2002 Lightning Turbo Build

[08SGT1234]

I know this isn’t a Shelby or even a Mustang, but I thought it would be cool to share a freelance build my youngest son has taken on. He’s building a custom turbo kit on a 2002 Lightning for my oldest sons neighbor.

Here’s a list of the mod’s the truck started with:

- Built Engine; fully stud heads and mains by Piedmont Custom Motorsports, Raleigh NC
- Bored .020 over
- TrickFlow 44cc heads
- Crane Stage 2 S/C cams
- CompCam Stage 3 springs
- Fully built trans and rear end by PCM

New Parts:
- 76 CompTurbo CT4 Triple ball bearing wheel water/oil cooled
- 46mm Precision Turbo waste gate
- 50mm Turbo Smart BOV
- ProM racing 4" maf cal to 80lb injectors
- Custom built 90mm TB (Infiniti Q45)
- Custom built upper plenum by Eric Bishop (TurboSquirrel Customs)
- Custom built stainless steel headers, up and down pipes by TurboSquirrel Customs

Enjoy…….

Parts:
76 CompTurbo CT4 Triple ball bearing turbo billet wheel water/oil cooled & miscellaneous parts:

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Parts/IMG_20120710_162836.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Parts/IMG_20120710_162953.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Parts/IMG_20120710_163005.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Parts/IMG_20120712_181223.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Parts/2012-10-099515-38-5895301.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/DSCN3865.jpg

Start of fabrication:

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Build/DSCN3662.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Build/DSCN3663.jpg

Electric fan conversion, needed to make some room

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Build/DSCN3668.jpg

[08SGT1234]

Custom Plenum:

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Plenum/DSCN3677.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Plenum/DSCN3771.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Plenum/DSCN3775.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Plenum/DSCN3860.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Plenum/2012-12-039516-00-0295838.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Plenum/DSCN3777.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Plenum/DSCN3860.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Plenum/DSCN3781.jpg

Custom mounting of the IAC:

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Plenum/DSCN3856.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Plenum/Resampled952012-12-209509-59-2695456.jpg

Throttle cable bracket:

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Plenum/Resampled952012-12-209509-58-5895243.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Plenum/Resampled952012-12-209509-59-3495123.jpg

Custom intake tube:

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Intake/Resampled952012-12-109520-25-0595927.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Intake/Resampled952012-12-109520-26-359512_2.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Intake/Resampled952012-12-109520-32-2895980.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Intake/2012-12-109520-32-159589.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Intake/2012-12-109520-34-3395649.jpg

[08SGT1234]

Custom headers & turbo mount:

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/2012-11-269521-40-259529.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/IMG_20121022_122350.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/IMG_20121022_122358.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/Resampled952012-10-239516-14-0095616.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/Resampled952012-10-259512-26-1695988.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/DSCN3799.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/DSCN3791.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/DSCN3798.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/2012-11-269521-39-5895626.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/2012-11-249516-07-3195437.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/2012-11-259517-21-0695615.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/2012-11-259517-21-2595250.jpg

[08SGT1234]

Custom headers & turbo mount part 2:

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/2012-11-289518-03-4995144.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/2012-11-289518-03-4395725.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/2012-11-289518-04-1595636.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/2012-11-289518-14-0695711.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/DSCN3838.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/2012-12-109520-23-5495797.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/2012-12-039521-18-5895932.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/2012-12-039521-25-0895601.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/Resampled952012-11-289512-11-0395770.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/Resampled952012-11-269521-39-3895780_2.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/Resampled952012-11-269521-40-0995128.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Headers/Resampled952012-11-269521-40-4095312.jpg

[08SGT1234]

Miscellaneous assembly pic’s:

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/Resampled952012-10-259512-27-2595877.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/DSCN3837-1.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/DSCN3803.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/2012-12-109520-32-009578.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/2012-12-109520-24-2095608.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/IMG_20121202_105141.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/IMG_20121202_103432.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/DSCN3850.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/DSCN3849.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/DSCN3843.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/DSCN3840.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/DSCN3841.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/IMG_20121222_155348.jpg

http://i259.photobucket.com/albums/hh283/08SGT1234/Turbo%20Lightning/IMG_20121222_155401.jpg

[Joe G]

Nice welds!

[08SGT1234]

He's self-taught... He pissed off his former boss because he could weld better than him after he went to a tech school for 2 years to learn how too.

[Gr8snkbite]

:wtg:

Sweet Carl.....look forward to updates......and very nice beads......:grin:

[Tommy Gun]

Very nice welds :wtg:

Is everything TIG welded?

[08SGT1234]

Is everything TIG welded?

Yes....


We got it running last night and finished putting it back together, I'll try and get a video up this weekend some time.. It will be heading to the speedshop on Monday for the finial tune.

[Carnut]

Man, that is a ton of skilled work. Looks great.

[68fastback]

Yeah, that is simply awesome ...from approach to workmanship :wtg:

:bowdown:

[mustang loco]

Wow,your son as great skills for sure,great project and work!!

[08SGT1234]

Here's a teaser video right after we got the wiring finished.....

http://youtu.be/YokjiuPBu_w
(sorry the sound is not synced)

I hope to get a video after it was put back together. It's not scheduled for the dyno-tune until next week sometime, the speedshop is backed up because of the holiday's.

[68fastback]

Sweet! I'd guess he's going to duct the turbo intake to fresh air?

[08SGT1234]

Not really, he ordered a K&N filter to place over the inlet...... I went to Lowes a bought a piece of stainless mesh screen to put over the turbo intake for now so not to suckin' any debris.

[08SGT1234]

UPDATE: Break in tune test drive.....

http://www.youtube.com/watch?v=slMeZZkDMxI&feature=youtu.be

[68fastback]

Sweet!! :wtg:

[The Bone]

That truck sounds nice. What a lot of work. Did you wrap the exhaust to keep the heat in the exhaust?

[08SGT1234]

That truck sounds nice. What a lot of work. Did you wrap the exhaust to keep the heat in the exhaust?

Basically he's working on the owners budget, future plans included pulling it apart to ceramic coat the headers, wrap the "hot side" and powder coating the plenum and intake tube. The goal was to get it built and tuned first, then take care of the cosmetics.

[The Bone]

It does look beautiful.Lots of work to build headers and have them look that nice