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'97 E350 Club Wagon 4x4 cummins conversion

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  #31  
Old 06-13-2016, 11:25 AM
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1/2" dynamat for the firewall. probably going to 1/2" the doghouse with an extra layer of 1/4" for extra measure. first have to modify the doghouse because the cylinder head and valve cover hit. Also had to do a custom trans dipstick so that's in the way too.




 
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  #32  
Old 06-13-2016, 11:30 AM
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mocking up the intercooler, tryin to figure out where it'll fit




 
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  #33  
Old 06-13-2016, 11:38 AM
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some of the cooler parts of the build. hood scoop is going to bolt on instead of glassing it in. I'm tryin to go for more of a military look at the finish.










 
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  #34  
Old 06-13-2016, 11:41 AM
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mock up of some of the piping and final pieces













 
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  #35  
Old 06-13-2016, 11:43 AM
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rough idea of what it'll look like behind the grill. had to heavily modify the hood latch to still function like factory between the billet grill and intercooler




 
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  #36  
Old 06-13-2016, 11:46 AM
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runnin out of room for everything. seriously, **** is getting tight. LOL






















 
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  #37  
Old 06-13-2016, 12:14 PM
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Originally Posted by Bones929K
Hey kountzecobra, thanks for the info. curious about you're setup what fuel pump are you running on you're rig? I saw on you're thread that you get about 13mpg, that sounds pretty low if its a P-Pump. Have you put it on a scale? What's the curb weight without the car in the back? How well does the factory trans controller work for you so far? I have a 1995 dodge standard cab 2wd manual 12v pickup and I pull a 10,000lbs buggy and trailer combo all the time. (gross weight at about 18k) At 55mph running roughly 1,800rpm i'm still getting about 17mpg.

Sorry, I know that's a bucket of questions. Not very many people out there willing to take on this kind of aggravation as a project so every little bit of info is golden.
I'm running a VE pumped Cummins. 13-14mpg is really good considering the bus weighs over 10,000# empty and makes a HUGH hole in the wind. Using the stock engine mounted lift pump. It would do better if I could keep it below 70-75mph. The Ford controller works very well after a bit of tuning. It also retains the Tow/Haul function that the PCS controller will not support.
 
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  #38  
Old 06-13-2016, 01:25 PM
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Sweet build!!! One question, what ya useing for a intercooler?
 
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  #39  
Old 06-13-2016, 01:57 PM
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This just keeps getting better and better! Great project.

But, why can I NOT get this scene out of my mind?

 
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  #40  
Old 06-13-2016, 03:01 PM
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A company called CXracing makes the intercooler. working pressure for it is 5-50psi. I think its safety rated up to like 150psi before it pops. I only plan on maxing at about 45psi so it should work well for me.
 
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  #41  
Old 06-13-2016, 03:11 PM
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Kountz, I'd be willing to bet if you switched to a P-Pump you could pick up a few mpg at least.

I also noticed in one of ur pics that it looked like the engine if way forward compared to mine. Did you do that for any reason in particular? and where did you put all the cooling equipment? Doesn't seem like there would be any more room up front.

Did you buy the trans box separate or did it come with the trans?
Do you have a aftermarket tuner on top of that as well to adjust the trans or can it all be done withiin the factory box.
 
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  #42  
Old 06-13-2016, 03:14 PM
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Had to wrap the intercooler tube because it runs directly over the exhaust manifold







 
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  #43  
Old 06-13-2016, 03:17 PM
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Mockup of the airbox to turbo pieces. That was 8hrs of fun let me tell ya! and 6 of them were on just the corkscrew pipe itself. Only have about a 1/4" clearance at any given point







 
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  #44  
Old 06-13-2016, 03:20 PM
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Wish I could weld aluminum. would've saved me a ton of money







 
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  #45  
Old 06-13-2016, 03:22 PM
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I don't know that these pics do it any justice but its really tight in there







 
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