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Intake plenums

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Old Apr 2, 2019 | 08:04 AM
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Intake plenums

Good morning, I have been a long time lurker, but never posted.

I have a 1994.5 powerstroke, after adding some swamps injectors and tunes over the winter, I believe I now have an intake plenum leak.

What are my options for plenums with a stock turbo, I do also have a banks intercooler on the truck.

Can I run the superduty 3 inch plenums ? and get a reducer boot? or can I run the IRate aluminum ones with a reducer boot?

While I have the truck apart I ordered a kc s300 billet wheel and turbine wheel. pretty excited to see the difference that makes

Thanks in advance


 
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Old Apr 2, 2019 | 08:21 AM
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Just reseal your intake plenums, use only Motorcraft TA-31. And build yourself a boost leak detector.
 
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Old Apr 2, 2019 | 08:22 AM
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@z31freakify How hard are they to remove without bending them ?
 
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Old Apr 2, 2019 | 08:25 AM
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Theres no bending them when being taken of just be careful and use a sharp knife/blade to cut in to the old sealant, there is one bolt on the passenger side that hits the timing cover and can't be removed, but the good news is that the plenum has a slot so you can just slide it out.
 
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Old Apr 2, 2019 | 08:30 AM
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I suppose Ill give it a shot, I just figured they were 1 time use. Worst case scenario I could order a set of the Irate ones since they seem like the only ones that fit an obs
 
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Old Apr 2, 2019 | 11:05 AM
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I still use the 'small' 2" ones. They work fine, the passenger side required leaving a bolt in the head as a stud. It takes a while to clean all the dead sealant. Driver side is much easier, pretty much requires turbo removal as I recall. Diesel Site makes plenum supports now too for the 2" guys! $30 only.

All sealed up I see about 18-19psi on my tow tune and 27-28psi on the street tune. Stock injectors, hot air.

Keep us posted on how you like the S300 drop in wheel, I am going to buy one too. Probably do my HPOP first.
 
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Old Apr 10, 2019 | 07:53 AM
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Heres a bit of an update,

I pulled the turbo off the truck in about an hour and a half Monday. most of the time spent was removing the intercooler piping and wiring. With the turbo pulled I got to rebuilding. Right off the bat the quality of the KC kit is top friggan notch. The packaging was beautiful along with the product!

Attached are photos of the rebuild, Last night I took on the task of puling the plenums. What a pain in the bum ! Because my truck is a very early powerstroke the passenger side lower bold in the plenum is not slotted. it took me 2 hours to Cut the plenum apart so I could remove it. With all the bolts loosened the plenum fell right off. there was no RTV holding it down..

Tonight's project is the drivers side



 
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Old Apr 10, 2019 | 08:58 AM
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Does all that go into a stock housing?
 
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Old Apr 10, 2019 | 09:09 AM
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yeah its a drop in turbo upgrade from KC,

I have mixed opinions on the wicked wheel but the turbine wheel looks like a massive gain in efficiency
 
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Old Apr 10, 2019 | 09:53 AM
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I would like to see the turbine side on a 66mm compressor. On the mobile so I cannot see your specifics, which injectors are you running?
 
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Old Apr 10, 2019 | 10:05 AM
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Im running a set of baby swamps,

I haven't had an issue with egt even on my aggressive tow tune in the hills. However im driving cross country this summer and don't want to worry in the hills of Colorado

Also since I had the turbo out for plenums, why not throw some money at the turbo...
 
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Old Apr 11, 2019 | 08:24 AM
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More plenum debacle,

It turns out the early 94's used much lower profile fuel fittings than the later ones. The Irate plenums appear to be too thick to fit under the fittings on the head. fortunately I have a bridgeport. I have marked off the locations the plenums need clearance. I will attach pictures tonight once everything is sorted out.

I really though that this would be an easier project than this. Guess this is what happens when you have an oddball
 
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Old Apr 11, 2019 | 08:29 AM
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Oh, thats right the early ones didnt have that slot. My bad man forgot about those early ones.
 
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Old Apr 11, 2019 | 08:36 AM
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Not having that slot was a major motivation killer! fortunately I was able to cut the plenums with tin snips.

Im going to call Irate today and see what my options are
 
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Old Apr 11, 2019 | 09:15 AM
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Originally Posted by TJLongworth
More plenum debacle,

It turns out the early 94's used much lower profile fuel fittings than the later ones. The Irate plenums appear to be too thick to fit under the fittings on the head. fortunately I have a bridgeport. I have marked off the locations the plenums need clearance. I will attach pictures tonight once everything is sorted out.

I really though that this would be an easier project than this. Guess this is what happens when you have an oddball
Dang, maybe that's why riffraff used to have a note about early 7.3 8 bolt ones.
looking forward to the pics as I might be going down this route soon
 
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