what did you use for exhaust manifold

 

I used a 2007 turbo and manifold, but any third gen would work(03-09). The 12v has the turbo centered front to back. Third gen places turbo at rear of engine down close to the block. The heater box is the only thing thats a close fit. The third gen manifold gives good clearance. The only mod is that the 12v head has rectangular ports and the third gen is round. A simple gasket port match job fixes that. Also, the turbo is larger on the one I used.

 

How much porting/cutting did you have to do on the manifolds to get the rounds ports to be rectangular? Got any pics?

 

Dont have pics but the round port is about the same size as the sides of the rectangle. You could probably just bolt it up, but I didnt want any restriction. Gasket matching is easy and really should be done on any engine build anyway.

 

I understand what gasket mathcing is, I just figured with going from round to square there would be quite a bit of grinding and may end up with some really thin spots in the manifold, depending on the casting. I haven't seen the 2 styles side by side though so I wasn't sure if this would be the case or not.

 

I have another third gen manifold I could take a picture of the port, but I doubt I have any old gaskets to show the difference. There was plenty of sealing area on the one I did. It was less grinding than the 302 manifolds I had in my Bronco. Didnt mean to sound like you didnt know what I was talking about. I just feel alot of people dont take the time to do it and it is easy and cheap power.

 

Gotcha and thanks for the clarification.

I've seen pics of the 2 manifolds apart, but never a gasket for the square holes on a newer manifold. It's good to know things don't get overly thin or close!

 

Topped off the fuel tank today. Wasnt empty but wanted to check the mileage, love the 44 gallon tank(until its empty). The mileage turned out to be 17mpg, which is exciting as I have been "testing" the limits of its performance. Once the excitement wears off I'm sure it will even be better. The V10 was getting, at best, 9-10mpg being babied. Im installing the cruise control and gauges this week. I havn't turned up the boost or fuel yet as I was waiting for gauges. I have the larger injectors, but the fuel plate is full rearward. I plan on running 35-40lbs of max boost and will adjust fuel accordingly. Now it has some black smoke at low rpm, low boost and just grey haze at WOT. I cant wait to fine tune it and see the results. I almost lost the tach wheel the other day. I installed it with the supplied hardware(small allen head bolts) and red loctite. I went out to warm it up the other day @30 degrees and noticed a weird noise from front of engine. It was too dark to see anything, so drove to work and checked it in the shop. Two bolts were missing and the other two were loose! I cant say I've had loctite fail before. I found bolts that were hex head (so I could torque them more) and applied the prep spray and red loctite again. I applied loctite blue or red on most parts. Hope this is a fluke. I know diesels rattle but come on.

 

I believe the Loctite failure might have been due to the temp. being too cold for it to take a proper set.

 

The tach ring was installed in September though. If that is the only re-do, I will be happy. Just glad I caught it before it went sailing like a saw blade through the engine compartment!

 

I agree, I had a fan come apart years ago and the damage it did brought a whole lot of respect to me of all things spinning fast.

 

Finished putting in gauges and cruise control. Started fine tuning fuel. Was getting alot of low end pre-boost smoke. Found previous engine owner had unscrewed the AFC starwheel all the way out. I adjusted, but not knowing where it was, had to experiment. First time got it too tight and the thing was a dog until I hit ten pounds of boost, then it was like a two stroke hitting the power band. I backed it off and it is close to where I want it, might back off just a little, and now I dont experience the low boost smoke. Just got back frome a 1500 mile trip, averaging 70-75 mph. The fuel mileage was consistent 18mpg(double what it was). Not bad considering the aerodynamics of a brick wall and probably heavier. Went through four states on same tank!

 

What year cummins is that? I want to o this to my 02 ex

 

The engine I have is a 1995, but you can use anyone you want. Different generations have their own characteristics. I chose the P pump 12v and this one was the first one I found. Unfortunately for me the previous owner made alot of adjustments and didnt know what they were doing(or at least didnt install gauges) and they damaged the pistons by over fueling. I found cracks in three pistons when I took it apart. It just depends on what your goals are. The 12v are known for their durability and easy adjustments, but they are also the loudest ones. The noise isnt bad in the cab, but have to shut off in the drive thru. The mechanical injected engines dont have the adjustability on the fly like the electronic ones. You just set it and forget it, while others can be turned up and down going down the road. I am happy with the one I have.

 

Thanks, I'm looking for MPG's 1st, and towing my travel trailer 2nd. I plan on getting one and rebuilding it before I slap it in. Did you use destroked for your plates? or Fordcummins? Also did you get their instruction manuel? how was it?
Thanks for your time
Dave