Gathering up some parts, need some help!
- Thread starter Cozze44
- Start date
Cozze44
Junkman
FSS is operating great now. Ended up grabbing an external starter relay and running the pull through that. A much better and safer setup for sure. Had to take the fans back out because like an idiot I had the waterman pump set up for the wrong rotation direction. Had to take the pump apart and switch it around, and now it pumps up great. FYI the pump should be offset to the right of the mounting plate for proper rotation direction in our application. Gonnna bleed injectors tomorrow and maybe fire it up to check for leaks. I don’t see it being an issue starting it without the manifold.
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Cozze44
Junkman
It lives! Bled the injectors and whame fired right off. All pressures look great. Fuel pressure is low at idle ~10psi, but quickly jumps to 40-50 with a slight tap of the pedal. All I need now is turbo piping and it’s time for break in and a ride. I haven’t programmed the standalone yet but it seems the trans engaged right away when shifted. Other then that, no leaks and all fluids circulate as they should.
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Cozze44
Junkman
Manifold is finished being welded, as is the hot pipe and the wastegate manifold. Still need to add the turn and merge for the wastegate dump into the hot pipe. Gonna start on the interstage and ic to manifold pipe Saturday as well as the wastegate / bov / boost controller plumbing.
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Cozze44
Junkman
I apologize for the absence! I was in a car accident and laid up for a while. I'm back now and we're cranking this thing out. The only thing left is to finish welding up the wastegate dump, and coat the manifold. After that, its on to final assembly. This thing has exceeded my initial expectations in the way it has come out, and the parts I had planned on putting into it. I had set out to built this truck one more time, but this time pull very few punches and built it in a way that I feel is nearly bullet proof. While I had some down time, I had decided to work up a list of all of the parts and modifications that had went into this, and tried to include as much as I could, although I know a lot is missing. I realized that many parts I was fortunate enough to obtain was from this CompD community, and other then the good people and information, it's just another reason to love this place. So here's the list...
Engine:
-All machine work, balancing and long block assembly done by UCF machine in Carlisle, PA
Bottom End:
-T-Rex Girdle
-No Limit Mfg Billet Main Caps (From CompD member)
-Calico Coated OEM Cummins main bearings
-Arp 12mm XL Main Studs tied into girdle (From CompD member)
-Crower Billet Rods
-ARP Rod bolts (From CompD member)
-Coated Early CR .020 over Pistons
-Fluidamper
-ARP Balancer bolts
-Billet Squirters
Valvetrain:
-187/220 No Limit Mfg Billet Steel Cam
-Eatsoot bolt on cam retainer
-Keating Bronze Cam retainer
-Calico coated 1.4" Tapets parkerized by No Limit Mfg
-Hamilton Xtreme Duty Push rods
-New OEM Cummins Rockers (Mamau Diesel)
-ARP rocker studs
-Trend Performance DLC coated Rocker trunnions
-Fleece Performance Billet Rocker Bridges
-Hamilton Valve Springs
-Hamilton Tool Steel Keepers (Coming Soon)
-Cummins Valves
Head:
-Intake Shelf removed
-Joker Fab Side Draft Intake
-All freeze plugs tapped
-Full Intake and Exhaust Port
-O-ringed
-Steed Speed T-4 manifold (From CompD memeber)
-ARP H11 Headstuds
Exterior Engine:
-Eat Soot billet Tappet cover anodized red
-Eat Soot billet Timing cover anodized red
-Eat Soot billet Side and rear freeze plugs anodized red
-Keating billet front freeze plug
Oil System:
-Factory filter mount
-Homemade Remote setup
Fuel:
-Tank mounted sump (From CompD member)
-Donaldson Filter and Water seperator setup
-Waterman Sprint Ultralite Cover Mounted pump
-Regulated with high speed by pass valves
-Maxed 180 pump from Farrel Diesel
-PDD max travel kit
-.084 Mild Steel lines into .093 tubes
-Infinite Performance 6x16 injectors
-PDD AFC Live Race
Cooling:
-Mishimoto Radiator
-Mishimoto Rad Hoses
-Mishimoto Intercooler
-Flex-a-lite Electric Fan
-Homemade coolant By-pass
Turbos:
-E.D. S363 over S477 (From CompD member)
-Homemade dual gate setup using On3 gates
-Controlled with in cab On3 Manual Boost controller
-Homemade stainless compound piping
-Thermal Zero turbo blankets
-Turbosmart Diesel BOV
Exhaust:
-5" Downpipe
-MBRP full 5" Stainless factory dump
Trans:
-Stage 6 ATS full billet trans (From CompD Member)
-ATS Standalone VB (From CompD Member)
-Cooled by an Art's Raditator Trans cooler and relocated trans heat exchanger.
-ATS billet flexplate (From CompD member)
-ARP Flexplate bolts (From CompD member)
T/Case:
-Fresh Rebuilt 241DHD
-ATS machined input to match their billet trans output (From CompD memeber)
Rear Driveshaft:
-Aluminum 6" one piece with 1480 series joints (From CompD member)
Rear Diff:
-Disc Brake Dana 80 w/ Eaton Tru-trac
-Mag-Hytec cover
-2" lowing blocks
-Bilstein shocks
Front End:
-Stock shafts and stock front diff
-Bilstein Dual steering stabilizer (From CompD memeber)
-Bilstein Shocks
-Mag-Hytec cover
More pictures to come!
Engine:
-All machine work, balancing and long block assembly done by UCF machine in Carlisle, PA
Bottom End:
-T-Rex Girdle
-No Limit Mfg Billet Main Caps (From CompD member)
-Calico Coated OEM Cummins main bearings
-Arp 12mm XL Main Studs tied into girdle (From CompD member)
-Crower Billet Rods
-ARP Rod bolts (From CompD member)
-Coated Early CR .020 over Pistons
-Fluidamper
-ARP Balancer bolts
-Billet Squirters
Valvetrain:
-187/220 No Limit Mfg Billet Steel Cam
-Eatsoot bolt on cam retainer
-Keating Bronze Cam retainer
-Calico coated 1.4" Tapets parkerized by No Limit Mfg
-Hamilton Xtreme Duty Push rods
-New OEM Cummins Rockers (Mamau Diesel)
-ARP rocker studs
-Trend Performance DLC coated Rocker trunnions
-Fleece Performance Billet Rocker Bridges
-Hamilton Valve Springs
-Hamilton Tool Steel Keepers (Coming Soon)
-Cummins Valves
Head:
-Intake Shelf removed
-Joker Fab Side Draft Intake
-All freeze plugs tapped
-Full Intake and Exhaust Port
-O-ringed
-Steed Speed T-4 manifold (From CompD memeber)
-ARP H11 Headstuds
Exterior Engine:
-Eat Soot billet Tappet cover anodized red
-Eat Soot billet Timing cover anodized red
-Eat Soot billet Side and rear freeze plugs anodized red
-Keating billet front freeze plug
Oil System:
-Factory filter mount
-Homemade Remote setup
Fuel:
-Tank mounted sump (From CompD member)
-Donaldson Filter and Water seperator setup
-Waterman Sprint Ultralite Cover Mounted pump
-Regulated with high speed by pass valves
-Maxed 180 pump from Farrel Diesel
-PDD max travel kit
-.084 Mild Steel lines into .093 tubes
-Infinite Performance 6x16 injectors
-PDD AFC Live Race
Cooling:
-Mishimoto Radiator
-Mishimoto Rad Hoses
-Mishimoto Intercooler
-Flex-a-lite Electric Fan
-Homemade coolant By-pass
Turbos:
-E.D. S363 over S477 (From CompD member)
-Homemade dual gate setup using On3 gates
-Controlled with in cab On3 Manual Boost controller
-Homemade stainless compound piping
-Thermal Zero turbo blankets
-Turbosmart Diesel BOV
Exhaust:
-5" Downpipe
-MBRP full 5" Stainless factory dump
Trans:
-Stage 6 ATS full billet trans (From CompD Member)
-ATS Standalone VB (From CompD Member)
-Cooled by an Art's Raditator Trans cooler and relocated trans heat exchanger.
-ATS billet flexplate (From CompD member)
-ARP Flexplate bolts (From CompD member)
T/Case:
-Fresh Rebuilt 241DHD
-ATS machined input to match their billet trans output (From CompD memeber)
Rear Driveshaft:
-Aluminum 6" one piece with 1480 series joints (From CompD member)
Rear Diff:
-Disc Brake Dana 80 w/ Eaton Tru-trac
-Mag-Hytec cover
-2" lowing blocks
-Bilstein shocks
Front End:
-Stock shafts and stock front diff
-Bilstein Dual steering stabilizer (From CompD memeber)
-Bilstein Shocks
-Mag-Hytec cover
More pictures to come!
Cozze44
Junkman
Waiting on the manifold coating to finish setting, so we knocked out a couple small items. Got the factory diff cover swapped out in the front and got a foot look at the front diff gears. Appears to have been rebuilt at sometime and looks great. Put an additional vent in the valve cover, mounted the boost controller in the cab, and changed out all the fittings in the boost controller, wastegates, and bov from push on rubber to swivel push on nylon line. Got the map sensor all hooked up in the new intercooler pipe and the afc lines all hooked up. Just a creepin along....
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Highwayman
bored.
Show off
Cozze44
Junkman
Haha I'm only responsible for the design and cuts, I can't claim the welds to be mine, as much as I'd like to!
Cozze44
Junkman
Tabs for ladder bars came today as well as the tubing, just a quick sketch of what I have in mind. Going to use leaf spring shackles for the front pivot. I had traction bars mounted solid before, and it made the ride horrible, so it's time to revamp.
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Last edited:
Cozze44
Junkman
All in cab controls are set, bov controller, manual boost controller and afc live all easily accessible.
Rerouted a portion of the harness into the cowl to clear space and protect from heat for turbos. Also mounted the bov solenoid in the cow as well.
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Highwayman
bored.
The fit up on those pie cuts is pretty important for those nice welds, so take SOME credit.
Also, I like the traction bar design, I try to talk everyone around here into using a shackle if they use that style and not caltracs.
Also, I like the traction bar design, I try to talk everyone around here into using a shackle if they use that style and not caltracs.
Cozze44
Junkman
It’s a very old air over hydraulic bender. It’s from the 80’s but still serves its purpose! I’ll get some pics when I go back. I gotta pick up a new liner, and gas for my welder so hopefully I have time to get back in tomorrow night.
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