What all mods are needed on the parts?

I'm alright with settling for 540-560ft-lbs at this point...

 

Machining the pistons to lower the compression for the higher boost on the IDI. I believe this is done for the PSD as well.

I'm not sure what you need to do on the Cummins.

 

The cummins is fine with just studs and gaskets to 50+lbs boost and the bosch mechanical pump will pump enough fuel for stage 2s and needed and deffinatly get a bigger hairdryer for it or with the pump up you will smoke a hilacious amount a cool idea is twin idi ats turbos would be sweet and not to bad on the $ and look mean and would spool quick or twin idi hypermaxes just my 2 cents these mods would set you about 600hp and some strong torque

 

Well I would start with the block cooked out, then magnafluxed.
Same for the heads, even the replacements.

Probably need to check the line bore of the crank and cam.

If you need to bore the block, then you need new oversized pistons.

How many miles on the cam and lifters in there now?
A whole lot cheaper and easier to change while you have it out and tore down than do it next year.

Oil pump, I would change that as well while it is apart.

Head gaskets, valley pan, and complete overhaul gasket set, close to 300 dollars.

Paint, miscellaneous this and that while putting it back in, couple hundred dollars.

That Power Stroke, well if you have the complete donor truck, not just the engine, you may get it in cheaper.
But if you have to buy sensors, throttle pedal, injector driver module, or the computer and the related wiring, you will be burning that money.

250 HP and 500 ft pounds at the crank on the 99 PSD, so you are still going to be spending money on mods to get where you want to be.

1200 for a complete running Cummins ready to drop in and run, don't see that happening either unless salvage yard parts are a lot cheaper there than they are here.
And you will still be short of your HP and torque numbers untill you throw more money at it.

When I built my engine, four ...almost five years ago I had right at 3000 dollars at the machine shop.
I bought most of my internal engine parts through them, they got better prices than I did.

I still spent around 2000 on gaskets, seals, paint, rebuilt turbo, injectors, IP, head studs, oil, filters, antifreeze and things like that.

And like I said before, I pulled my own engine, tore it down, cleaned it up, hauled the parts that needed to go there to the machine shop, picked them up, did the complete assembly and then put it back in the truck.
So there are no labor charges at all in that price, just my time.

 

so what would your hp and tq be even if just an estimate? do you think that for less than 5k you could get a 6bt and have it out power your engine?

 

Whats cooking it? And thats a good idea...

I wouldn't do that on an IDI, I'd sleeve it or get a new block. To thin of walls isn't it? Either way it is expensive.

202,000mi

I was planning on the oil pump, never looked up cost though.

That's all auto wrecker stuff, except for maybe the ECU (which I have, but want a different one - $120 on ebay). I have most if not all the sensors. I also have all under hood wiring, but need some under dash wiring. The rest I will do custom. I want to make it a stand alone system before dropping it in.

SCT Tuner on 120hp tune + big boost mod = ~550ft-lbs RWTQ right? And cost totals under $500... that's close.

5.9 Dodge Diesel Cummins Motor
1991 Dodge Cummins

So far from what everyone's said, it wouldn't take more than $1500 to make a Cummins put those numbers out.

That's a lot... hopefully I wouldn't have to spend that much! At that point I wouldn't rebuild the IDI unless I had a lot of money to burn.

That part I get.. although I really didn't think much about the fluids and stuff.

Sounds like you must have a hell of a motor now though! Hows she run?


Your probably talking to Dave, but...

Aprox. 225hp/435ft-lbs (flywheel), and a solid yes haha
If I could find a place to dyno my truck in Reno, I'd do it.

Anyone know where a diesel dyno is in Reno?

On another note, there's a few PSD for sale on CL for $1500 or less. Not running of course. But that would serve the purpose. To bad I don't have it right now

 

Yeah i was asking dave so we can see if 5 grand is worth the "self" rebuild on an IDI or should 5 grand be spent on a 6bt rebuild. Stock the two motors have some minor adjustments that can produce more power but with some simple fuel mods to a Cummins you can get a stoopid amount of power haha. I dont know, seems like there is some merit to a 6 cylinder that can out run our trucks, granted the 1st gens and up are turboed and ford didnt get it till 93-94 but which way should a guy go to get the most "bang" for his buck, 5 grand into an engine that cant go too heavy in the boost dept or 5 grand into a truck that you can throw some serious power into. Im not jumping ship but when my trucks engine dies, i might just venture this way. Tell you what though, the new cummins engines are so friggin quiet i couldnt believe it, same with ford. haha sounds like a gasser at idle, if you can hear it! haha

 

Oh ok, and I second that! Except after thinking about it, I'd kinda rather put a PSD in rather than a Cummins, but idk...

 

i hope u can do it that sounds awsome i dont think a 3208 cat will fit in f-250 thow

 

international is a great motor, and cummins doesnt do much for me BUT the cummins swap is just easier, being mechanical and all. now, once you tap into 94+ cummins then your computer controlled then its tit for tat then. same electronic issues except the fact that your able to put ford/international parts back in ford so less fit and function issues.

 

theres a 92 with 70,000 mile cummins for sale right now on my cl for 1200 dang good deal comes with everything id like to get it but would rather get new can am atv

 

for $1200 something has to be wrong with it... around here the cummins alone is worth 3k

 

98.5 is when cummins went electronic.

 

I see rotten dodges around here all the time for around $1500-$2000 dollars, typically low miles!

Just did the middle man thing for a 98 near me for some one in other parts of the country, $2400 delivered!

-Enjoy
fh : )_~

 

Check out this website for information and associated adapters plates/wiring harnesses for performing a swap: fordcummins.com - Increase Horsepower with Ford Cummins Diesel conversion kits
Good luck