The BOMB'rs new set of lungs....

[DoghouseDiesel]

Finished up the initial fab work today.....

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide6-64.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide7-56.jpg

[2007 5.9]

Rich...am I seeing this right...

Your primary is on the manifold which drives the secondary??

Why the change?? What's the benefit?

[DoghouseDiesel]

Rich...am I seeing this right...

Your primary is on the manifold which drives the secondary??

Why the change?? What's the benefit?

Yup, you are seeing that right....

The top one is a Garrett 4718 and the bottom is a BW S475.

[2007 5.9]

Lucy!!!

You got some splaining to do!!!

[DoghouseDiesel]

Lucy!!!

You got some splaining to do!!!

:mrgreen:

[DoghouseDiesel]

Testing a theory I have.....hopefully to the tune of around 1200 hp.

Ya know ya like that piping job...

[2007 5.9]

Testing a theory I have.....hopefully to the tune of around 1200 hp.

Ya know ya like that piping job...

Piping is sweet!!!

I think I can smell your theory...I've pondered that many times but took the norm for a given.

I think it'll work well

[DoghouseDiesel]

Yeah, I'm not going with the norm on this one.

Why feed a fire hose with a garden hose, know what I mean.

I'm gonna toss the big heat at that 88 first and not choke the motor.

[2007 5.9]

Sweet...very curious to the result.

I expect great things from you rich!!

[DoghouseDiesel]

I expect great things from you rich!!


I'm glad you do.....I expect something to blow up....

:anitoof:

[DoghouseDiesel]

I'll let ya know what I find.

There's a few things I'm looking at with this.

[FUBAR]

Definitely watching this one...curious to see how the tuning plays out. Les's got me dreaming 'triples' now.

[2007 5.9]

Mmmmm triples....mmmmm

[DoghouseDiesel]

Mmmmm triples....mmmmm

Smack it up, flip it, rub it down......:mrgreen:

[DoghouseDiesel]

Definitely watching this one...curious to see how the tuning plays out. Les's got me dreaming 'triples' now.

This will be a whole new tune for this configuration.

Not just because of the turbos, but I'm also changing to a larger cam, a set of Exergy injectors to flow 400 lph at 3000 uS at 26k psi, both pumps are getting worked over, and I'm waiting on the head to come back from the machine shop so I can cut the intake plenum off and put one of Shane's XHP side draft manifolds on and port / polish it, as well as change all the intake valves over to exhaust valves.

[2007 5.9]

Are you going with the 143* marine nozzles or staying with the factory 124* ones?

Who's cam and what size??

And I assume Todd is "working" your pumps...lol!!!

[L31Sleeper]

I saw this "unconventional" set up and had to chime in. I really don't think the compressors will care either way, but I definitely see the small turbine chocking the larger turbine unless you install a waste gate between the turbines. If you place a 60mm waste gate in that 90* elbow, set to open when the small turbo tops out the large turbo will think it's dumping into atmosphere.

trying to help
-Justin

[DoghouseDiesel]

Justin,

That's already part of the plan.

What I want to do first is see just how much back pressure is in the hot pipe and how it effects the pressure ratios.

That small 1/8 NPT port you see on the hot pipe is for the fitting for the drive pressure. The Steed Speed manifold is the competition version, so there are already 6 ports tapped into it for various sensors.

I already up'd the size of the turbine housing that was on the 475 from a 1.10 to 1.25, so it really shouldn't present a problem for the Garrett. Also, both turbine housing and the hot pipe will be getting ceramic coated inside and out. I already have a blanket for the Garrett's turbo, so all that heat is going in the right direction.

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide6-62.jpg

Here's the reason I don't see much of an issue....

In a conventional setup, with the small tubo on top, you're already choking the engine at the manifold when it has to pass through what is usually a T3 divided flange. This already causes a pressure drop that effects the, what would be the larger turbo down stream, which usually has a T4 or T6 flange and larger turbine. The other effect is the drop in exhaust gas temp that drops significantly after going through the small charger. This also effects the down stream charger.

In this setup, all the pressure and heat is hitting that big turbine first through a T6 flange and a 1.23 housing. Now even though the size of the turbine is pretty large, the turbine wheel is a 93 with an 82 trim, so the exducer is only about 3.5". That dumps into a T4 flanged, 1.25 turbine housing. So, technically, it has enough flow to not back up and dead head the Garrett.

But yes, a 60mm gate is part of the plan, but I want to do some measuring before we go that route. And yes, you are correct that it would be like dump straight into a down pipe, but I want to measure that actual pressure first.

[DoghouseDiesel]

And I assume Todd is "working" your pumps...lol!!!

You know it brotha!

Only the most technically skilled, knowledgeable, and competent hands and minds will touch those pumps. Who better to send them to....

:mrgreen:

If my sarcasm didn't shine through bright enough, just follow THIS LINK (http://www.cumminsforum.com/forum/3rd-gen-performance-parts-discussion/500600-cp3-questions-coming-head.html) and you'll see what we're talking about..

[L31Sleeper]

How can you take pressure measurements with all that heat ?

-Justin

[2007 5.9]

About 10' of copper tubing coiled creates a heat sink so you can then plumb a sensor in line to measure drive pressure.

[GMPX]

It just screams masses of power, love it.

[2006Cummins]

I had been think of a setup like that too. The more more I thought about it, the more it seemed like it just might work. Thanks for putting the theory to life! Looking forward to seeing how it turns out.

Mike

[DoghouseDiesel]

How can you take pressure measurements with all that heat ?

-Justin

Just like this....

You use the copper line for the first 10' of tube, then use some fine steel wool to act as a filter inside of a 1/8 NPT female - female connector and then the plastic tubing can get run to your gauge or an electronic pressure sensor can be conencted to it.

This is the setup on my previous turbos.....

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide5-65.jpg

I only use this for tuning purposes, after that I either remove the line and put a 1/8 NPT pipe plug in the hole or put an EGT probe in there.

[flat_lander]

I'm suffering from some serious turbo envy! My bigger <much smaller than yours> single upgrade is looking pretty inferior. However it looks very exciting.

[DoghouseDiesel]

Started to shine up the hot side before I send them out to coating. Obviously, they won't be shiny after coating, but I wanted the cast parting lines gone and for them to be fairly smooth when finished. I still need to do the "small" turbine housing. The whole hot side will be a grey ceramic, inside and out. The cold side will be powder coated black, inluding the compressor housings. Should match the rest of the motor and truck nicely.

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide1-198.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide2-197.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide3-154.jpg

[DoghouseDiesel]

And yes, everything on this setup is one off.....

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide4-110.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide5-84.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide2-192.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide1-197.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide2-196.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide3-153.jpg

http://i929.photobucket.com/albums/ad137/BigSwole1255/Diesel%20Misc%20Pics/c3b2109b.jpg

http://i929.photobucket.com/albums/ad137/BigSwole1255/Diesel%20Misc%20Pics/bac7b0fd.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide4-111.jpg

[FUBAR]

One off me one!! Lol. Looks good man. Got any type of goal in my in having the thing back together and running?

[DoghouseDiesel]

I have the pumps, injectors and head out right now.

I'm bringing the turbos in to get fresh rebuilds on them today.

I'm planning on another month before I have it all back together.

It'll have enough fuel and air for 1200 HP, but I'm gonna run it at around 1000 to the tires so it's not constantly tearing up transmissions.

[FUBAR]

1,000, 1,200, 1,500, meh, what's the difference...who's counting anyways? Lmao

[06redram]

1,000, 1,200, 1,500, meh, what's the difference...who's counting anyways? Lmao

It's all about your foot control; LOL

[DoghouseDiesel]

No, sometimes it's about intelligently engineering the system as a whole, both in parts and tuning.

And then again, sometimes it's about foot control....

:mrgreen:

[L31Sleeper]

One off me one!! Lol. Looks good man. Got any type of goal in my in having the thing back together and running?

If enough people ask that, it's called production !!!:banana:

-Justin

[06redram]

No, sometimes it's about intelligently engineering the system as a whole, both in parts and tuning.

And then again, sometimes it's about foot control....

:mrgreen:

You are so right

[nonnieselman]

Is that fella using a 1/8" filler rod? or does the picture just make it look big?


I hope this setup works out for ya, it looks insane!!

[DoghouseDiesel]

Exergy got the green light for the new fire hoses today.

:muahaha:

[2007 5.9]

Rich...are you doing the 143* nozzles or the 124* ones??

Very curious...

[DoghouseDiesel]

143* SAC nozzles.

As big as they are, my damn pressure tables are going to look more like a 6.7 tune than a 5.9 tune.

[2007 5.9]

Let me know how your timing tables like the wide spray angle in the wide bowls...lol

[DoghouseDiesel]

Let me know how your timing tables like the wide spray angle in the wide bowls...lol

Yeah, the timing is definitely going to have to come back a few degrees.

[DoghouseDiesel]

Time to start slamming this sucker back together.....I'm about tired of looking at the damn parking lot ornament sitting out there.

Cleaned up most of the parts today. Last big items that I need to get cleaned up are the rods, pistons and cam.

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide1-199.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide2-198.jpg

Unlike some other stuff that you're not too concerned about being really accurate with when it comes to fasteners and clearances, the rotating assembly isn't one of those. Most automotive torque wrenches need to be within 5%. My buddy Drew takes care of us and gets our torque wrenches to aircraft spec when it comes to the ones we use for rotating assemblies.

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide3-155.jpg

Now, for final assembly we need to make a last check of the clearances between the main journals and the bearings. .002" is the final goal. A little plastigauge is your friend at this step....

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide4-112.jpg

And, we're good. .002" across the board....

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide5-86.jpg

Now, for those that have never dropped a crank in, you can spend the better part of an afternoon getting a crank setup correctly. You normally do the crank torque sequence 3 times. First time, everything gets tightened down starting at 50 ft/lbs and going up 20 ft/lbs at a time to 125 ft/lbs. After this, you loosen the mains back up and do your final clearance check with the plastigauge. Again, back through the torque sequence. then you break it all loose again and check your clearance. If everything is good, you lift the crank out, lube up the main bearings LIBERALLY and set the crank back in. Now you do your final torque sequence and she's ready for the reast of the rotating assembly.

LOTS AND LOTS OF QUALITY ASSEMBLY LUBE! You really can't use enough of this. Lubes are cheap, engines arean't.

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide6-65.jpg

Now, with that, I'm done for tonight. I'll do the rest of the rotating assembly tomorrow.

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Slide7-57.jpg

[Tobin]

Interested to see how this runs.

If you want to get crazy with the torque, throw a dial indicator on the main studs and measure the actual stretch.

Tobin

[DoghouseDiesel]

Here's a few more pics of my debotchery on this motor.....

http://i288.photobucket.com/albums/ll189/Cumminalong/f2ec45f8.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/fe6abc7f.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/79b5e73d.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/1268adf8.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/4d296617.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/292f9bbd.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/1619388f.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/628c058b.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/ff515228.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/b2c8e82a.jpg

[DoghouseDiesel]

Here are the new fire hoses.....

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/InjectorFlowSheet.jpg

[DoghouseDiesel]

In between everything else going, had to pick up a new trailer for the shop. Figured it was time for something a little more fitting of the tow rig....

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/8b6b748a.jpg

[DoghouseDiesel]

Here's the intake manifold that'll be getting bolted on this week, as soon as I finish up the mill work on the head.

This is just set in place after I made the rough cuts.

http://i288.photobucket.com/albums/ll189/Cumminalong/456841cd.jpg

[Tobin]

Looks good. I want that trailer.

Tobin

[06redram]

👍👍👍

[Smoken Gun]

Awesome build!! I am eager to see how everything performs.

Just curious, why no build thread on CompD?

[DoghouseDiesel]

Alright, the head is just about finished.

Finished up final alignment and drilling and tapping the mountng holes, now I need to pick up some nice stainless cap heads to actually mount the manifold. The bolts pictured are just to test alignment, you can't actually clear regular hex heads with this manifold.

The only thing I need to do is mill down the riser for the fuel rail slightly as, after measuring over and over for final placement, I had to raise the location of the manifold so the existing bolt holes for the second CP3 would be in the correct location and alignment and not destroy the belt in short order. This in turn raised the rail and tookmthe lines slightly out of alignment. Easy fix, a few thou' off the riser and we'll be all set.

http://i288.photobucket.com/albums/ll189/Cumminalong/60550b22.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/d3241d51.jpg

[DoghouseDiesel]

Awesome build!! I am eager to see how everything performs.

Just curious, why no build thread on CompD?

Being as polite as I can, I have no interest in CompD what so ever.

I'll leave it at that.

[Smoken Gun]

Being as polite as I can, I have no interest in CompD what so ever.

I'll leave it at that. Understood.

[05chevy]

Thats some nice work you got going on there. Ready to see it run

[DoghouseDiesel]

Okay, got the rail and lines all lined up. Had to take .100" off the riser to bring the lines down a bit to connect without stressing them.


I'll put some fresh lines and connecting tubes on before it actually goes back on the truck, but otherwise we're about ready to drop the head off one more time for a final check.


After I took this all back apart, I capped off all the fittings on the rail and put it through the bead blaster to get that dull azz coating off. After that it got painted to match everything else. Don't want any little raggedy looking parts under there.


http://i288.photobucket.com/albums/ll189/Cumminalong/13fc3509.jpg

[FUBAR]

Where's 'slobbery/drooling' smiley??

[DoghouseDiesel]

Gettin' close to wrapping this sucker up. Then the fun starts......dialing this thing in.

http://i288.photobucket.com/albums/ll189/Cumminalong/edddf174.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/46f3afaa.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/Slide2-26.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/Engine.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/3a64dcfa.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/91d151ef.jpg

[Tobin]

No 6.7 rail?

Looks good. Interested to see how the turbo setup works.

Tobin

[DoghouseDiesel]

No 6.7 rail?

Looks good. Interested to see how the turbo setup works.

Tobin

No need for the 6.7 rail. It's all hocus pocus like those modified rails that ole slim shady sells.

No reason to run a larger rail.

[DoghouseDiesel]

Last couple things I needed to button up the motor got here today. New high pressure fuel lines, cross over tubes, and head gasket, so tomorrow I'll have the motor back together and I'll be able to check the PV clearance and make sure that's all good.


If I get that done early enough, I start getting the truck cleaned up a bit and get the engine bay ready to shove this sum beotch back in.


I still have a little work to do on the chargers and I need to lock down the accessory belt routing, but we're getting close.


Once I get the PV clearance confirmed, I'll start going through the pre-start checks. This weekend I finalize the initial tune and then it's "Hold my beer and watch this 'ish, y'all!"

[Dmaxink]

Its been exciting watching your build...can't wait to see it run!:thumbup::D

[DoghouseDiesel]

Alright.....here's todays updates.

http://i288.photobucket.com/albums/ll189/Cumminalong/355f260e.jpg


http://i288.photobucket.com/albums/ll189/Cumminalong/d24add23.jpg


Time to let these 250% over Sexergy's outta the bag....


http://i288.photobucket.com/albums/ll189/Cumminalong/6fa9c89f.jpg


These are the new style crossover tubes compared to the old style....


http://i288.photobucket.com/albums/ll189/Cumminalong/ac39d301.jpg


http://i288.photobucket.com/albums/ll189/Cumminalong/b20098cb.jpg


Injectors and rocker studs in place....


http://i288.photobucket.com/albums/ll189/Cumminalong/222d6b76.jpg


http://i288.photobucket.com/albums/ll189/Cumminalong/62bf096a.jpg


Ready to fuel the fire.....


http://i288.photobucket.com/albums/ll189/Cumminalong/b0498569.jpg


Driver side buttoned up.....


http://i288.photobucket.com/albums/ll189/Cumminalong/d58aeb8c.jpg


Just waiting on the new v-band for the Garrett and we can get 'er dropped back in. Just need to pick up a few more -12 AN fittings for the drain lines and this hooker's ready to go to bed......


http://i288.photobucket.com/albums/ll189/Cumminalong/21538e94.jpg

[FUBAR]

Nice! One word comes to mind when looking at this build..thorough...thoroughly bad a$$!! Okay, two words, so shoot me!

[DoghouseDiesel]

Gettin' closer....


Had to make a new bracket for a lifting provision, being that it fell off with the intake plenum....


http://i288.photobucket.com/albums/ll189/Cumminalong/047937d5.jpg


Moved ole girl up to the shop and started cleaning 'er up a bit. Haven't opened the doors in 4 months so she was a 'lil stale in there. Got the engine bay cleaned up and she's ready to get stuffed...


http://i288.photobucket.com/albums/ll189/Cumminalong/e3dfca84.jpg


And, finished getting the belt routing layed out. I was debating whether or not I was just gonna toss the AC compressor back on there and leave the wiring disconnected, but I decided I'm gonna make a bracket and add another idler pulley. It would just piss me off knowing I left a completely worthless piece on there, even if it weighs like 2 pounds.


I had to throw the idler pulley up top in the lathe and cut the ribs so it has a flat surface surface for the back side of the belt, so that's all I got down after this picture before I called it quits today.


http://i288.photobucket.com/albums/ll189/Cumminalong/95b31987.jpg

[DoghouseDiesel]

Well, she's done.....at least until I get the v-band for the Garrett so we can stuff 'er back in.


Instead of making a bracket and adding another idler pulley, I picked up a 12V belt tensioner and drilled another locator hole. The 12V tensioner pulls in the opposite direction and worked perfect.


The wiring is done. Fuel lines are done. All I have left is making one more bracket to support the 75 and this sumbeotch is ready for some fire.


I also polished up the upper coolant tube. Its stainless so it came out real nice.


http://i288.photobucket.com/albums/ll189/Cumminalong/2e3acfd3.jpg


http://i288.photobucket.com/albums/ll189/Cumminalong/d78c7fe5.jpg


http://i288.photobucket.com/albums/ll189/Cumminalong/72143be1.jpg


Man, I was so dreading having to ugly up this motor with this mess.....


http://i288.photobucket.com/albums/ll189/Cumminalong/f18ed563.jpg


For those that don't know, I have a serious OCD issue with wiring. I asolutely hate seeing wires. The first time I tore this motor out of the truck, it was specifically to clean upmthe wiring. Nothing makes an engine bay look like garbage like a rats nest of wire.


http://i288.photobucket.com/albums/ll189/Cumminalong/f8253072.jpg


http://i288.photobucket.com/albums/ll189/Cumminalong/d4b9221e.jpg


The plan is light 'er off next weekend.

[FUBAR]

Pshh...$10k and a phone call to ii and I can have the same thang...

[DoghouseDiesel]

Pshh...$10k and a phone call to ii and I can have the same thang...

Mmmmm......not so much.

Might get ya a stock short block and head for $10k.

[FUBAR]

Lol..okay, okay. I don't think you could compare anyways. Be like comparing apples to oranges. You got apples and they got sh!t!

[DoghouseDiesel]

Touchdown! Stuffed 'er back in today. I'll get all the running gear back in order this week and finish up all the little BS and light 'er off this weekend if everything goes to plan.

http://i288.photobucket.com/albums/ll189/Cumminalong/59e04729.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/e1516e73.jpg

[DoghouseDiesel]

She's damn near falling together now.


Fresh new converter courtesy of Mr Garmon....


http://i288.photobucket.com/albums/ll189/Cumminalong/e1d03ff1.jpg


Fresh trans also...


http://i288.photobucket.com/albums/ll189/Cumminalong/03f90c7d.jpg


And, this is where I called it quits tonight...


http://i288.photobucket.com/albums/ll189/Cumminalong/82b5b1be.jpg

[GMPX]

For those that don't know, I have a serious OCD issue with wiring. I asolutely hate seeing wires. The first time I tore this motor out of the truck, it was specifically to clean upmthe wiring. Nothing makes an engine bay look like garbage like a rats nest of wire.
Me too Rich, when I was in my 20's I used to work at a film/video production house, we used to wire up racks of equipment (exactly like the photo below), so I now suffer from neat wiring OCD, there is no cure, you'll take it to the grave.

The build is looking great, can't wait to see how the tuning goes.

http://clenmdev.files.wordpress.com/2010/05/img_2149.jpg

[DoghouseDiesel]

Me too Rich, when I was in my 20's I used to work at a film/video production house, we used to wire up racks of equipment (exactly like the photo below), so I now suffer from neat wiring OCD, there is no cure, you'll take it to the grave.

The build is looking great, can't wait to see how the tuning goes.



The tuning is gonna be a monster on this one.

My old injectors were approx 45% over stock and had enough in them for 933 hp without going crazy on rail pressure.

These new ones are 250% over. Without going nuts on the rail pressure (24,500 psi is where I like to max out) or duration, it has enough fuel and air for 1200 hp. With the numbers turned up a bit and running the bottle, it should have enough for 1400 - 1500.

I'm certainly not tuning it that high, as the trans just won't handle that at the trucks weight. Jeff has another big shaft trans waiting if this one takes a crap, but I'd really rather not have the sucker come apart unexpectedly.

Probably going to tune it for 1000 hp on turbo and 1200 on the bottle. That'll keep the motor happy and if I leave the power on the top end of the RPM range and don't try making 2000 ft/lbs at 1400 RPM's, it should hold out okay......for a little while anyways.

[DoghouseDiesel]

Closer and closer......

http://i288.photobucket.com/albums/ll189/Cumminalong/4ae1cde9.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/e5d854e2.jpg

[K80]

This is one of the sexiest builds. Keep up the good work Rich!

[DoghouseDiesel]

Well, here's the not so sexy part.....

I decided to unscrew 6 years worth of wiring, adding crap, splicing, moving, etc.

I hate wires!....I really do.

Spent all day un-F'ing this mess. Now she's a clean sheet of music again. Hell, I think the truck lost 5 lbs just in wire...

http://i288.photobucket.com/albums/ll189/Cumminalong/705ced0d.jpg

[DoghouseDiesel]

Okay, over the last few days, between a stay in the ER this weekend, I've got all the wiring in the truck redone and up tl snuff.

Tomorrow I'll finish the wiring for the fans and water pump and then I can get the cooling system reinstalled and we can light this sucker off.

[06redram]

Hope ur OK

[relay93]

Yep. Glad you are doing better.

[FUBAR]

Just curious, but with all the electrical components you've swapped to such as the fans and pump, etc. Do you fear that maybe it might wig out the TIPM? Speaking from experience where extra electrical accessories have altered the values sent over the CAN-bus system causing the TIPM processor to have a heart attack.

[DoghouseDiesel]

Alright......brought her back to life today....at least electrically.

Got all the wiring done, got the radiator and fans mounted, hit the key and everything went through the checks.

Started going through all the gauges, switches, etc., and everything is working correctly. The default setting turns the pump on and the fans are on the thermostat, but I can turn them off or on as needed, so that'll be nice after runs.

Got the cooling system filled. Man, it fills so much easier with the t-stat gutted and having an electric pump.

Tommorrow we should be able to fire it up. Need to fill the oil and trans, make the oil lines for the turbo drains, charge the batteries for a bit, hook up the exhaust and then we'll bring 'er back to life.

Still need to make the charge pipes, so it won't be "driveable" yet, but at least it'll move under its own power. I'm gonna take off the shock towers, lower ther front of the truck a bit and put some shorter shocks and limiting straps on the front end so it doesn't have so much weight transfer and pull the front tires any more.

But, we're almost there....

http://i288.photobucket.com/albums/ll189/Cumminalong/7DFF1815-8AF8-4961-85FA-54086741F8BE-37542-00001399F318360C.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/BBE43AE3-353D-4D1C-AFC5-1A3CC6BCF9A0-37542-00001399FAE06DE7.jpg

[DoghouseDiesel]

Just curious, but with all the electrical components you've swapped to such as the fans and pump, etc. Do you fear that maybe it might wig out the TIPM? Speaking from experience where extra electrical accessories have altered the values sent over the CAN-bus system causing the TIPM processor to have a heart attack.

I don't power anything from the TIPM. Anything I add has it's own dedicated power source, nothing gets tapped into the TIPM.

I run two main power wires up the frame from the batteries in the back. One is solely for the starter and the other is the stud for the TIPM.

Any accessories are on the stud and not actually on the TIPM.

[DoghouseDiesel]

Well, didn't get to light 'er up today. Had a little SNAFU with the fittings for the oil return lines. I ordered -12 AN to -12 hose ends and I didn't look in the package until today and they were -12 tube ends, so that put us on hold.

The new ones are getting over nighted, so we'll light it up tomorow.

She's all topped off and ready to go otherwise.

http://i288.photobucket.com/albums/ll189/Cumminalong/54EAABC4-4627-4D6D-8503-66827AD6DB37-39439-000014BF7FA080E7.jpg

[DoghouseDiesel]

Game on.....

http://i288.photobucket.com/albums/ll189/Cumminalong/BB057AC5-7C7A-4082-A155-5503FB2EA385-42944-000016EB25926191.mp4

http://i288.photobucket.com/albums/ll189/Cumminalong/E20F44BC-C5BB-48F1-A64D-F33DBADA5507-42944-000016F24C4C86D7.mp4

http://i288.photobucket.com/albums/ll189/Cumminalong/3CC51E60-E2DD-41D5-80BF-7562C618D547-42944-000016F4EB84C420.mp4

[06redram]

Awesome

[codymorri]

Great job Rich! Glad to see her back together and running! :mrgreen:

[DoghouseDiesel]

Okay, here's a much more proper video.

All those links were from the phone at the track last night.

http://www.youtube.com/watch?v=Z650YrmB4Co&hd=1

[FUBAR]

Smoooothh....Keith Stone Smooooth!

[jp-4.5]

Reading thru this thread is amazing..

As much as this build is awesome.. Some of the empty shells around the shop could be incredible..
Vette.. Camino..

Anxious to see how this setup actually drives..

[Smoken Gun]

Hell of a build Rich!! Amazing work! Best of luck at the track with it man!

Also, like JP-4.5 said, that El Camino in the shop background....that thing NEEDS a CR Cummins shoved in it!

[DoghouseDiesel]

Actually, none of those are empty shells, just waiting on their turn for assembly.

The El Camino is a customer that just needed the motor rebuilt. He works for a carnival and they're on the road for months and aren't allowed to take personal vehicles with them. That motor is done and will be going back in shortly.

The '65 is getting a complete overhaul. Engine, trans, suspension, etc. it was all original and needed it bad. We have the 327 back from the machine shop and it'll be up next after we get the El Camino out. The trans is alteady done and all the suspension components are here, they just need to be blasted, painted and new bushings pressed in. We're planning on this one for over the winter. Just too much stuff coming in and out with it being race season. It's one thing after another.

We get some REALLY odd ball stuff in as well. Once people know that you do machine work and can do more than just hang parts, you start getting some weird crap. But weird crap pays bills and it beats working on 6.0 PSD's. Like we do all the maintenance on Little Ceasars dough rollers. Bearings, tensioners, service the drives and chains, $600 vs $4000 for a new machine, so they're more than happy. We get a steady flow of those. Right now we have 2 of their big azz dough ballers, same kind of stuff, just basic mechanical crap.

Then there's all the normal crap that eats up the day, but pays the bills. Lots of busted trailers, welding jobs, occassionally a tractor or two with busted implements.

Skills pay bills, but its not always the sexy stuff.

[DoghouseDiesel]

Hell of a build Rich!! Amazing work! Best of luck at the track with it man!

Also, like JP-4.5 said, that El Camino in the shop background....that thing NEEDS a CR Cummins shoved in it!

Actually, my next project, if I find the right vehicle is either gonna be a C10 or an El Camino with a Duramax and 4L80. Nothing retarded crazy, just 600 hp, nice street cruiser. Enough to boil the tires, but driveable everyday.

[DoghouseDiesel]

Been a few days since I've touched the ole girl. I decided to take last week off from working on it, had to get caught up on everything in the shop and really just needed to step away from it for a few days to get some thoughts together and recharge my own batteries.

Felt good to get back to work on 'er this evening. I'm just itching to pull the trigger on this sucker.

Dropped the front an inch and a half. Needed to get it so the front tires will stay on the ground so it'll stop killing my 60's and ET's.

http://i288.photobucket.com/albums/ll189/Cumminalong/Drop1.jpg

One full coil dropped it 1.5" and I have about 1" of clearance over the bump stops. I'll trim those down a bit though, no big deal. Not really worried about "ride quality" anymore, as long as it doesn't upset the front end.

http://i288.photobucket.com/albums/ll189/Cumminalong/Drop2.jpg

My rear was already lowered about 2". The truck sat nearly perfectly level before. The front was at 39.5" to the top of the wheel well and the rear was at 40" even. Now it's 38" front, 40" rear.

http://i288.photobucket.com/albums/ll189/Cumminalong/Drop3.jpg

I need to make the new upper shock rings, just need to weld in a center section for the shock stud and measure it all out.

I need to make some tabs for some limiting straps. The shocks I'm gonna spec are gonna have really heavy rebound damping, so it should keep the spring energy to a minimum, but I want some limiters on there so I have a little adjustability in just how much it limits.

Also have an oil filter relocation kit coming....well, at least a sandwich adapter, I'll put the rest of the lines and fittings togther.

[Wheelz]

Did I read that right? You were having problems keeping the front tires on the ground?

Sweet looking truck btw

[DoghouseDiesel]

Did I read that right? You were having problems keeping the front tires on the ground?

Sweet looking truck btw

Just a little.....

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Launching.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/Truck%20Pictures/Launchon1089Passsmall.jpg

[Wheelz]

That's awesome

If you don't mind me asking, how do you think this turbo config would effect spool time with a set of normal sized twins? I definitely see your thought for better top end.

[DoghouseDiesel]

Gettin' closer....

http://i288.photobucket.com/albums/ll189/Cumminalong/4D959D87-9B9F-4A09-B279-2D2E7D1B8AEA-52720-000025389E5FC86A.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/52A59CB6-DD14-451C-8137-6D26919C3204-52720-00002538DA50186C.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/0E4F15D7-A77B-4CA4-9A4D-2C511FEDE1A5-52720-00002538E74F5C21.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/5DDEC549-0037-4E2E-8F25-32870018C24A-52720-00002538EFA06DD3.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/D3513D22-D1D6-4066-A00A-F24E2FD29CF2-52720-0000253909C349B7.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/1AC8202A-78AF-458D-9429-1D4BAD8F84DF-52720-00002539143243F6.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/119CC80C-C134-4A5A-93D7-8127A8F9A8FA-52720-000025391AD78ABC.jpg

[DoghouseDiesel]

Should have 'er back under boost next week.

Got the driver side charge piping done today. After these pictures I took the pipes back out, rolled beads into everything, and got it all painted.

All I'm waiting on now is a pair of silicone couplers I had made and she'll be ready to roll.

http://i288.photobucket.com/albums/ll189/Cumminalong/DF6503F6-52D3-412A-80F6-83953E869737-53034-000025F3A513CC47.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/A83FA909-2D11-4F37-8309-077C4104D4F2-53034-000025F6C31DCBD6.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/B041DC72-585B-4E08-841A-CDB138DCCA98-53034-000025FD0101F2CD.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/ACBE48D1-2DEA-40A7-B09C-4BFDBA5B4B0F-53034-000025FD129BA9CD.jpg

[06redram]

Rich what is these used for?http://img.tapatalk.com/601a5f88-b797-1592.jpg

[FUBAR]

Almost looks like a 'filter' what would be filled with steel wool and one end plumped to monitor drive pressure, the other to the gauge. Although it's on the driver's side of the bay, so....

[DoghouseDiesel]

Almost looks like a 'filter' what would be filled with steel wool and one end plumped to monitor drive pressure, the other to the gauge. Although it's on the driver's side of the bay, so....

Bingo.

The pressure sender is mounted above that in the battery box. The first 10 feet of the line going to that sender is copper and coiled to dissipate the heat from the exhaust manifold. It transitions to regular plastic line and then goes to that "filter" before the pressure transducer. Then the transducer is a one-wire hook up to the gauge in the cab.

[06redram]

Thanks Rich and Fubar

[DoghouseDiesel]

Here is the piping from the 75 to the intercooler. Just need the last few couplers and I'll have the 88 plumbed in also.

What I'm going to do with that piping is weld the 90* elbow onto the compressor cover and then weld in a v-band flange where it goes from the aluminum elbow to the steel piping. An aluminum flange on the elbow and a steel on the pipe. The only boots in the system will be at the intercooler and the inlet to the 75 from the 88.

http://i288.photobucket.com/albums/ll189/Cumminalong/A93EC75F-1795-4D37-9663-840CBEE2B434-54202-0000275685698C0D-1.jpg

Here's what it looks like with my previous tune for 45% over injectors with the new set of 250% over injectors. At the point it snuffed the charger, it was only calling for 1700 uS of duration.

http://www.youtube.com/watch?v=ApvE7IOnYrY&hd=1

[DoghouseDiesel]

Well, I was hoping the couplers would be here with the shocks tomorrow, but they won't be here until Monday and we're heading out on vacation for two weeks on Wednesday morning, so it won't be read to go until I get back.

I got a bunch of tuning done on it today and right now it's "streetable" just running on the 75. Had to make the bottom end of the rail pressure and duration maps super mild. It's idling at pressures lower than an early common rail and the duration map looks a lot more like a 6.7 than a 5.9.

The shocks will be here tomorrow, so for sh!ts and giggles I may throw a filter on the 75 and take it for a ride down the road.

Les and I had a little discussion yesterday regarding these big ole Exergy injectors and we're both in agreement on a few things with these 143* nozzles and a few settings for tuning them in. Today for example, I brought it up to around 3000 RPM's and not a rattle to be heard.

[Wheelz]

I'm sure I'm not the only person wanting to see a video of that on the street

And I'm very intrigued about your comment of no rattle to 3k rpms. Does that mean its pretty quiet?

[Smoken Gun]

So Rich, would you say that your experience with these massive 250% over Exergy injectors with 143* nozzles has been positive overall so far?

If you don't care to comment on that at this time (or ever) I understand. Just curious as always. Thanks!

[DoghouseDiesel]

I can't say good or bad either way really, it hasn't left the shop yet.

Tuning wise it's a monster, but that's to be expected with the components on it.

What has been good is that it looks like the cause of the rattle that folks have been having with these 143* nozzles is tunable, it's just not as simple as changing some a little timing and a little pressure.

[DoghouseDiesel]

I'm sure I'm not the only person wanting to see a video of that on the street

And I'm very intrigued about your comment of no rattle to 3k rpms. Does that mean its pretty quiet?

Well, I'm not too concerned about it on the street, as the only real street miles its going to get is to put a few on the motor before I strap it down.

And, it's no louder than any other 5.9. I's actually a lot quieter is most aspects.

[DoghouseDiesel]

Front suspension issues are now taken care of.

If I can't get the front dialed in with 44 rebound settings and 24 compression settings, I have issues.

http://i288.photobucket.com/albums/ll189/Cumminalong/B046C5A6-7135-450A-96D1-4E786E42D430-58308-00002D5BD026DE95.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/25D8711F-47AD-405B-961D-83E240AFA024-58308-00002D5BD963EBCD.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/A9391420-B3CB-4758-B066-260B2BD5459A-58308-00002D5BE0EF9060.jpg

[06redram]

Rich you have a loose bolthttp://img.tapatalk.com/d/12/09/10/ymumy2at.jpg

[DoghouseDiesel]

Rich you have a loose bolt

Ahhh, don't sweat that one....I'll just lump it in with all of the other loose screws I have.

:grin:

j/k....good catch.

:good:

[06redram]

Thanks! LOL

[DoghouseDiesel]

Thanks! LOL

You won't ever hear me claim to be perfect. I'm humble enough to admit I missed something.

Ya gotta be able to laugh at yourself once in a while, ya know.

I tell ya what.....what fuel system are you running? Stock, AirDog, FASS?

Let me know and I'll shoot ya some filters for spotting that.

:cheers:

[06redram]

Big thanks Rich; the system I am using is FASS HD 150, fuel is FF1010 separator I forgot the part number. I will a IM with my contact info. :)http://img.tapatalk.com/d/12/09/11/5amymygu.jpg

[DoghouseDiesel]

Yeah, we'll get ya some much better Fleetguards.

[06redram]

Sounds awesome

[FUBAR]

I spy...lol

I love how you deleted the shock towers. Even though this isn't gonna be a 'street' truck, I'm curious to the feedback on how it feels when you do ride up and down the street.

[DoghouseDiesel]

The last few pieces of my little motor puzzle are here....

http://i288.photobucket.com/albums/ll189/Cumminalong/46EDE499-CCC0-437D-8EA3-52FF2E9F3661-59921-00002F9F9EB25CDB.jpg

And, the cage got ordered yesterday. 10-pt chrome moly from S&W.

http://i288.photobucket.com/albums/ll189/Cumminalong/10PTCage.jpg

[06redram]

You won't ever hear me claim to be perfect. I'm humble enough to admit I missed something.

Ya gotta be able to laugh at yourself once in a while, ya know.

I tell ya what.....what fuel system are you running? Stock, AirDog, FASS?

Let me know and I'll shoot ya some filters for spotting that.

:cheers:

Rich I received the set of fuel filter that you sent to me. I like to say Big Thanks to you for all the help that you throw there on this forum.http://img.tapatalk.com/d/12/10/10/qajagu7e.jpg

[estrada5.9]

Updates?

Awesome thread, thanks.

[stevens669]

Hey Rich just read the whole thread, any updates? How did it turn out??

[DoghouseDiesel]

I had to snatch the motor out.

Normally, whenever I do a motor I have the machine shop leave the plugs out of the oil galleys so I can flush everything until I'm satisfied that it's spotless.

Well, the one time I get the motor back with the freeze plugs in it there was a bunch of iron from the magnaflux in the oil galley and it tore up the the rear main bearing and the #6 rod bearing.

It was my fault. I know better than to trust the machine shop, even though they get paid to clean the block. Good thing though is all it did was tear up those two bearings.

But, right now I tossing in some monotherms and once they get here I'll get the rotating assembly rebalanced and put it back together. I'm gonna start working on it after the holidays are over, I've just been too busy to do anything with it. Jan and early Feb are the good times to work on my personal stuff....the holidays are over and everyone is broke until they get taxes, so it's slow enough to do my own work.

[FUBAR]

Rich,
Would you entertain the idea of dynoing my pig during those time frames in late winter?? I've been dying to put a number on my setup. Also if I make the long haul from the hillbilly hollers from Wv down to your place..could you pm me a quote on a cam swap? Thinking of a 188/220 or a recommendation would be invited too. Box S363 w/ .91 divided housing, Shane's stroked pump, and 45-50% injectors. Thinking of doing a 63/480 setup in the future..dyno results may sway my decision doing a twin setup (don't ask, lol.) Thanks,

[2007 5.9]

Rich,
Would you entertain the idea of dynoing my pig during those time frames in late winter?? I've been dying to put a number on my setup. Also if I make the long haul from the hillbilly hollers from Wv down to your place..could you pm me a quote on a cam swap? Thinking of a 188/220 or a recommendation would be invited too. Box S363 w/ .91 divided housing, Shane's stroked pump, and 45-50% injectors. Thinking of doing a 63/480 setup in the future..dyno results may sway my decision doing a twin setup (don't ask, lol.) Thanks,

Mmmmm...I smell a busy winter!!

[Tobin]

How about a EFI class during the winter??

Tobin

[FUBAR]

Has Rich been confined to the slavery dungeons of his shop and is not allowed to come out and play?

[DoghouseDiesel]

Sorry, been busy as the proverbial one legged man.

Doing final inventory and getting all the tax nonsense done this week and I'll be able to get started back on this pig.

[K80]

How's this setup running Rich?

[Dmaxink]

Likely not fast enough to catch my max for this season if we ever catch up :-) LOL!

[DoghouseDiesel]

Likely not fast enough to catch my max for this season if we ever catch up :-) LOL!

Careful what you ask for junior. That "max" will be looking a bit micro if you wanna get beside me. I've been keeping her a bit on he DL but that doesn't mean she ain't been getting turned inside out.

What she was and what she is is about 300 hp before I put the bottle to 'er.

Just a few hints......

http://i288.photobucket.com/albums/ll189/Cumminalong/9943bb410d48c64775f80a88b3c85322.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/04BDD35E-684B-42C6-B0D2-7664A96B4212-33878-00001122F79DC5BF.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/0E5948F5-FF60-4845-AF68-FC339F33C134-33878-00001123015AD7C5.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/47FC0792-EE93-47F6-854B-B99326B295FA-33878-000011230F84661F.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/3282C523-BD0E-41CD-AE4A-F6324F86D345-33878-000011054918D882-1.jpg

But, I'll be more than happy to lighten your wallet for ya.

[Dmaxink]

Careful what you ask for junior. That "max" will be looking a bit micro if you wanna get beside me. I've been keeping her a bit on he DL but that doesn't mean she ain't been getting turned inside out.

What she was and what she is is about 300 hp before I put the bottle to 'er.

Just a few hints......

http://i288.photobucket.com/albums/ll189/Cumminalong/9943bb410d48c64775f80a88b3c85322.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/04BDD35E-684B-42C6-B0D2-7664A96B4212-33878-00001122F79DC5BF.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/0E5948F5-FF60-4845-AF68-FC339F33C134-33878-00001123015AD7C5.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/47FC0792-EE93-47F6-854B-B99326B295FA-33878-000011230F84661F.jpg

http://i288.photobucket.com/albums/ll189/Cumminalong/3282C523-BD0E-41CD-AE4A-F6324F86D345-33878-000011054918D882-1.jpg

But, I'll be more than happy to lighten your wallet for ya.

I haven't said anything about mine either... Here is a hint! :-) haha
Better be deep in the single digits!http://img.tapatalk.com/d/13/04/29/8ahejy4u.jpghttp://img.tapatalk.com/d/13/04/29/ru4u2e2u.jpghttp://img.tapatalk.com/d/13/04/29/7y9egysa.jpg

Enough fuel to power 2 trucks to 1000hp ... Enough bottle to take them to paradise :-)

5klbs and bye bye Allison!

[DoghouseDiesel]

Now we're talkin'....