So I'm wanting to do a build this winter (november/december) when I'm not working 60-80 hours a week....

Anyways I got a 97 4x4 250, crew cab.

Thinking:
D66 turbo
T500 HPOP (or better)
electronic fuel system
Stage 2 injectors (new injectors, too afraid of remans
BTS trans
ARP head studs
DP tunes
CX racing intercooler
smith brothers pushrods
Valve springs?

Suggestions? Comments? More or less wanting 400HP with stock reliability.

 

you wont get much love with the d66. There are better options.

otherwise you are on the right track.

 

Do you have any other suggestions? Thought about a garrett 38R or a hypermax H2E... I heard you can make 400 easy with a D66 and from what I understand it's a bolt on install...

I've heard the hypermax and garrett kits are close but not always 100%

 

the 38r is a super dootie deal more or less. IF you obtain all the sd parts it could be easily done.The 38r is not very cheap and not rebuildable either. I actually have all the sd stuff for it but no turbo.someday I might go that route. I am not sure right now.
the h2e I have no experience with but there are guys out there on here with it. at that power level an s366 or something along that line would be good. BUT the install kit plus the turbo is not free.

glenn has a d66 on the mule and pulled for years like that. I think in the end egt issues were just not ideal.Maybe he and travis will chime in.

 

build: BASB, injector and spring upgrade, and zf5 rebuild - PowerStrokeNation : Ford Powerstroke Diesel Forum

This guy used an Irate T4 kit with the BASB turbo. The kit addresses bellowed up pipes, the downpipe, inter cooler pipes and intake plenums, all in one shot. If I had it to do over, I wouldn't have done the D66.

Rusty

 

For the money, the D66 isn't worth it. Its only a tiny bit better then stock.

 

Break out the BIG credit card
6637 intake
3" downpipe
4" exhaust
TS chip with custom tuning
StageII 180/80
T500
Comp 910 valve springs
Head studs
Push rods
BTS
E-fuel
T4 with s366
Intercooler
With the correct tuning this setup will have you 12-15k in the hole and 450hp
Before spending this kind of cash do a compression test.

 

The D66 will do 400hp, but you have to ask yourself what you're going to do with the truck and whether or not the turbo setup will fill your needs/wants. If you're going to be towing a lot, the D66 may not be ideal.

It has always been my opinion that the stock turbo is not a great turbo to build on for performance purposes. Going to a T4 mounting kit gives you a HUGE array of options for turbos in the aftermarket world. If ever there comes a time when you want to upgrade down the road with a T4 kit, you simply pull the turbo and bolt on a larger one. Easy as pie.

If it were me building a 400hp setup with an auto trans, I'd do stage 1's and an S366 on a T4 mount. If you want a little more power, 160/80s with the same S366 will usually stretch out there to around 440hp and 160/100s will usually push it out to around 460hp.

As far as the intercooler on your list, I've never heard of that company. If it were me, I'd just do a stock aluminum SD intercooler.

For valve springs, just do shimmed comp 910s. They will be adequate for this power level.

 

Travis that IC is a eBay IC

 

I'm not sure how much I trust an ebay IC.. I'd still put an OEM aluminum SD intercooler in it.

 

That intercooler IS for sale on ebay, but CX racing actually specializes in intercoolers for Japanese cars. I've never met anyone who owned one and didn't like them. Really not all that bad, the banks kit is way over priced and a SD... Eh, I hate getting pipe bent. No one in this god forsaken town will do a job like that.

I do need to do a compression test, LOL. But I'm making power... Hell I can outrun my dads 7.3 lol. May not be a bad idea to put in new rings, maybe hone the cylinders while I'm in there. Hell go ahead a pull the valves... OR hell I could use my borescope hahahaha.

AS for the money... I was planning on dropping $15-20k

 

If you do a 366 turbo and get the T4 kit from Irate, it comes with inter cooler pipes, all you need is an inter cooler, even just a Super Duty one.

Here are his install directions, I/C pipes look mandrel bent http://www.iratediesel.com/guide/IDP...stallation.pdf


Rusty

 

Put in with BTS to have a tranny built. Looking at July first!

 

Do you think a big oil system is necessary? Also, what about main studs?

 

When I did my build in my signature, because I pull heavy, the guys thought I should put studs in. Some said its not necessary until 500 hp. As far as 'big' oil, the T500 is about the best you can do unless you go with a dual HPOP setup which I don't think is necessary with 400hp+. In towing in hot tune I can run out of oil but by the time I do that I have to back out of it because EGT's are to high.