My 2004 (late year) 6.0L Excursion needs head gaskets. I think I have convinced myself to go with O-ringed heads when I get this work is done. There are several options out there and I'd greatly appreciate some advice on what option to go with and why.

My build goals are to ensure reliability, 10K lb tow performance, and towing fuel economy. I am also planning on upgrading power mildly past OEM to include 155/stock injectors, new manifolds, ODAWG intake, KC Stage 1 turbo, and associated tunes for my application. No plans for 'hot tunes' or going fast. I am willing to pay a little more for quality and best value for my money. Here are the options I have found so far...

1. Do nothing and just have the heads inspected and decked; price TBD but will be the lowest
2. Machine shop inspect, deck, and O-ring the existing heads; price TBD but cheaper than heads.
3. IPR New OEM O-ringed heads (link); $1,800.00
4. DK 'New' O-ringed heads (link) ;$1,823.44
5. UCF Machine Shop O-ringed Reman heads (link); $2,343.00
6. Powerstroke Products OEM O-ringed heads (link); $2,468.00
7. Kill Devil Diesel New Design O-ringed heads (link); $2,499.00
8. Kill Devil Diesel ICON Ported Aluminum O-ringed heads (link); $3,499.00

Thanks in advance,
4Kids

 

Considering that the Powerstroke version of the International V-365 is already power upped from what International designed it to be, I don't consider what you have listed as 'upgrading power mildly'.

Your '04 heads are an earlier version of the five different part number heads produced for this engine, so they are likely not the best cores to play with. If you had 20mm '06.5-07 heads, I'd rework them. Out of the list you have, the choice would be firmly #7, maybe #8.

 

Jack, I have watched your incredibly good videos (thank you) and trust your recommendation on Option #7...I assume you would also recommend combining this with Fel-Pro gaskets instead of the Ford OEM. My novice/neophyte going in choice was the KDD heads anyhow since they have a solid reputation and are not a ton more money than the competition, but its good to get input and validation from experts. I'm still open to others' opinions as this is a forum intended for conversation, debate, and learning from other perspectives.

So...are the Aluminum ported ICON heads worth an extra $1,000.00? I like that they are 75lbs lighter, improved cooling, and the improved 'swirl' for combustion efficiency. If this can provide improved towing fuel economy, then I could convince myself that its worth it. I really have not seen a lot of posts regarding real-world advantages of the ICON heads for 'normal people' like me. What I have seen is that they hold up well for the Stage 2/3 hot rodders.

Quick maths if my baseline MPG is 15 miles/gallon (I don't know what it is actually)...
If it improves it by 0.5 miles/gallon, then it would take ~140,000 miles to amortize the cost at $3.50/gallon or ~120,000 miles at $4.00/gallon.
If it improves it by 1.0 miles/gallon, then it would take ~70,000 miles to amortize the cost at $3.50/gallon or ~60,000 miles at $4.00/gallon.
Amortization mileage shortens with a lower baseline MPG and vice versa.

 

Thanks, I need to get back to making videos.

Improved cooling ... well. Aluminum has a higher thermal transfer rate, and with gas engines, it's been shown that combustion temps are lower while coolant temperatures rise when switching to aluminum heads. I don't think anyone has done any research on the ICONs in that manner or diesels in general, no matter what KDD may say. I concur that adapting the 6.4L stiffening methods is a great improvement; I wish they had been incorporated into an aftermarket iron heads option.

I'm not sure you will improve your mpg with any of this. Your best option is to Granny drive under 65mph. Other than that, the best MPG I've seen was with stock-size tires and a spare EGR valve plugged in and sitting next to the installed one. That probably raises combustion temps a little.

 

Since I'm not planning to go to extreme power, the ICON heads are probably not worth the extra cost. For the record, the KDD website does not claim that they will improve MPG. They do claim higher combustion efficiency do to the improved 'swirl', so I inferred that there may be an MPG improvement potential.

I am good on driving under 65mph. I rarely break 65mph when currently towing with my V-10 gasser Excursion, partly because of the lower fuel economy and need for more downshifts, but mostly because I find it dangerous to move 18K lb total at those kinds of speeds and I enjoy the simpler, lower-stress life in the slow lane.

My poor unfortunate EGR cooler is expected to be clogged up completely on either end. When that happens I'll definitely schedule to get that unclogged in the year 2074 because I've heard that there is about a 50 year lead time on that repair.

I may start another thread later for more advice when I begin to finalize the notional build plan to achieve real-world improvements in towing MPGs and manageable EGTs.

 

Well you asked... I'd defer to Jack as he has the actual expertise here, but if it were my money and my truck, I'd spring for the $500 per head and go with the ICONs - I don't see any real downsides but there are definite real and potential upsides - just the gussets to better distribute the clamping force alone is a biggee to me. Just my $.02 and I doubt I'll ever need to make this decision...

 

That's valid rationale. It also sounds a lot better the way you proposed it. Heck, its really only $125 per cylinder!

I guess this would also future-proof the engine [top end] if someone else ever wanted to go full-nutzo Stage 2/3/4 on power.

 

DK heads would not be my first choice.

 

Scott has a valid point, although the gussets don't help as much as they would with an iron head; aluminum has a lower bending strength. If you are willing to throw the coin, that's fine.

 

Would they even be your last choice? Because I've seen your videos, and they aren't good.

 

Door stops.

 

That's one list they could top I guess.


OP - If you go with KDD heads, order them from Full Force Diesel. I got them for $2300 out the door due to free shipping and no sales tax for TX residents (may also apply in your state), AND I got them in record time compared to others.

 

Thanks for the tip Chris! Did you even consider the ICON heads for your truck?

Does anybody know if KDD or their distributors offer a military discount?

 

I just couldn't talk myself into the extra cost. I still have a long list of expensive things I want to do to this truck that were higher priority. And the way exhaust manifold bolts break on these trucks, the thought of drilling out a broken stud in an aluminum head makes my nether region pucker. Like Jack noted above, if they offered a cast iron option for the ICONs it would have been easier for them to separate me from my money.