Engine/Transmission (1994 - 1998) high hp rebuild.

[omenica]

I recently picked up a 98 12 valve, 180 hp pump, that I am doing a complete rebuild on. I am shooting for 550-600 hp at the wheels. I understand the costs associated with a build like this, but I still want the best price I can get. This will be a street/play truck that will do the occassional towing.



anyways, I have torn the motor down and taken it to a machine shop. Bad news, block needs to be bored (not sure if . 020 or . 040 over yet. ) as well as the block and head need to be decked. The crank also has to be turned and polished in one spot.



I have done a lot of reading and this is what I have come up with so far in terms of a build list, although I have a number of unanswered questions.



Pistons, mahle seems to be a good price and good reputation. Do I want marine style pistons or stay with a stock bowl?

marine If I choose to run marine do I have to run a 370 injector (or a different injector specifically for marine style pistons?)

stock I have read conflicting information that the 215 pistons are different/better then the 180. I have not found any aftermarket pistons that verify this, they all seem to be the same for the 12 valve?



Injectors which would be recommened, a 5 or 7 hole injector? I would either use a 5x014/5x016 or 7x010/7x012. I know that 7's have better fuel atomization, so that would relate to better power with less fuel and smoke? SDX seems to be a good choice at a reasonable price.



Head studs I don't know much about them, would 12mm ones be fine instead of 14mm?



Head head will be decked, o-ringed, port and polished with a 3 angle valve job, #60 valve springs. Head gasket thickness will be determined based on how much has to be taken off the block and head.



Cam I would like to get a cam, but I don't want to have to run fly cut pistons. Will valve clearance become an issue with decked block/head? Any suggestions?



3 piece manifold necessary?



P7100 I think I will send the pump away to get benched and flow tested. afc kit, 181 dv's, 4K GSK, no fuel plate with mack rack. Does this sound right? I am going to call piers or one of the other reputable shops on monday about this.



Push rodsnecessary?



Turbo/s I would like to run twins if possible, although a large single is also considering. If I go with twins I'd like to keep my hx35 with a ht3b. Any suggestions?



Does that sound like a build that will reach my hp goals? if not what needs to be changed? Any advice would be appreciated.

 

[Nyoest]

For a first post you've got a whopper! Welcome!

As far as head studs go as big as you can. Who ever said I wish I would of put smaller ones in?

Plenty of cams available that won't require fly cutting that will make good power. Lots a folks gong with Hamilton cams lately.

You need to decide if your going to run OR tow. No fuel plate is fun but a mess to tow with. You can't give the road the attention it needs with your eyeball glued to the pyro.

And if you want a true 600 horse DD get your check book ready.

 

[KBurgoyne]

since the block is getting worked over ypu can bore it and stroke it out to a 6. 7. all the new 6. 7 is is a 5. 9 block bored out more and a bit more stroke.

injectors stick with DDP, SDX, scheid diesel.

stock pistons will handle the power 180 or 215 doesnt matter.

definately new manifold. not all are 3 piece, but definately a new one for better flow.

181s not gonna cut it. spend the extra 30 bucks on laser cuts.

power could definately possible with a fuel plate and would be much more controllable for daily driving.

tons of options out there for turbos comes down to prefferance. do homework. ATS, BD, industrial injection, and many others i'm sure make ready made twin kits that are ready to install.

dont forget about the 6-7k that the transmission will need to live beyong a stroll arouns the block.

 

[HBarlow]

Read every word written by Joe Donnelly that you can find in old issues of TDR magazine. He built one that produced over 700 hp IIRC and drove it as a daily driver and occasional trailer puller for years. Joe is a scientist not a seat of the pants type of guy. He tried and tested many approaches to that power level and rejected some. If you follow his recipe for Cummins high performance with care you may have one that will hold together for awhile. Otherwise, sadly, you are about to spend thousands of dollars to buy extended heartbreak.