Jay Miller - Turbo: Real World High-Performance Turbocharger Systems

Copyright 2008 by Jay K. Miller

All rights reserved. All text and photographs in this publication are the property of the author, unless otherwise noted or credited. It is unlawful to reproduce or copy in any way resell, or redistribute this information without the express written permission of the publisher.

All text, photographs, drawings, and other artwork (hereafter referred to as information) contained in this publication is sold without any warranty as to its usability or performance. In all cases, original manufacturers recommendations, procedures, and instructions supersede and take precedence over descriptions herein. Specific component design and mechanical procedures and the qualifications of individual readers are beyond the control of the publisher, therefore the publisher disclaims all liability, either expressed or implied, for use of the information in this publication. All risk for its use is entirely assumed by the purchaser/user. In no event will CarTech, Inc., or the author, be liable for any indirect, special, or consequential damages, including but not limited to personal injury or any other damages, arising out of the use or misuse of any information in this publication.

This book is an independent publication, and the author(s) and/or publisher thereof are not in any way associated with, and are not authorized to act on behalf of, any of the manufacturers included in this book. All registered trademarks are the property of their owners. The publisher reserves the right to revise this publication or change its content from time to time without obligation to notify any persons of such revisions or changes.

All trademarks, trade names, model names and numbers, and other product designations referred to herein are the property of their respective owners and are used solely for identification purposes. This work is a publication of CarTech, Inc. and has not been licensed, approved, sponsored or endorsed by any other person or entity.

Edited by: Travis Thompson
Designed by: Monica Bahr

ISBN-13 978-1-61325-017-4

CarTech
39966 Grand Avenue
North Branch, MN 55056
Telephone (651) 277-1200 (800) 551-4754 Fax: (651) 277-1203
www.cartechbooks.com

Cover Photo by Travis Thompson

CONTENTS

This book covers a broad base from the most elemental parts of turbocharging and how a turbo works to some fairly in-depth aspects of turbocharger technology. It touches on a few difficult concepts intending to give the average reader an above-average insight into various aspects of the subject. A future expansion of this material is tentatively planned, however. I invite interested persons to contact me with areas of interest and concern so that any future expansion of material covered can be directed in those specific areas, thereby maximizing the value of the research and information to be added in the future. Please contact me at:

This is not a general correspondence address but a utility address used to compile areas of interest and comments for the benefit of all.

I would like to acknowledge the assistance of those who have helped make this book possible through their input and product photography. Specifically, Gale Banks of Gale Banks Engineering, Tracie Parker, Brian Regnier, and Steve Arnold of Honeywell Turbo Technologies, John Concialdi of AEM, John Todd with BD Power, Harry Hruska of PrecisionTurbo and Engine, Dan Strezo of DLS Engine Development, Kenny Taylor of Cummins Turbo Technologies, Thom Miles of BorgWarner Turbo Systems, Brad Lewis of Turbonetics, Diesel Injection Service Company, Inc., Columbus Diesel Supply, Vibrant Performance, Matly Digital Solutions, Linn Begley, Robert Bob Keller, and an extra special thanks to Nate Clark for having the time and patience to teach a young man all about the world of high-performance engines.

Author Jay K. Miller speaks frequently on the subject of turbochargers

Jay Miller was born and raised in Indianapolis, Indiana. Growing up in Indy during the 1950s, 60s, and 70s had a powerful impact on young men. Known as the Racing Capital of the World, Indianapolis was a hard place to escape heavy involvement in motorsports with what may be the finest oval track (The Indianapolis Motor Speedway) and the finest drag strip (Indianapolis Raceway Park) in America right at your doorstep.

Jays first involvement in racing came around the age of 12 when he helped with engine assembly of an NHRA C/GAS Camaro campaigned by his brother-in-law, Nate Clark. That experience lead to numerous street car projects and finally into building and campaigning his own NHRA Super Pro Camaro with partner Phil Love, which appeared on the cover of Popular Hot Rodding magazine, and which Super Chevy magazine called one of the most consistent money winners in the mid west.

Miller is a graduate of Indiana State Universitys Automotive Technology Department in Terre Haute, Indiana. While attending Indiana State, he worked at building and racing his earliest cars. He also was president of the student chapter of the Society of Automotive Engineers. While on a fieldtrip with the chapter, he toured the engineering facility of Schwitzer, the then Indianapolis based turbocharger manufacturer. That led to a career in turbochargers at Schwitzer that began straight out of college.

After 11 months in the Engineering Laboratory, Jay was promoted to a sales engineering position and ultimately to the position of national sales manager for Schwitzers turbocharger aftermarket. From there he went on to become the executive vice president and general manager of Gale Banks Engineering in Azusa, California. Gale Banks Engineering is perhaps most noted for its turbocharger application engineering expertise and designing beauty into turbo systems that have powered several land speed record vehicles, and whose commercial products are applied to street vehicles all across America.

Today, Jay Miller is the director of sales and marketing for Diesel Injection Service Company, Inc., based in Louisville, Kentucky. In addition to specializing in diesel fuel injection, Diesel Injection Service Company is also the largest turbocharger distributor in North America. Miller frequently speaks publicly on the subject of turbochargers and has published numerous articles in trade publications. Besides his hobbies of collecting 70s vintage stereo equipment, Lionel trains, and watching his daughter Kimberly saddle-up her favorite 4-legged, 1-horsepower ride, Jay is founder and co-host of DieselRadio, a tech-talk show that is web cast from the archives at www.dieselradio.com.