating! How does your % over stock injector sizing work in a mechanical injection engine like my Yanmar? Am I not limited mostly by the injection pump? So for example I send mine out and ask that they be setup to flow 50% more, and I change nothing else. Will I just be riding around with a cloud behind me or will the extra fuel generate extra exhaust to generate extra boost to supply enough additional air to compensate?

According to the service manual the pump can deliver a maximum of 111 cubic mm per stroke. If it says how much the injectors flow I am not seeing it.

Also I think that number may be half of what it is putting out because it says that amount of fuel is delivered under 700 mmhg of boost or around 13 psi, my engines make double that so I think these may be the pump specs for the Toyota engine the Yanmar is based on. Forgive my ramble don't mean to derail your thread.

No problem pstorti.

From all my reading, in mechanical pump injection they typcially rated injectors by HP gain over stock. This is because the mechanical pump pulse was pretty well set, while timing could be changed by moving or turning the pump. By installing a 20% oversized injector nozzle for example, would likely yield say 40hp at WOT cause there was no other changes to the pulse width or timing. With the new common rail design, nozzle flow rate is only one part of the equation so a 20% over injector might yield 40hp in one tune and 60hp in the next..

I'm by no means any sort of expert on mechanical injection. Have owned a few older diesels, but never modified one for extra power. But I bet if you do some searching for Yanmar oversized injectors you'll find where someone has listed the timing changes needed to match larger injectors.

-K

Very cool, I have lots of questions but I will wait till you are done posting, as I am sure you will answer them. I am subscribed.

Kid.....Ended up just under 32" wide, plan to install @ 36" centers.
Pretty much same footprint as BBC.

still have to machine out an aluminum block to weld to the underside of the plate that the power steering reseviour sits on for a 3" pulley to get the belt clearance at the center pulley.

Looking good !!

I saw a pic the other day with an idler in that bolt hole right behind the belt below factory AC location. It allowed better clearance with that PS pump setup. Will try to dig it up tonight.

36 " is exactly what I have to fit on the Baja build. :eureka:

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Exhaust and Turbo Options
 

Since I've fallen behind, I'm merging exhaust and turbos sections since they ultimately flow together.

To date the manifold and up pipe options for Duramax marnization have been very limited. Factory manifolds and up pipes have proven to work fine in trucks making upwards of 7-900hp according to the Duramax racers. But for boats, performance isn't our main concern, it's heat and legality issues. According to a 2008 USCG Marine Safety Alert modifying powertrain with turbo charger applications had led to vessel losses and injures in reported incidents. Report cited failure to comply with correct 46 CFR 182.430 - engine exhaust pipe installation rules. Along with failure to properly submit documentation for plan review "Guidance for Repowering Vessels Inspected Under 46 CFR Subchapter T" which right off I don't know how that works with the personal DIY builds.. Maybe someone can update us on that rule.

While explosion is the main concern with marine gas engines, fires related to high surface temps are the concern with anything diesel or kero powered. As some recent turbine powered burn downs have proven, high surfaces temps and diesel fuel don't mix well. Diesel can flash off when in contact with anything above 450F, like piece of exhaust pipe. While I've read there is a USCG 200F engine surface temp limit, I couldn't find that rule to quote right off either. But here are the main ones I feel we should be most concerned with.

• 46 CFR 177.970 - Protection against hot piping.
  Piping, including valves, pipe fittings and flanges, conveying vapor, gas, or liquid, the temperature of which exceeds 65.5 °C (150 °F), must be suitably insulated where necessary to prevent injuries.
• 46 CFR 182.430 - Engine exhaust pipe installation.
  *Provide exhaust system insulation between the point of cooling water injection and the engine manifold.
  *An exhaust installation subject to pressures in excess of 105 kPa (15 psig) gauge or having exhaust pipes passing through living or working spaces must meet the material requirements of part 56 of subchapter F (Marine Engineering) of this chapter.
  *Provide the proper material to be used in the exhaust piping. It must be Schedule 80 steel or corrosion resistant.

The original Duramax marinizatoin boat came equipped with wrapped exhaust, up pipes and turbo, along with a water cooled T4 turbo pedestal. While I made a lot of changes like different manifolds and extra wrapping to cut engine bay temps, the overall design remained the same. Factory style exhaust from heads to the turbo, water cooled from turbo though the transom.

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That setup worked ok I guess, but the new owner had a slight issue after changing a fuel filter that he needed resolved with a fire extinguisher.... I'll spare ya the pics, but just say she flashed off some excess fuel when he left the dock and quick thinking saved the boat.

Choices for full USCG approved exhaust wraps range from custom fit covers like these PPE Fabric Heat Shield Blankets and Inconel Heat Shields, to build your own Marine Exhaust Insulation kits from heatshieldproducts.com. Those options will run ya between $1000 to $2500 a set.

Next up I'll cover the water jacked options like posted Hoodoo's custom manifolds and up pipes show above. But one piece you will most likely have to cover due to very limited marine choices is the turbo. Luckily there is plenty of affordable nice custom made thermal shields on the market to fit any turbo option.

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No option for water cooled turbos for these engines?

Water cooled turbos yes. The stock unit have a water cooled center section. Water cooled exhaust housings is limited to what's out there from existing marine engine manufactures.

Here is the only one I've seen setup with full water cooled housing. Is an LB7 engine, and I have no idea who's it is or who built it. Nice headers though...

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No source that I know of, Innovation uses a cover like your pic's and their parts guy says he has no supplier.
The background in that pic looks like their parking lot though.