haha! too funny

 

Those stock 7.3 intercoolers can handle a fair bit more than 40 PSI...

 

Have any idea how much more? I'd love to not swap out my intercooler considering it fits! I am not going to go over 70 psi that's for sure.

 

The all aluminum intercoolers will be fine. I am going to be using an all aluminum 99-03 Powerstroke intercooler. It is the ones with the plastic ends on them you have to worry about.

 

So I have this straight no problem with the all aluminum inter cooler handling the 70 psi boost of a set of compounds?

I will upgrade my intake a little too to a set of twin horns. I know that is a common restriction including the intake ports in the head. I'd love to run a cut intake but that is more money than it's worth.

 

The HX35/S475 turbo setup I plan to run is good for about 550-600 rwhp with 20° timing, 4k gov springs, and 60lbs boost. I am going to consider that good enough. That alone is going to get you 1200+ lb-ft torque at the flywheel and the NV4500 will eventually give out.

I would not see much point in shaving the intake, the extra boost, etc. Those are all good power mods but probably really only have their benefit at 4k-5k-6k rpms for sled pull trucks.

 

I agree completely. I want the much cooler egt's. That's what I'm really after. Not so much the extra Torque even though that's a byproduct. The intake is all about lowering the temps with more flow. I will probably limit it to 60 psi anyway that's as high as my boost gauge goes. Irregardless this was not so much about boost either but most people don't understand that boost psi is the restriction in your engine etc. what makes power is the actual volume that your turbo can push.

I have 3k governor springs in now. I have 4K but the throttle is way too touchy. I just want to be able to sustain full throttle for more than 5-10 seconds before the egt's pop 1250 along with the intercooler not popping. I can tune all that out with the afc but another turbo would eliminate the issue and reduce the turbo lag.

Thanks for letting me know. Keeping my current intercooler makes this a lot easier to swallow. I just need an s475 and some piping I have everything else.

 

Ok so I just finished reading through this entire thread. Holy cow that is a lot of hard work, sweat, and tears!! Really really good looking hard work too!!

I am planning on dropping a 7.3 powerstroke into my high boy as soon as I buy a house with a shop.... or my buddy lets me take his over for like two or three months while I work through the swap (not holding my breath).

and by the way, thank you for distracting me from work for almost a week. Now I have to find another build thread to drool over....

 

Thank you, and you're welcome.

 

just curious have you ever had it on the rollers? kinda curious about power since i know you did some upgrading, and i'm in the planning phase of my own cummins build for my conversion

 

No I have not. Dyno numbers are basically subjective. Every dyno is different so I don't bother. Mechanical diesels are pretty easy to tune, I don't feel tuning on a dyno is required.

I estimated power output based on a common combination of parts on other peoples average dyno numbers. The combo I am running seems to be pretty common minus the cam I am running. I will say it's a stump puller for sure. Believe me it makes plenty of power. However if you have the afc housing, and fuel stop maxed out with the aneroid set to full fuel at a mid level boost number you will get excessive smoke and high egt's. I have mine set to full fuel at 22 psi with 35 psi full boost. I am considering going to full fuel at 35 psi at 40 psi boost to control my egt's a little better.

 

my general plan is to put a 24 valve head fire ringed, cam 188/220, 24 valve h.o. pistons, head studs, 4k governor springs, 120 pound valve springs, main studs, 75 horse injectors, and a hx35 over ht3b on the 12 valve block when i find my donor truck. i was trying to guesstimate what my power might be if i had a benchmark. i've been doing research and haven't happened across anyone with that exact combo so i've been looking at other builds in general trying to get a gauge lol. it should be stout i'm just trying to figure out how stout....

 

What are those 75 horse injectors 5 x .010? With twins you should be able to turn up the fuel with no issues. I would stay away from the 4k it makes for a really touchy throttle if you are running a p7100. I have tried double springs, stiffer springs etc to make the throttle less sensitive. I just ended up taking the spring out to make it a 3k. Either way with that combo you will not have a lack of torque for sure.

 

one set i was looking at were 5x.017
another was 7x.015 i think

i'm shooting for around 500 hp weather at the crank or tire i don't much care, the end use for the truck is to be an every day truck weather it be on dd duty or towing occasionally hence the compounds

 

That is a big difference in power between the two. Try to get away from the horsepower thing with diesels. It's the torque that you feel with diesel not horsepower.

5x .017 are huge injectors. You are going to need a lot of air flow to clean those up. As stated above I have 5x 0.012 and can really pour out the smoke at full throttle. I know I have a single, but I don't think even a small set of twins will handle that much fuel.

Also size and hole count don't really equate to a certain amount of power. It's more of an overall thing. Turbo size(s), intercooler efficiency, restrictions into the engine, etc. You can tune some things out via the afc and the fuel stop. However at a certain injector size/ delivery valve cut etc. you will not be able to keep it from smoking and the egt's down.