Zero Buck Mods!

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Zero Buck Mods!

Postby m880cummins » Wed Mar 14, 2012 5:05 pm

Hi Guys,

I figured I would start a topic for some free mods you can do with simple tools. Some are known, some are what I did...

Typical:

Timing advance

Smoke screw, rotate fuel pin, fuel screw

Slack taken out of throttle cable

High idle screw removed (allows around 2900 RPM)

Starwheel bottomed (allows more fuel pin travel)

My home brew stuff:

NON IC air intake pipe ported by the turbo coupling. Great if your turbo has a bigger outlet than the pipe (HX35/WH1C turbo) I just used a die grinder and then polished with a cylindrical sanding piece with the die grinder.

Banjo bolts that hold the fuel lines to the head casting by the fuel filter can be drilled to 3/16". This makes a HUGE difference. I gained another 700+ RPMs of full fueling! Also, there's a pressure port on the outlet banjo (10MM bolt)-take it out and grind it down until the step in the bolt is gone. As is, it blocks roughly 40% of two of the banjo bolt ports!

Ports matched on exhaust manifold with the die grinder


Lets keep it COST FREE!!!!!

Chime in!

Charlie
1977 M880 Cummins 5 speed SOLD :(
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Re: Zero Buck Mods!

Postby Tacoclaw » Wed Mar 14, 2012 5:25 pm

m880cummins wrote:Hi Guys,

fuel screw

Slack taken out of throttle cable

High idle screw removed (allows around 2900 RPM)


Just noting which ones made the most difference in my personal truck. Removing the high idle screw and getting the slack out of the cable made it a different animal!

Awesome tips on the banjo stuff, I never got around to those...


Cool thread. 8)
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Re: Zero Buck Mods!

Postby m880cummins » Wed Mar 14, 2012 6:13 pm

Yeah, I was doing the filter and lift pump today and saw that and figured why not! So glad i did that. Roasting those bald 235s away!

Charlie
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1985 Crew cab Cummins P7100 NV4500 D60/D80
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Re: Zero Buck Mods!

Postby Remps » Wed Mar 14, 2012 6:26 pm

The throttle linkage can be moved to the upper hole for increased throttle travel. The high idle stop can be ground off the throttle linkage, where it would contact the pump at wot. This sometimes requires grinding the other side of the linkage where it might contact the IP fuel inlet line. I just used a sidegrinder and pair of vicegrips for this mod.
'90 D250 R/C,727,IC,6x.009's,1/8" bump,fuel psi,straight pipe w/5" stack.
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'96 2500 S/C L/B,2wd,NV5600,3.54 L/S,cai,egt,pacbrake,mbrp exhaust,10 plate.
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Re: Zero Buck Mods!

Postby m880cummins » Wed Mar 14, 2012 7:09 pm

Wow, didn't realize the high idle screw being removed still limits the arm when it hits the pump. I guess I will grind that off :bom:

Charlie
1977 M880 Cummins 5 speed SOLD :(
1985 Crew cab Cummins P7100 NV4500 D60/D80
SUNY Maritime Class of 2017!
m880cummins
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Re: Zero Buck Mods!

Postby Tacoclaw » Wed Mar 14, 2012 7:23 pm

To an extent.

On my truck the throttle linkage hits the inlet line to the IP before it hits anything else.

Image
I guess I could have hacked all that off, but just moving that far was pretty impressive to me.
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Re: Zero Buck Mods!

Postby Remps » Wed Mar 14, 2012 7:41 pm

I ground the whole top left corner off, left the low idle stop of course. Just beware of the little hook underneath where the return spring on the throttle shaft hooks to when grinding on it.
'90 D250 R/C,727,IC,6x.009's,1/8" bump,fuel psi,straight pipe w/5" stack.
'90 W250 R/C,47rh,K@N,HX35,1/8" bump,2nd gen IC,boost,egt,trans temp.3.07's.
'96 2500 S/C L/B,2wd,NV5600,3.54 L/S,cai,egt,pacbrake,mbrp exhaust,10 plate.
Bring back the Bank of Canada, PRE- 1974.
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Re: Zero Buck Mods!

Postby Tsbourne09 » Mon Mar 19, 2012 4:37 am

Fil me in more on this grinding and drilling!! Where
93 D250- pump maxed, 3800 spring, hx35, denny T pump top, 7x.015 injectors, timing+, Coolertubz, raptor 150, boost nipple, 4" DP to 6" aussie stacks, built tranny, asa intake, DNR tps, more HP mods, isspro boost, fuel pressure, egt, tranny temp, 5k tach, chrome and powder coating here & there.
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Re: Zero Buck Mods!

Postby cmann250 » Mon Mar 19, 2012 4:56 am

m880cummins wrote:High idle screw removed (allows around 2900 RPM)


I'd say this is an equal gain in RPMs to the 3200 spring. I really noticed th increased RPMs when I did this. I may have to try that banjo bolt "porting".
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Re: Zero Buck Mods!

Postby m880cummins » Mon Mar 19, 2012 3:00 pm

Well with the screw delete and the 3200 spring it is more like 3500 rpms (getting a tach soon) all I know is it sounds like a Detroit diesel when I flip the valet switch and do a hard 4th gear pull.

Here's yesterday: I consider this a zero buck mod for me because I got the lokar cable for free. Now I get even more throttle travel and gets rid of all the clunky brackets for the throttle (mines a 5 speed so I don't need the kickdown).

Image

Image

Just need to clean up the wiring and spritz some black on the area that was covered by the throttle bracket.

Charlie
1977 M880 Cummins 5 speed SOLD :(
1985 Crew cab Cummins P7100 NV4500 D60/D80
SUNY Maritime Class of 2017!
m880cummins
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Re: Zero Buck Mods!

Postby gobigorgohome » Mon Mar 19, 2012 5:08 pm

m880cummins wrote:Well with the screw delete and the 3200 spring it is more like 3500 rpms (getting a tach soon) all I know is it sounds like a Detroit diesel when I flip the valet switch and do a hard 4th gear pull.

Here's yesterday: I consider this a zero buck mod for me because I got the lokar cable for free. Now I get even more throttle travel and gets rid of all the clunky brackets for the throttle (mines a 5 speed so I don't need the kickdown).

Image

Image

Just need to clean up the wiring and spritz some black on the area that was covered by the throttle bracket.

Charlie

whats the setup that you got goin on the pump top there? mind sharin? looks interesting
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Re: Zero Buck Mods!

Postby PToombs » Mon Mar 19, 2012 5:16 pm

Valet switch, cuts boost to the AFC housing to conserve fuel. Allegedly. ;) I can still burn a ton of it with mine off. I have a square solenoid I got from Graingers. Never seen a round one, looks close to the throttle stuff.
pete

Just enough power to break everything behind the crankshaft.
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Re: Zero Buck Mods!

Postby m880cummins » Mon Mar 19, 2012 6:50 pm

Clears the throttle stuff by about 3/16" I gain a few mpg with it off and only get 25psi max with it off. On is a whole different story....50lbs and lots of smoke and squealing tires. :mrgreen:

Charlie
1977 M880 Cummins 5 speed SOLD :(
1985 Crew cab Cummins P7100 NV4500 D60/D80
SUNY Maritime Class of 2017!
m880cummins
fuel screw!!!!
 
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Re: Zero Buck Mods!

Postby revemup15 » Thu Mar 22, 2012 8:46 pm

what's the proper way to adjust the TV cable?
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Re: Zero Buck Mods!

Postby Tacoclaw » Thu Mar 22, 2012 10:09 pm

Here's a link to a thread from Ahale where he made his factory cable work without the linkage setup:

viewtopic.php?f=1&t=10235&hilit=throttle

And here's a pic of my setup:

Image

I just bolted a plate up to where the factory linkage sat and drilled a hole in it. I then filed that hole into a square that would fit the stock cable setup. If you don't have some rod ends and a welder sitting around like I did, this may not be zero-buck...

Considering the amount of fabbing, I'd just as soon leave the throttle linkage alone, but if you find yourself with an afternoon and the parts to do it it's a pretty cool mod. A little easier to control the smoke your truck puts out, since the factory linkage isn't doing any weird swiveling or anything like that.
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