A '40 would not be a bad idea and would allow more fuel.

I'd bet it has a air to water cooler.

 

A hx40 should be more than you need, you probably won't be able to spool it without some fuel. An hx35 flows a lot more air than a H1C. If you can find a WH1C like I have it is just an updated H1C meaning it flows like a 35 and uses a 12cm2 housing. My truck stock would not even get close to 1000* towing 10k. and my truck weighs a little less then 8k. You need more fuel if you plan to run a 40. You could always rebuild your 35 and if it gets hot on a test run buy a 14wg housing. If you add any fuel you can always get a 40 cold side on your 35 (a hybrid).

If you can find a intake horn that will fit your truck, it will help cool, not give as much hp as they say but everyone I have heard use them has cooled their egts by at least 100*. Theirs plenty to do to your motor, its all up to how fast you want to go and how much money you have to put into it.

Remember your truck only has 160hp... My truck had 160/400 stock and with my fuel plate and a boost fitting I only see 31 psi but I'm at 220/590 now. Wow that extra hp and tq made all the difference in the world!!! I wouldn't worry about over spooling your bus with a 12cm wg housing, its WASTEGATED!!! You set it at 5psi lower than what you want to hit max and no worries. Stock they are set around 18-20 psi... Have fun with it!!

Jered

Oh and yes my old truck was a 91 non ic 16cm housing 5spd. So I have driven both and felt the difference in a H1C and a WH1C

 

I looked at the housing a little closer and it IS a 18.5 cm housing. I just assumed it was a 21 cm housing because it is on a bus. I think I will just leave the turbo alone at this point and play with the pump a little. After all it is a school bus.

I do like the idea of running the HX35, especially since I have it sitting around, and if it gets too hot I can get a bigger housing or just switch back. Once again, my main concern is my egt's when I am cruising down the road at 3,000 rpms and pulling a full bus with a trailer behind it.

By the way, the bus is an automatic that is non-intercooled. I might try looking into fitting a second gen intercooler on here somewhere, someday.

Thanks again for all the help and suggestions. I'll keep ya'll posted as I keep working, it has been a little cold here which has hindered my work.

 

Don't waste time with a pickup truck intercooler, get one from a medium duty truck. I'm sure you can find room for a good sized one.

 

You would think I have quite a bit of room but I actually don't. From the radiator to the grill I have about 3 inches. Routing the tubing is a whole other problem.