whats up PSN? I noticed there is a decent sized IDI section over here, so I thought I would bring my current build and the new build (starting next week) over here to share, and hopefully help people revive their old motors.
I bought this truck last june in hopes of using it to replace my 2001 Chevy 2500HD w/ 6.0. The chevy was a great tow rig, but the gas mileage flat out sucked. I owned 94 PSD a few years back and was never impressed with it (stock), liked the idea of the mechanical IDI's, and refused to hear that they wouldn't make power.
So... $500 later I brought this truck home - (see it in the background)
I started by tearing the engine down to the block, and no further. I had custom MLS gaskets cut for it, used ARP head studs, modded x-over and up-pipe, built my own 3" exhaust housing, and used the 3" banks downpipe. 4" straightpipe from there, DPS turbo cal pump, and DPS stage 1 sticks. I later upgraded the compressor side of the ATS 093 turbo, which helped alot, but is still not good enough, as the exhaust side of this turbo is an issue as well.
this is what I started with:
and this is what I ended up with (picture taken months later)
I put a PSD ZF5S47 trans behind it with SMF conversion and 12.5" southbend clutch.
Now, this truck is an absolute rust bucket, I dont particularly care for the slantnose body style, and it is a HEAVY pig... 8,000lbs with a full tank of fuel and driver. I added as many nice things as I could, because it is my dedicated tow rig, but it was mainly a "tester" to see what kind of power and efficiency I could pull out of the IDI.
Here is its purpose:
14,720lbs with 60 of 100gallons of fuel.
I have put 13,000 miles on it since about november, 2600 miles of that was recently done when I PCS'd from Ft. Polk, LA to Ft. Lewis, WA.
I learned alot about my setup during the trip, as most of it was in high elevation, and pulling 3 separate mountain passes. Here is a shot I snagged (notice 7200ft elevation on my gps speedo.)
This was pulling one of the grades through utah
The GPS speedo is nice, but the needle accells slow, and the final readout is a couple mph low. Speedhut says this happens sometimes, and I can send it in for a free reface (100mph) and recal on them. I will probably do this before I sell the gauge cluster.
Go pedal extremely limited by EGT's... I could only safely push around 14-15psi tops on grades without getting EGT's out of control, or the turbo starting to surge (remember I said the exhaust side still sucked)
here is a video of the flatbed pulling roughly a 7% grade here in washington....
here is a ride along video
and finally a dyno video
the dyno was a mustang dyno... Now, there was a little bit of a "controversy" started by members on another board about the validity of this dyno run because I didn't have RPM readout. The dyno shop did not have a crank probe, or the right software to calibrate RPM through the rollers, so we only had an accurate torque readout, hp readout is just randomly generated, as the machine doesnt know the RPM to calculate it off of torque.
The pull was from 40mph-72mph in 4th gear, and I guestimated the RPM range (on the road after the pull as well) to find that its roughly 1600rpm - 3200rpm, so I calculated the HP in with the formula on my own, it may not be dead nuts perfect.. but its close enough to have a good idea.
So at this point IMO the IDI power rumors have been completely squashed by putting in a good fuel system, modifying the exhaust, and swapping to a better compressor on the still ####ty stock ATS turbo, and I was able to create this power. It certainly has room for much improvement in the efficiency side, but overall was a success.
So, I purchased this:
7.3 Turbo, power everything, a/c, air seats, 5spd, blah blah blah. A MUCH nicer cruiser, but gutless.
I will be selling a bunch of parts including a complete ATS 093 kit (minus stock air box) with 3" exh housing and DP, as well as many other parts...
because....
starting next weekend the flatbed is being torn down, engine pulled out, parted out, ect.... to be repowered and placed in the new truck.
I'm not laying all of my cards out now, but a few hints and teasers would be that I am using an S300 chassis turbo, d-max style exhaust, a custom-hybrid 4-plunger injection pump, intercooled, water injected, and a bunch of other goodies that I will post and document as I start the build up. For anyone that has ever possibly seen my builds on Pirate or any other websites... I build fast, so you wont be waiting for months to see the results!!
Enjoy!
I bought this truck last june in hopes of using it to replace my 2001 Chevy 2500HD w/ 6.0. The chevy was a great tow rig, but the gas mileage flat out sucked. I owned 94 PSD a few years back and was never impressed with it (stock), liked the idea of the mechanical IDI's, and refused to hear that they wouldn't make power.
So... $500 later I brought this truck home - (see it in the background)
I started by tearing the engine down to the block, and no further. I had custom MLS gaskets cut for it, used ARP head studs, modded x-over and up-pipe, built my own 3" exhaust housing, and used the 3" banks downpipe. 4" straightpipe from there, DPS turbo cal pump, and DPS stage 1 sticks. I later upgraded the compressor side of the ATS 093 turbo, which helped alot, but is still not good enough, as the exhaust side of this turbo is an issue as well.
this is what I started with:
and this is what I ended up with (picture taken months later)
I put a PSD ZF5S47 trans behind it with SMF conversion and 12.5" southbend clutch.
Now, this truck is an absolute rust bucket, I dont particularly care for the slantnose body style, and it is a HEAVY pig... 8,000lbs with a full tank of fuel and driver. I added as many nice things as I could, because it is my dedicated tow rig, but it was mainly a "tester" to see what kind of power and efficiency I could pull out of the IDI.
Here is its purpose:
14,720lbs with 60 of 100gallons of fuel.
I have put 13,000 miles on it since about november, 2600 miles of that was recently done when I PCS'd from Ft. Polk, LA to Ft. Lewis, WA.
I learned alot about my setup during the trip, as most of it was in high elevation, and pulling 3 separate mountain passes. Here is a shot I snagged (notice 7200ft elevation on my gps speedo.)
This was pulling one of the grades through utah
The GPS speedo is nice, but the needle accells slow, and the final readout is a couple mph low. Speedhut says this happens sometimes, and I can send it in for a free reface (100mph) and recal on them. I will probably do this before I sell the gauge cluster.
Go pedal extremely limited by EGT's... I could only safely push around 14-15psi tops on grades without getting EGT's out of control, or the turbo starting to surge (remember I said the exhaust side still sucked)
here is a video of the flatbed pulling roughly a 7% grade here in washington....
here is a ride along video
and finally a dyno video
the dyno was a mustang dyno... Now, there was a little bit of a "controversy" started by members on another board about the validity of this dyno run because I didn't have RPM readout. The dyno shop did not have a crank probe, or the right software to calibrate RPM through the rollers, so we only had an accurate torque readout, hp readout is just randomly generated, as the machine doesnt know the RPM to calculate it off of torque.
The pull was from 40mph-72mph in 4th gear, and I guestimated the RPM range (on the road after the pull as well) to find that its roughly 1600rpm - 3200rpm, so I calculated the HP in with the formula on my own, it may not be dead nuts perfect.. but its close enough to have a good idea.
So at this point IMO the IDI power rumors have been completely squashed by putting in a good fuel system, modifying the exhaust, and swapping to a better compressor on the still ####ty stock ATS turbo, and I was able to create this power. It certainly has room for much improvement in the efficiency side, but overall was a success.
So, I purchased this:
7.3 Turbo, power everything, a/c, air seats, 5spd, blah blah blah. A MUCH nicer cruiser, but gutless.
I will be selling a bunch of parts including a complete ATS 093 kit (minus stock air box) with 3" exh housing and DP, as well as many other parts...
because....
starting next weekend the flatbed is being torn down, engine pulled out, parted out, ect.... to be repowered and placed in the new truck.
I'm not laying all of my cards out now, but a few hints and teasers would be that I am using an S300 chassis turbo, d-max style exhaust, a custom-hybrid 4-plunger injection pump, intercooled, water injected, and a bunch of other goodies that I will post and document as I start the build up. For anyone that has ever possibly seen my builds on Pirate or any other websites... I build fast, so you wont be waiting for months to see the results!!
Enjoy!