Engine building ideas?

[mrpbody]

I am picking up a 5. 9 long block core to rebuild for a crewcab conversion I am building and I was wondering how you might build it or what modifications you would do to it since it was all tore down. Because some things are different I am basing it off of the 1991 to 93 intercooled year models.



The basics are that it is going into a 1-ton 4x4 crewcab and I will be using the nv4500 transmission. (unless you can tell me why a Getrag would be better). I pull a boat and a camp trailer (not at the same time) based on (12k lbs) and I would like to do some traveling with it but I just dread the thought of driving over mountain passes with the gas engine that's in it now.



Drivability and reliability would be most important and with whatever combination is put together I am hoping fuel mileage will not be terrible. I guess in a nut shell, I want a tow rig with torque to pull the hills without sacrificing street-ability.



I'm trying to figure out what a good all around level would be. I know the higher the horsepower ratings the more parts start to break or the more parts you will need to go along with it to support everything else, and then it turns into a vicious circle of fixing the weakest link.



I'm not looking to break the bank or go over-board on building it and I was trying to stay with a single turbo (cost reasons) unless there was a definite reason why I should have to go with a twin turbo combination.



What kinda torque could a person expect from a 350hp or 450hp engine and is it still tame to drive on the street? At what Horse Power figure does it become too much to use as a driver/tow rig?



With your experience and some of the things you have built and know now, if you did it all over again basing it on the parameters above, how would you build it this time?

 

[Shadrach]

What is the engine out of? Is it an automotive spec? Is there a serial number on the gear housing?Internally I would use a PDR ( or similar ) camshaft. It will improve mileage, lower EGT's and help the power come in sooner. If you are going to have to replace pistons order the ones from Cummins for a 97 215hp engine as they will take more abuse. You will find a 4 digit number on the top of the old pistons. This the the last 4 digits of the 7 digit p/n that Cummins uses. It is NOT the part number that you would order as they come in a kit with rings, but the p/n of the "bare" piston. Example: 6631 on piston translates to 3926631 which is the piston in kit 3802561. Shadrach

 

[mrpbody]

What is the engine out of? Is it an automotive spec? Is there a serial number on the gear housing?Internally I would use a PDR ( or similar ) camshaft. It will improve mileage, lower EGT's and help the power come in sooner. If you are going to have to replace pistons order the ones from Cummins for a 97 215hp engine as they will take more abuse. You will find a 4 digit number on the top of the old pistons. This the the last 4 digits of the 7 digit p/n that Cummins uses. It is NOT the part number that you would order as they come in a kit with rings, but the p/n of the "bare" piston. Example: 6631 on piston translates to 3926631 which is the piston in kit 3802561. Shadrach

Thanks Shadrach, The core is out of a 1992 Dodge truck with auto transmission. I will be tearing it all the way down as it sat out in the rain at some point. I have not pulled the head yet but there is evidence that water had gotten into the intake manifold so I am pretty sure it leaked into the bores. Boring it and new pistons were already on the list and I will contact PDR about the camshaft.

I read on there website that they offer head porting and "O" ringing. Any thoughts on this? Is it over kill for what I want to do?

 

[Shadrach]

That's a 160hp engine with the VE fuel pump. Although it can make ponies it is not the "best" one to start with. How much power do you want/need? Shadrach

 

[JR2]

That may only be 160 HP with a VE but my Dad's old 92 got 23 mpg on the highway and 15 towing heavy... you will not win many races but its a towing machine.

If you stick with that motor I don't think you have to do much in the way of porting or 0-ringing. I would put a set of injectors and a different turbo (the HX35 works well on the 92) and call it good. There are a few guys that can help turn up the HP on the VE motors, I think Nascar Mark here on TDR has a hot one but just for towing I would probably just leave it alone.

 

[Shadrach]

JR2 is right. It is a good engine. it depends on what you want/need. Shadrach

 

[mrpbody]

Not looking to win any races. I am building a tow rig and was just hoping to increase the hp/tq numbers without losing drivability. As far as numbers go, I am not sure what they are capable of without re-inventing the wheel. 600 to 700 ft lbs of torque would be a great number if it was possible.

 

[JLEONARD]

600 to 700 ft lbs of torque would be a great number if it was possible

That's easy with a first gen without doing too much or spending a lot of $$.

I was there with mine with very mild tweaks and it wasn't intercooled and it never hit 1200 F.

Also never broke anything, could get 24/25 mpg daily.