Did a little diesel work today

[AgDieseler]

I ran up to Dallas for the 4th, put a 3.5" exhaust on my Dad's 96 6.5TD with a few other mods, did a little bit of tuning on my engine, and realized that I need to do a little redesign work so that changing my thermostats doesn't involve removing the entire crossover pipe. Pics pending.

[AgDieseler]

I had 160 and 180 degree thermostats installed, and I wasn't getting the economy I should, and was blowing too much black smoke too early. Living up to my reputation for being anal (I prefer the terms demanding or exacting :flipoff2: ), I tested my new 180 degree t-stats before installing them.

[AgDieseler]

Because of the low pressure fuel return line is directly in the way of one lower bolt, and I couldn't fit any 15mm tool in there anyway (socket, box end, racheting box end, open end, crows foot, shorty open end, mexican socket,...nothing) I ended up pulling the whole crossover pipe.:D Not too bad actually, but it sure was easier doing all this on the engine stand.

[AgDieseler]

My modified dual thermostat crossover pipe. This is originally intened for 1997+ 6.5TD with the DS-4 pump, but with a little cutting and welding, it was made to work around my mechanical DB-2 pump. On the way back to College Station, my black smoke was cut in half, my economy went from a solid 15 to about 17. There was no noticeable increase in power.

[AgDieseler]

We pulled that sorry excuse for an exhaust system off my Dad's 96 6.5TD, and put on a 3.5" mandrel bent system.

[AgDieseler]

It came with a fully welded, louvered muffler. We turned it backwards for better flow, and to hear the turbo a little better.:D

[AgDieseler]

Genuine GM downpipe.

[AgDieseler]

This past Sunday, I cut my low-hanging shock mounts off the rear axle. I had already destroyed one at TCC, and figured I had put this project off long enough, so I ordered new 1/4" thick tabs from Poison Spider Customs and picked up some RS9005s. Since I don't have my welder here, I'm going to run by Custom Fab this afternoon, and get the new tabs welded on.

I'll snap a finished pic later, but this shows just how low the stock mount hangs.

[AgDieseler]

Poison Spider Customs' shock tabs. They measure 2 1/8" tall with a radius of 1 3/4". (pn:BURLEYSML) At $3.75 each, it's a no brainer.

[Doug Krebs]

who the **** welded that??? A fab shop??? I could weld better with the mig gun in my ass!!!!

[AgDieseler]

There might be a problem with 'dirt' in the weld if you did that.

[jerryg79]

Doug we know what happened last time you tried to weld with your mig gun in your ass.....you may remember the product of this incident....you called it your first bumper.:D

[Doug Krebs]

Oh no, that was learning how to Arc weld with the stinger in my ass!!!

[jerryg79]

Oh yes, I should remember that.....

By the way David that was so nice of you to let those kids in the welding class at the Vocational School for the Blind practice welding on your truck.

PS that axle looks a little scratched...better put some paint on it!!!!!

[AgDieseler]

Originally posted by Snatch Adams
By the way David that was so nice of you to let those kids in the welding class at the Vocational School for the Blind practice welding on your truck.

PS that axle looks a little scratched...better put some paint on it!!!!!
I believe the guy's word were, "I'll weld 'er on there real good!" I know it's not the prettiest, but those tabs are on there, and aren't coming off soon.

PS: Jerry, after letting it cool, the first thing I did was paint it. :flipoff2:

[Doug Krebs]

Holy **** I can tell that was done with a Mig because of the silicon remanants. Was this guy old and shaking like a mo fo?? Or was he bent over and you thought his ass was cute and pinched it??

[chevsu]

how much did you fork over for those tabs?

[Doug Krebs]

Poison Spider Customs' shock tabs. They measure 2 1/8" tall with a radius of 1 3/4". (pn:BURLEYSML) At $3.75 each, it's a no brainer.

[bburris]

What's that? $3.50 profit?

[AgDieseler]

Probably, but that's well worth not building it myself. I used the money from selling my textbook back.:D

[Doug Krebs]

So was he old or did you pinch his ass!??

[AgDieseler]

;)

[bburris]

Originally posted by AgDieseler
Probably, but that's well worth not building it myself. I used the money from selling my textbook back.:D

I still haven't sold mine...not sure what I'll do with my $5.

[BMFScout]

did he weld them to the remnants of the old shock mounts? that is what it looks like in the pic. Here is how you build shock mounts. :D Can you say 5012's? I also integrated my brake line hanger into the mount so that I could lower it some, but I think it will still be too short for the massive articulation :D :flipoff2:

[AgDieseler]

I used those same F250 mounts on my front mounts with 9012s. Finally, I'm not alone with my Ford brackets!:flipoff2:

[BMFScout]

did he weld the teh tabs to what was left of the old mounts or is that just what the pic looks like?

[AgDieseler]

Though I asked him not to, he did weld over the old spots. The new brackets are actually not as wide as the old ones, so they should have set inside of the old welds, but he put one tab right on top of an old weld. I'm about halfway pleased with the quality. I know that it will hold and that there is nothing wrong structurally, but it has been mentioned (and I do agree) that they beez some ugly welds. I guess that's that I get for going to a professional welder.;)

[robertf03]

why didnt you 6011 that bitch up?

[AgDieseler]

no welder down herre

[AgDieseler]

Finally, the truck has a turbo on it. I ordered the rest of the kit from Banks, and got it all installed two weeks ago. I went back to Dallas yesterday to finish up the exhaust and get some miles on it before bringing it down here. I dialed in the boost to 11-13 psi, and adjusted the injector pump +1/4 turn. That should make about 220 hp and 450 lb. ft.

A big thanks to Jimmy, Fred, and Robert for their help. All that driving we did looking for a manifold gasket could have been avoided. There was one in the garage I didn't know about.:p Thanks Jimmy for using a torque wrench; thanks Fred for giving me "the eye" when I tried to go back without that header gasket; and thanks Flem for letting me eat your fries.:D

Thanks to Ryan St. John for re-indexing my tailpipe. The muffler hung down too low in stock form, and to get it up high enough, the tailpipe was pointed up a little. Ryan gave it the chop, and TIGed that puppy in the right position.

In the old 300,000 mile motor, 75 mph was attainable only with a tailwind heading down a hill. With the new engine, I could maintain 75 no problem until I hit anything more than a 5% grade. Now, I can bury the needle past 85 mph up a 6% grade hill, and still have room left to go. I'll be towing Jose's Dodge to Houston before too long, so that will be part two of the power test. I'm looking forward to getting an idea of how this thing pulls.:D