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The BIG DZL Project: 500hp...1000tq...20mpg

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The BIG DZL Project: 500hp...1000tq...20mpg

 
  #1  
Old 04-08-2015, 04:31 PM
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The BIG DZL Project: 500hp...1000tq...20mpg

Picked up this 2015 Ford F350 Platinum 6.7 Power Stroke from Texas a few weeks ago. BIG DZL was built in Kentucky on 1/15, arrived to the Texas dealer in February and was in Florida by March.

The truck will have to work hard; towing a 12,000lb boat, hauling palettes of pavers, stone and other materials, working on construction sites around the country, traveling long highway miles and performing off-road from Florida swamps to the Colorado Rockies.

BIG DZL serves as the foundation for a 500/1000/20 project build. We'll be working to get up to 500hp, 1000 ft-lb of torque and over 20mpg overall. The objective is to create the ideal balance of beauty, performance, efficiency and utility...to upgrade the truck and still achieve these milestone numbers...all without sacrificing any of the Super Duty's significant capabilities, including reliability.

As configured today, we should be at ~450hp/900tq (will be running real Titan dyno numbers soon)...we averaged 15 mpg calculated at 75-80 mph traveling from Texas to Florida and we've gotten 17 mpg over 90 minutes on cruise at 70 mph speed limit. Truck has 1940 miles as of 4/8/15.

Welcome any and all suggestions, recommendations and advice to help reach our objectives from the many experts on this forum. As well as any other comments anyone might have for that matter.

Starting stock configuration:
2015 Ford F350 SRW 4x4 Crew Cab Platinum 172" Longbed, 6.7 Power Stroke V8 Diesel
Ruby Red Metallic over Black Leather
Preferred Equipment Package 618A with 20-inch wheels
3.55 Electronic Locking Axle
11,500 GVWR
Engine Block Heater
Roof Clearance Lights
Upfitter Switches
Spray-in Bedliner

The mavens at Texas Truxx kicked off the modifications and added the following as of 3/2/15:
Suspension and Steering:
  • BDS 588H 4-inch Lift
  • BDS Dual Steering Stabilizer
  • FOX Shocks Pro 2.0 Performance Series shocks all around
Wheels and Tires:
  • KMC XD779 Badlands 20x9 Wheels -12 Offset, Black with Machined Chrome details
  • Toyo Open Country M/T 35x12.5x20 Tires
  • Hypertech Inline Speed-O-Meter
Bed:
  • BakFlip F1 #72311 Flush-mount Bed Cover
RECON Light Package:
  • SMOKED Projector Headlights
  • SMOKED LED Tail Lights
  • T15 6-Watt Ultra High Power Reverse Upgrade
  • SMOKED 3rd Brake
  • Red/Red LED License Plate Kit
  • Red License Plate Bulbs
  • SMOKED/White LED Side Mirror
  • Ultra Hi-Power Domes
  • SMOKED Cab Roof Light Lens Kit
  • T10 White High Power 3-watt LED Bulbs Cab Lights
  • SUPERDUTY Billet Illuminated Door Sills Aluminum/RED
  • F350 Illuminated Fender Emblems Chrome/RED

Once back in Florida, we added these bits (3/9/15):
  • Rolling Big Power Powdercoat RBP Race Pedals
  • RBP Powdercoat Hitch Cover
  • Rigid Industries Front Bumper Grill Mount
  • OPT7 C2 22-inch LED Flood/Spot Combo Bar
  • RECON White Lightning 60" Tailgate LED Brake Bar
  • Master Lock HD Receiver Lock

Completed as of 4/3/15:
  • RECON HID 9006 Low-Beam Upgrade w/35 watt Ballast
  • Rigid Industries Dually Floodlight Pair #20211 (Reverse light add)
  • Rigid Industries Dually DOT/SAE Fog Light Pair #50481 (Fog light replacement)
  • MagnaFlow Performance Series Stainless 5-inch Exhaust to 6-inch Intercooled Tip, single passenger-side rear exit #15350
  • S&B 75-5053 Cold Air Intake System
  • MGP Custom One-off RR Color-matched "Platinum" Brake Caliper Covers
  • Llumar Paint Protection Film (New Llumar product released April 2015) Full Hood, Front Bumper, Full-Length Rockers up 18", Half-Fenders with Grille Surround to come
  • Llumar CTX15 and Llumar Air Blue Tint
  • AMSOIL OE 10W-30 Synthetic Diesel Oil at 1500 miles

Completed as of 4/28/15:
  • Hellwig 7890 Rear Sway Bar Complete Assembly for 4" Lift
  • WeatherTech DigitalFit Floor Liners 444331-443052

Entertainment system upgrade completed as of 5/3/15:
Installation link HERE
  • JL Audio C2-650 6.5-Inch 2-Way Component Speaker System (2 sets)
  • JL Audio 13TW5v2-2 13.5" Thin-Line Series Subwoofer
  • JL Audio JX500/1D 500W Mono Class D Sub Amp
  • JL Audio RBC-1 Remote Bass Control
  • AudioControl LC2i 2-Channel Line Out Converter
  • Stinger SK4641 4 Gauge 4000 Series Car Audio Amplifier Installation Kit and Stinger Pro 12-gauge speaker wire
  • Dynamat Xtreme 12 sqft Thick Self-Adhesive Sound Deadener (4 packs)
  • SuperCrewSound Custom JL Audio 13" TW5 Subwoofer Box with black carpet, gold banana-plug speaker terminal upgrade and acoustic stuffing, plus JL Audio SGR-13 speaker grille
RR Three-Stage Color-matched Grille Surround Completed as of 5/7/15

Planned and/or in Process:
  • Royalty Core one-off Custom Grille and Emblem Assembly
  • Custom Aerodynamics
  • Dyno Testing

Here are few images...starting with factory-fresh. Will post ongoing updates in this thread as the build progresses...

From Holiday Ford...hands down one of the best dealerships in the nation:


Build as of 3/12/15 (more updated pictures coming soon):






























You can find many more images in this slideshow:
Library Slideshow by ducatitalia | Photobucket

More to come...stay tuned...
 
  #2  
Old 04-08-2015, 04:58 PM
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None of the stuff you have done til now, tho pretty nice looking, contributes toward the goal you mentioned.

at 440/880 (stock hp/torque), you should be able to get the 500/1000 easily with any of the tuners. Might have to do a delete..

that 20mpg (average) will be a challenge, unless you are going to drive 55.
also, that lift pushes you in the opposite direction.. more lift, more wind effect, less mileage. you are driving a big flat front sail.
same for the larger tires.

I got 16.7 hand calculated on my 2012 f250, highway over 13,000 miles.. some short spikes to 17.. never higher.. with the 3.31 rear. Once saw the dash say 20, but only for a few miles, and was running in slow traffic.

if you get it, I want it. my 2012 dually usually gets 14.. I don't need any more power.
 
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Old 04-08-2015, 05:03 PM
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Definitely possible. My ol tuned hot rod has been making these kinds of numbers for a few years now with no issues

20ish mpg would be easier to achieve with stock height/tires though, lol. I used to be around there driving on the highway before I added bigger tires, etc
 
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Old 04-08-2015, 05:12 PM
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Also, many of us tow FW trailers well over the 12,000 lb weight with the stock setup and don't consider this 'hard' work on the truck. My FW weighs 12,000 dry and you would hardly know it is there except for startup from stop. Mileage drops to 10, but it also is a big sail.
 
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Old 04-08-2015, 05:17 PM
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Originally Posted by sdetweil View Post
None of the stuff you have done til now, tho pretty nice looking, contributes toward the goal you mentioned....SNIP

Thanks much for the perspective...forgive if I didn't explain the objective clearly enough. Keep in mind...the goal is not just mpg, that is just one (though important and very challenging) aspect of the overall objective...which to reiterate is "...to create the ideal balance of beauty, performance, efficiency and utility...to upgrade the truck and still achieve these milestone numbers...all without sacrificing any of the Super Duty's significant capabilities, including reliability." All the candy improves aesthetics and some of it various aspects of performance, the CAI and exhaust improve power, performance and mpg, the flush bed cover improves mpg, etc.

The point of this build is to prove that you can have it all...what we are doing is attempting to find the right combination to get us there...something very few have been able to do, which is what creates a worthwhile challenge.

Of course, the easy way out would be to just leave everything stock and drive 55...and that's all well and good, but it's done all the time. We want to prove that you can upgrade your truck, including lift/tires and still achieve these milestone numbers (500/1000/20). It would have been just as easy to go the other way too, say 10" Fabtech on 40's and No Limit the whole truck...but that sacrifices balance, efficiency, utility...etc.

By finding just the right balance of mods, we might (and that's a big might, especially on the mpg-front) just be able to have a great looking, lifted truck that performs and gets great mpg. Hope this helps clarify...
 
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Old 04-08-2015, 05:18 PM
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Welcome to the forum... As others have stated, you'll have no problem towing 12k stock. I just picked up my new RV that was 16k dry and it towed like an arrow. I'm all stock. I also agree that your mileage goal is the toughest to achieve. The rest, many have done. I'd be doing it too if I didn't live in a state that checks for emission equipment every year at inspection. Enjoy your project. Looks like you're having fun so far!
 
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Old 04-08-2015, 05:27 PM
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Based on long participation here, watching others. I don't think for this breed of engine, CAI or exhaust size make one difference, til you get WAY up in power.. 7-800hp.. but as noted that is way outside the balance point.

the headlights, if they actually improved vision, might be something I am interested in, but most of the rest is just fluff. It doesn't improve or detract from the trucks effectiveness or utility. it does empty someones pocket pretty well tho. I have an led light bar on my dually, cause the headlight mods haven't helped practical vision.

I'm interested, tho skeptical, in one primary goal, mileage. I would have set out to get the 3 goals, and saved the rest til it was achieved. but to each their own.. I throw money into customizing old trucks, and the FW.
 
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Old 04-08-2015, 05:27 PM
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Originally Posted by Karl4Cat View Post
Welcome to the forum... As others have stated, you'll have no problem towing 12k stock. I just picked up my new RV that was 16k dry and it towed like an arrow. I'm all stock. I also agree that your mileage goal is the toughest to achieve. The rest, many have done. I'd be doing it too if I didn't live in a state that checks for emission equipment every year at inspection. Enjoy your project. Looks like you're having fun so far!
Absolutely and thanks much for the welcome...the possibilities are truly endless with these rigs!

Towing capacity for this particular 3:55 truck as configured is 14,000lb, so consistent work at 12,000 will prove hard work enough...

Here is Ford's SD towing chart...which I'm sure has been posted countless times, but is still useful as reference...
2015 Ford Super Duty | View Towing Specifications | Ford.com
 
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Old 04-08-2015, 05:31 PM
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Originally Posted by BIGDZL View Post
Absolutely and thanks much for the welcome...the possibilities are truly endless with these rigs!

Towing capacity for this particular 3:55 truck as configured is 14,000lb, so consistent work at 12,000 will prove hard work enough...

Here is Ford's SD towing chart...which I'm sure has been posted countless times, but is still useful as reference...
2015 Ford Super Duty | View Towing Specifications | Ford.com
I think I've read something about them there limits... Haven't seemed to be able to take them to heart...
 
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Old 04-08-2015, 05:39 PM
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Originally Posted by sdetweil View Post
Based on long participation here, watching others. I don't think for this breed of engine, CAI or exhaust size make one difference, til you get WAY up in power.. 7-800hp.. but as noted that is way outside the balance point.

the headlights, if they actually improved vision, might be something I am interested in, but most of the rest is just fluff. It doesn't improve or detract from the trucks effectiveness or utility. it does empty someones pocket pretty well tho. I have an led light bar on my dually, cause the headlight mods haven't helped practical vision.

I'm interested, tho skeptical, in one primary goal, mileage. I would have set out to get the 3 goals, and saved the rest til it was achieved. but to each their own.. I throw money into customizing old trucks, and the FW.
Right on. HID's are a solid headlight upgrade until LED improves. Been hearing good things about Lifetime LED bulbs:
https://www.lifetimeledlights.com/pr...ory/headlights

And since you tow...I highly recommend the 3000 lumen Rigid Dually reverse upgrade...you would love'em going backwards...they turn night into day!

This might be helpful regarding intakes and exhaust...The legend that is bigrpowr sent these dyno numbers recently to illustrate the difference a good CAI can make...the numbers speak for themselves, especially when looking at the lower register...

"I dynoed my truck this past saturday. I am still waiting on the dyno graphs which I will post up later but I wanted to fill everyone in with the results. For the dyno testing we felt that to get the most accurate results we would dyno mikes intake, the afe intake, and then the stock intake.

Here are the peak hp and tq of each intake:

Peak Hp
Stock-442
Afe-444
No Limit-451

Peak Tq
Stock-1027
Afe-1044
No Limit-1058

As you can see the no limit has a pretty good gain over the afe. But what was really impressive was when we started breaking the tq numbers at a given rpm.

At 1600 rpm (Tq)
Stock-386
Afe-448
No Limit-512

At 1700 rpm (Tq)
Stock-515
Afe-571
No Limit-663

At 1800 rpm (Tq)
Stock-693
Afe-748
No Limit-825

At 1900 rpm (Tq)
Stock-872
Afe-931
No Limit-942"
 
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Old 04-08-2015, 05:44 PM
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Originally Posted by Karl4Cat View Post
I think I've read something about them there limits... Haven't seemed to be able to take them to heart...
Yeh, Rodney, you DO seem to get up there..

this is mostly a tire & conventional hitch location limit..

the dually, with the same engine and trans can go to 23500, 19000 if you use the conventional hitch.

so the guts are good.. engine/trans/chassis. and the surrounding stuff is the issue.. tires, wheels, springs, and hitch location.

I've seen some cool wheels and tires, but a lot of times they reduce the weight capacity. One of our other members, PaintedHorse, with a newly arrived 15, had to select specific wheels to keep capacity up on his 350 SRW.
 
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Old 04-08-2015, 06:43 PM
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Welcome to FTE Big! I hope I can call you Big?

Anyway, it sounds like quite an interesting project. Like some of the others, I'm a bit skeptical on the fuel economy, but won't say never...

When you select your place to do the dyno testing, see if they will give you the graphs exported to Excel spreadsheet (they are literally all capable of doing this now) and they should include the IAT, Coolant Temp and BFSC figures through the range of the pulls.
The headlights are of key importance to me as well.. Mileage not so much.
My camper weighs roughly 18k and the truck never breaks a sweat dragging it..
The Ford 6.7 is a mature and very capable engine...
 
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Old 04-08-2015, 07:09 PM
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Truck looks great so far, few minor things id change but i think you've sold me on ruby red for the color of my 6.7... curious to see how you get 20mpg though
 
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Old 04-08-2015, 10:57 PM
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Originally Posted by Big-Foot View Post
Welcome to FTE Big! I hope I can call you Big?

Anyway, it sounds like quite an interesting project. Like some of the others, I'm a bit skeptical on the fuel economy, but won't say never...

When you select your place to do the dyno testing, see if they will give you the graphs exported to Excel spreadsheet (they are literally all capable of doing this now) and they should include the IAT, Coolant Temp and BFSC figures through the range of the pulls.
The headlights are of key importance to me as well.. Mileage not so much.
My camper weighs roughly 18k and the truck never breaks a sweat dragging it..
The Ford 6.7 is a mature and very capable engine...
Appreciate the welcome Big...the original! So much experience and knowledge on this forum...looking forward to hearing and reading about any and all experiences or info that folks are willing to share.

Certainly will do regarding the dyno runs...Titan has all the toys and data.

Going to have to get creative to increase mpg further...could use all the advice we can get (even reached out the to the hyper-milers...no, we're not doing a monster-dam or fastback tonneau!). Might have to dive into gearing and aero...tunes might help as well. At the end of the day, the best solution on this one might just be to trade in on the lighter/leaner aluminum 2017!!

acf6--loving the throw-back candy-apple red. Ford calls it RR, but it's really just ol-school candy in the sun. Everyone has their preferences...but please feel free to send along any ideas you might have. We've already made several tweaks based on feedback we've gotten along the way...
 
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Old 04-09-2015, 05:45 AM
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The mpg is going to be hard unless you do some wind tunnel treatments. I contend that without some aero work under the truck and some kind of fastback treatment behind the cab/above front of bed you'll be fighting much too much low pressure drag to get consistent numbers in all kinds of wind conditions.

Good luck, I truly hope you find a wind tunnel somewhere to work some things out. I've been thinking very hard about some way to negate the drag behind the back windows. I have the back flip too and at 72 mph the back flip cover is actually pulled up from the bed 12-26" behind the rear windows. I'm not a good engineer so I don't know how to work the numbers but there has to be a good 20hp drag right there.
 

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