Invisible Ceiling?

[BC847]

Am I there?

My heap amounts to an internally stock 6BTA5.9 with ~

(Air In - -> - - >Out)

IN ~ 100% outdoor air free-flowing into a fully enclosed BHAF - - > Four inch smooth walled turbo feed duct - - > PDR HX35 hybrid turbocharger - - > Three inch duct - - > Banks After-cooler - - > Three inch duct - - > Banks TwinRam intake.

OEM Stock Long-block.

OUT ~ Ported ATP exhaust manifold - - > 14cm W/G turbine housing - - > Four inch down pipe - - > Four inch full exhaust including a very large, very quiet high-flow muffler and resonator.


FUELING ~
* Cummins piston lift pump.
* IP mods include: 3200 gov spring, OEM grind fuel pin set to most aggressive position with washer removed. Fuel pin spring set for moderate low boost smoke. Fuel screw won't go in any more. Timed at 2.0mm @ 0*TDC.
* PDR 190 injectors.
* All linkage etc set to ensure full throttle travel.

MISC ~
* MBC set for 38psig max.
* Fluidampr
* Synthetic oil
* CoolerMist Varicool W/M (50/50%) start 15psig, full on 30psig. Two 18gph (@ 150psig) nozzles. (Still can't bog it).
* Valves set at 0.008" and 0.016" cold.

A WOT blast from 0 to 70mph presents with 1300*ish pre-turbo EGT's and just shy of 38psig boost.

Seems to accelerate OK. I figure 200hp to the ground considering the OEM TC (it's next).


I think the injectors are holding me back.


Would I be correct in thinking that if I want to go to the next level, I'd do well to consider larger injectors with a matching increase of air via a larger single turbo? I assume I'd also do well to strongly consider O-Ringing the head. Perhaps new valve springs (minimum) while I'm at it?

I can't justify twins to be honest.


I'm pretty much set in sticking with a VE pump so I guess that'll set the tone.

I'm planning on pulling the approx year old injectors and have the pop pressure tested/adjusted in the next week.

First time on the dyno this coming Feb 17th. We'll see.

Suggestions? Comments? Rude remarks?

[TWorline]

I would say that you are heading in the right direction, they say that you can figure 10hp for each 1psi of boost as a rough estimate.

[wannadiesel]

I think it's time for bigger injectors and a larger turbo. My HG is still holding, but I wouldn't discourage you from getting studs. I think that and a 0.020 over HG will keep the head down just fine.

[KTA]

NOTHING can make such a night and day diffrence in power in a first gen than a good set of injectors, or wait is that nothing can turn day into night like a good set of first gen injectors. LOL Seriously I say it all the time big power from the VE comes from good injectors and lots of air flow mods. You have a great list of mods going. I am shure with good injectors you could make your truck fly and the slushbox beg for mercy.

[BC847]

Thanks for the replies folks!

Yeah Wannadiesel, I'm pretty-much set on when I go into the top of the engine, I'll O-Ring the head, install studs, and address the head gasket (I'm assuming a thicker gasket will drop the compression ratio a little so as to help keep peak combustion pressures reasonable).

KTA, good injectors. LOL! I know enough about the engineering of injectors to irritate someone who does. As far a nozzles go, I'm sure EDM'ed units would offer superior pattern control. I guess the question is: How many holes of what size EDM'ed in an injector set xxx" with the right washer would give approx 400hp (+/- 50hp) without regularly bringing out the local Fire Dept for a smoke investigation?

Then there's the thing of a larger, single turbo, I'm assuming I'll still be able to run my current 14cm WG housing (if not go to a 16cm to accommodate the higher overall flow).


Gents, I appreciate your taking the time to offer suggestion. The parts we're talking about above can easily cost at least $2500. With that I'm in no hurry to go out and buy anything without a bait of homework being done on my part. . . .. mess makes my head hurt.

[KTA]

There is more to good injectors than just punching a bunch of holes in tips, but with that being said anything from a 5X .016 to a 5X.020 or 6x .016 to a 6x .018 or some 8 X .014's or 7x. 016 would probably do it. On a side not and as a shamelss plug I have some injectors listed in the for sale section here that I know from experience will make 450+hp with a 12mm VE and a single turbo. On the turbo deal I would say you will need something totaly bigger. I would go with whatever S300 styled turbo flavor of the week you like. Something like a 62 or 64mm inducer with a big turbine wheel. The B-1 series, HTT, and Industrial Injection all offer a version in this combo.

[TugboatPhil]

BC847

If you don't mind me asking, what is the muffler you're running? I'm running open 4" from the tranny back right now. We have a lot of envirotypes around here and I'm wanting to find something that looks like a muffler, that won't slow things down too much.

Thanks.

[JLeonard]

I'm wanting to find something that looks like a muffler, that won't slow things down too much.

The build yourself an empty cylinder and weld it to the exhaust pipe.
I won't tell anybody.

[BC847]

BC847

If you don't mind me asking, what is the muffler you're running? I'm running open 4" from the tranny back right now. We have a lot of envirotypes around here and I'm wanting to find something that looks like a muffler, that won't slow things down too much.

Thanks.

Mine's an actual 4" muffler (Donaldson M110189, very quiet, high flow) followed by a 4" resonator. Pretty-much a Performance Cadillac system for a diesel. (Oddly, there's more sound coming from the pipe next to the transfer case . . . weird ringing at idle).

Many run a muffler like this one with good results ~ http://store.airflo.com/m085171.html

[TugboatPhil]

Thanks for the info, and the link!

[sdstriper]

I've got the same one. Stan's headers claims our trucks will flow exhaust better with that set-up due to scavenging. The muffler is huge, lengthwise that is. Laughable even. If the envirofreaks don't notice it after install they would have to be blind...

[RumbleFish]

Old driveshafts always make nice mufflers