0411 swap + boost?

[The_Family_Tahoe]

Since you're going that far in, I personally would go with a Terminator X Max. From what I hear they're easier to work with. For the intake manifold, have you considered a traditional squarebore manifold with a throttle body?

Yes. The Holley Terminator Stealth x Max on a performer rpm air gap intake manifold seems like it might make more low end torque than the Holley port injection intake manifold linked above.
It seems like I'd be going backwards though if I swap to a throttle body type injection because these trucks, after 1995, came with port injection. It sure looks like it would be easier to assemble though, just to bolt on the throttle body vs a throttle body and separate injectors and regulator. I have read on some forums the standalone throttle body units like the stealth can have trouble working correctly on a dual plane intake manifold. I have searched around the web about getting an RPM Air Gap converted to allow port injection. The only place I could find was asking upwards of $800 and that was some time ago. It's probably more expensive now.
I've also considered TPI but saw some photos where the throttle body on those is too far forward and starts to interfere with the accessory drive requiring even more modification.

 

[The_Family_Tahoe]

You're probably aware that the stock block is not going to make much more than 500 hp without some bottom end upgrades. It's highly unlikely your Tahoe came with 4-bolt mains, but that's probably better because at that power level you're going to want splayed bolts and a girdle.

Right. RPM kills connecting rods and rod bolts while boost + detonation kills pistons. I've never broken a crankshaft under power, though.

I intend to do this in two primary phases.
The first phase will have two parts:
Part 1 is getting control of the fuel and spark with an aftermarket controller and making sure everything like gauges, abs, and climate control still function like they should.
Part 2 of phase 1 is adding the turbo to the stock motor and tuning it on a low boost setting
The second phase will run concurrently to the first phase starting at part 2. During this phase I'll build a super mild small block that can hold a reasonable level of boost and couple it with 4l80 or 6l80 and make the swap

 

[RDF1]

Holley EFI 300-263 Holley EFI SBC 4150 Single Plane Fuel Injection Intake Manifold - Chevy Small Block V8 with L31 Vortec cylinder heads

The new single plane EFI (Electronic Fuel Injection) intake manifold is designed to provide a broad RPM powerband for high-performance street/strip engine applications to a maximum engine speed of 7500 RPM. The manifold is designed to work with 4150 Style Throttle body EFI systems like the...

www.holley.com

Holley EFI 112-588 Universal 4BBL 1000CFM Throttle Body

Holley's new 1000 CFM Throttle Body shares the same air entry area design that powers every NASCAR Sprint Cup Series™ car! The throttle body features integrated throttle position, idle air control and intake air temperature sensors, Ford and GM transmission kick down levers as well as all...

www.holley.com

Holley EFI 522-768X Terminator X Performance Fuel Injectors - Set of Eight

Terminator X High Impedance Fuel Injectors feature a precision lapped disc valve, high-quality brass windings, and high-temp o-rings. These injectors provide excellent linearity with no discernible "bounce" at low pulse widths as commonly found in other injectors. With a wide variety of fuel...

www.holley.com

 

[RDF1]

Holley EFI 554-153 Holley EFI Terminator X Max - Service ECU

These standalone Terminator X ECU's (Electronic Control Unit) are intended to be used as service components for your Terminator X EFI installation. The Terminator X ECU features real-time fuel learn, high impedance injector drivers, an integrated 1bar MAP sensor, and 4 programmable inputs and...

www.holley.com

Holley EFI 558-126 Unterminated 15' Flying Lead Main Harness

The unterminated main harness comes with both J1A and J1B connectors full terminated with 15' of flying lead wiring.

www.holley.com

Holley EFI 558-499 Terminator X Max GM 6L80/90 Transmission Kits

Add GM 6L80/90E transmission control to any existing vehicle utilizing a Terminator X Max ECU. A departure from traditional Holley EFI transmission control, the Terminator X Max ECU allows the ability to use 2007+ GM 6L80E and 6L90E transmissions by communicating via CAN with the internal TCM...

www.holley.com

 

[RDF1]

How about those parts?
That intake and throttle body would get you Port injection.


ECU, Wiring, TCM control in 2nd post.

Best part of the holley is how advanced or plain jane you want to go with the control. When you get around to doing the turbo setup run the absolute minimum Wastegate spring so you can run as little boost as possible and use the holley to raise boost as needed.

 

[The_Family_Tahoe]

How about those parts?
That intake and throttle body would get you Port injection.


ECU, Wiring, TCM control in 2nd post.

Best part of the holley is how advanced or plain jane you want to go with the control. When you get around to doing the turbo setup run the absolute minimum Wastegate spring so you can run as little boost as possible and use the holley to raise boost as needed.

Thanks for the links!
Holley seems to have dominated the efi aftermarket. It's good to read another endorsement of the engine management systems.
My struggle is the intake manifold. Mercruiser intakes are iron, heavy, and expensive. I have concerns about the Holley intake linked here, being a single plane, hurting the low end torque. The other readily available port injection units, like the stealth ram, ramjet, proflo, and TPI, look like the throttle body inlet interferes with the accessory drive. I've seen where fabricators move the AC compressor over to the driver side with a piece of steel plate for clearance on those setups, but it seems like the best option would be a dual plane intake configured for port injection, just like the single plane linked here. The only option I've found for a dual plane port injection manifold is to have a Performer RPM Air Gap configured for fuel injection.
What if I used the Stealth Ram Base for port injection and used a single carb top on it with the throttle body? This would provide longer intake runners vs the single plane and still allow for port injection.

 

[RDF1]

Yea that was the first intake manifold i found. Im not well versed on the older SBC's as 99% of the stuff i work on is LSx.
Holley makes some really cool stuff tho. I use Terminator x max or Dominator ECU's in everything i build or work on.

That 4 barrel Throttle body i linked above works very good too. used one on a 72? transam with the factory shaker hood and incorperted the shaker to the TB and turned out very nice. Used a progressive linkage on the TB so it drove around nice and smooth and at 40-50% throttle the secondarys started opening.

Since you havent gotten deep in the pocket book yet, why not just LS swap it and have everything you would need? Wouldnt have to go thru the trouble of throwing money at the bottom end and just needs a cam, springs, and pushrods.

 

[Erik the Awful]

I have concerns about the Holley intake linked here, being a single plane, hurting the low end torque.

From everything I've read, that's not an issue with port injection. Single plane intakes dominate everywhere with port fueling.

Carburetors and throttle body injection prefer dual plane intakes at the low end.

 

[The_Family_Tahoe]

Since you havent gotten deep in the pocket book yet, why not just LS swap it and have everything you would need? Wouldnt have to go thru the trouble of throwing money at the bottom end and just needs a cam, springs, and pushrods.

I agree with what you're saying. I just don't want to LS swap it. I may change my mind further down the road. I think a gen I small block can make good torque and power but not as much peak power as a comparable LS of the same displacement and cam timing. This particular build is for driveability not all out maximum power and at the moment I'm still of the mindset I can do this with a Gen I and have a really nice combination.

 

[RDF1]

I look at the money aspect of it.
I towed with a turbo 6.0 for years and couldnt have been happier. 6-8psi at 1800rpms and it chugged along like it didnt care.