No rain, just dry roads. I don't like to go fast in my truck, so they are all very "low-speed" if you know what i mean. Where the back wheels are going fast but the fronts arent.

Jamie, i know that Mad Matt from TDS is in the process of fully building his engine, wow the time flies but he wanted to have one ready for the BTS open house going on "now". He was going to run BWD compounds in hopes of 700 on fuel ( ) and i think he has them.

 

Kris

Those DP numbers are high. How are you measuring drive pressure? From the EBP sensor w/AE, or a mechanical gauge in the manifold?

You may need to subtract atmosphere, and then the numbers are closer to what we've measured.

Here is what CSI measured with a mechanical gauge

Here is some testing we have done comparing the HFO to stock on a 1.00 TN

link

 

I have a Tee in the pipe coming off the front of the passenger manifold. The EBP sensor screws in like normal on top and then i have a ferrule and a copper line to a nylon boost line at the firewall to a 0-60 guage. I dont know what's normal for me, but it seems like DP is always twice thereof the boost.

Could the turbo not being fully broken in yet cause extra resistance and higher BP? Should i have not even asked that?

 

Your not looking for two small ones compared to one big one. . . your looking for a small one connected to a big one. I have them both spinning in mine. . . but I'm having a hard time lighting up the big one. i have some sort of fuel delivery issue that I'm working out. I'm hoping its not just too small injectors and I have stage II singles. That would be a bummer, but I'm pretty sure thats not the issue and its all fuel pressure, either a problem with the PCM or the oil pump. Either way kris stock sticks and compounds would be worthless. The big charger would just idle all the time
Tim

 

Alan,

I am VERY glad I went with the 1.0 housing because surge was my biggest problem/gripe/nemesis with the factory turbo during tow. I have, however, learned that the 1.0 has some slight lag to it and doesn't build too much boost. I'm not complaining...this thing has a ton more power at less boost than the stocker....not that power was really what I was after.

The new turbo doesn't make more than 23 PSI of boost. Yes, I have an ITP boost regulator. There is still TONS of black smoke being produced even at 2700+ RPM...makes me think that even bigger sticks won't make more boost. Intake system holds 20 PSI near indefinitely (5 minutes @25 PSI shop air)

I can't really get my EGTs above 1200 in 60 Tow up a 6% grade pulling 10K lbs. either.

My highest recorded boost levels in each power range:
Stock: 15 PSI
20 Tow: 20 PSI
60 Tow: 23 PSI
80: 23 PSI
120: 23 PSI

The boost gauge hits 23 PSI nearly immediately and STOPS!! But I can't figure out why. My up-pipes aren't leaking, my IC and related plumbing holds 25 PSI, and I am still fueling like a mad chief....WHAT GIVES!?!?!?

 

Cody, I'm wondering if your boost regulator isn't adjusted just a shade to the high side, causing some sort of de-fueling and resulting boost limitations. Have you tried adjusting it down a couple of psi to see what happens. You should build more boost in your higher settings. Or, another thought is the stock IC is causing a little restriction at that CFM of airflow. Figuring out if it's airflow or fuel that's limiting your boost would be my first step. But, with you saying it's still pouring out the black, it almost makes me think it's an airflow limitation. Have you tried a couple of runs without the air filter, just to test it?

 

I don't have my wastegate plugged in. I'm still looking for one more part of the thing i know its somewhere around the shop and i'm going to move the MAP and boost senders to the hot side of the manifold for better response.

 

Jeremy,

No, I haven't removed the air filter. I guess it never crossed my mind, but I have a true 4" hose all the way to the 6637 filter (that's only 2000 miles old). I have backed off the regulator about 1/8 turn so far...no change.

The only real PROBLEM that I have (because the truck runs so darn good!!) is that the stock turbo was capable of 26+ PSI with NO black smoke at WOT 2700+ RPM. Just a lot of surge and really high EGT.

I am pretty sure I don't have a fueling problem.....but why do I have tons of black smoke and no boost? No boost leaks or drive pressure leaks.

 

Oh, and I should also add (thanks for the remider, Kris) that the wastegate actuator is unplugged and the wastegate actuator pull is 41 lbs. on a fish scale...don't think I have a wastegate opening problem.

 

Just got done flogging the living heck out of the truck. I guess it's not worth it to me to break the transmission just to find out that I have a small problem....if it shows up, fine, but I'm out of ideas for the moment.

Cleaned EBP sensor tube....nothing (flowed freely)
Disconnected EBP sensor....nothing
Disconnected MAP sensor....RUNS LIKE A RA--- APE...still 23 PSI boost though.
Triple checked all IC boots and intake clamps.

Peace, I'm outta here

 

I think I've found it...I think that Jeremy should get a gold star!!!!

Check where I have underlined.

"When compared to the stock turbo, crossover from positive pressure to negative pressure is moved up to about 25 psi, this is the point where the intake manifold pressure and exhaust back pressure equaled out. Pressure started going negative after 25. Remember that the stock turbo has over 35 psi of exhaust backpressure at 17 psi intake pressure! When compared to the ball bearing turbo, our turbo makes about 10 psi less backpressure at equal intake pressures (the ball bearing turbo makes 35 psi of exhaust backpressure at 25 psi intake pressure). The GDS Ball Busters turbos crossover point is optimum because it matches the maximum that you can get through the intercooler on the 99-03 Powerstroke." Blah, blah, blah "same horsepower as the ball bearing turbo at 4 p.s.i. less intake pressure and 10 psi less exhaust backpressure."

So I suppose my next step is to drill and tap the hot side of the 5-way sum-bucky and see what my numbers are there.....

Makes sense I guess.


Now what to do? Dang it. Just like everything else. Fix one thing and now it needs more!!